check engine YAMAHA TMAX 2003 Owners Manual

2-1
EAU00026
DESCRIPTION
2
1. Fuel tank cap (page 3-9)
2. Rear storage compartment (page 3-14)
3. Helmet holder (page 3-13)
4. Grab bar (page 5-2)
5. Chain drive oil filler cap (page 6-15)
6. Engine oil filler cap (page 6-13)7. V-belt air filter element (left)
8. Engine oil drain bolt (page 6-13)
9. Engine oil level check window (page 6-12)
10. Oil filter cartridge (page 6-13)
1234
9876510
Part locations
Left view
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3-2
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03733.(Parking)
The steering is locked, and the tail-
light, license light and auxiliary light
are on, but all other electrical sys-
tems are off. The key can be
removed.
To turn the main switch to “
.”:
1. Turn the key to “LOCK”.
2. Slightly turn the key counter-
clockwise until it stops.
3. While still turning the key coun-
terclockwise, push it in until it
snaps into place.
ECA00043
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Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
If the engine oil is changed before the
oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light must be reset after the oil
change for the next periodic oil
change to be indicated at the correct
time. (See page 6-15 for the resetting
procedure.)
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Set the engine stop switch to “#”
and turn the key to “ON”.
2. Check that the indicator comes
on for a few seconds and then
goes off.
3. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
EAU00056
Indicator lightsIndicator lights
EAU03797
Oil change indicator light “7”Oil change indicator light
This indicator light comes on at the
initial 1,000 km, then at 5,000 km and
every 5,000 km thereafter to indicate
that the engine oil should be
changed.
After changing the engine oil, reset
the oil change indicator light. (See
page 6-15 for the resetting proce-
dure.)
1234
1. Oil change indicator light “7”
2. V-belt replacement indicator light “V-BELT”
3. High beam indicator light “&”
4. Turn signal indicator lights “4” and “6”
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3-3
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU04424
V-belt replacement indicator light
“V-BELT”
V-belt replacement indicator light
This indicator light comes on every
20,000 km when the V-belt needs to
be replaced.
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
2. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
1234
1. Oil change indicator light “7”
2. V-belt replacement indicator light “V-BELT”
3. High beam indicator light “&”
4. Turn signal indicator lights “4” and “6”
EAU00063
High beam indicator light “&”High beam indicator light
This indicator light comes on when
the high beam of the headlight is
switched on.
EAU04121
Turn signal indicator lights “4”
and “6”
Turn signal indicator lights
The corresponding indicator light
flashes when the turn signal switch is
pushed to the left or right.
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3-6
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03840
Self-diagnosis device
This model is equipped with a self-
diagnosis device for the throttle posi-
tion sensor, the speed sensor, and
the overturn switch. If any of those
circuits are defective, the oil change
indicator light will flash.
If the indicator light flashes, have a
Yamaha dealer check the scooter as
soon as possible.
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
EAU00118
Handlebar switches
Handlebar switches
EAU00120
Pass switch “PASS”Pass switch
Press this switch to flash the head-
light.
EAU03888
Dimmer switch “&/%”Dimmer switch
Set this switch to “&” for the high
beam and to “%” for the low beam.
1
2
3
4
1. Pass switch “PASS”
2. Dimmer switch “&/%”
3. Turn signal switch “4/6”
4. Horn switch “*”
EAU00109
Anti-theft alarm (optional)Anti-theft alarm (optional)
This scooter can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
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3-15
EW000044
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The scooter must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00337
Ignition circuit cut-off
system
Ignition circuit cut-off system
The ignition circuit cut-off system
(comprising the sidestand switch and
brake light switches) has the follow-
ing functions.
8It prevents starting when the
sidestand is up, but neither brake
is applied.
8It prevents starting when either
brake is applied, but the side-
stand is still down.
8It cuts the running engine when
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
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If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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3-16
INSTRUMENT AND CONTROL FUNCTIONS
3
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.YES NO
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “#”.
3. Turn the key to “ON”.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
NOTE:
This check is most reliable if performed with
a warmed-up engine.
YES NO
The system is OK. The scooter can be ridden.
YES NO
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4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-4,3-9–3-11
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-12–6-15
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-17–6-18
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-9, 6-25–6-28
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-9, 6-25–6-28
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5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
5
EAU03981
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8 8
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8 8
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8 8
For safety, always start the
engine with the centerstand
down.
8 8
When the centerstand is down
and the engine is idling, keep
your hands and feet away from
the rear wheel.
EAU03843
Starting the engineStarting the engine
EC000046
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See page 5-4 for engine break-in
instructions prior to operating the
vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
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8 8
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-16.
8 8
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake.
NOTE:
If the engine does not start, release
the start switch, wait a few seconds,
and then try again. Each starting
attempt should be as short as possi-
ble to preserve the battery. Do not
crank the engine more than
10 seconds on any one attempt. If
the engine does not start, try with the
throttle open 1/8 turn.
ECA00045
cC
For maximum engine life, never
accelerate hard when the engine is
cold!
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5-2
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00433
Starting off
Starting off
NOTE:
Before starting off, allow the engine
to warm up.
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the center-
stand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
EAU00434
Acceleration and
deceleration
Acceleration and deceleration
The speed can be adjusted by open-
ing and closing the throttle. To
increase the speed, turn the throttle
grip in direction a. To reduce the
speed, turn the throttle grip in direc-
tion b.
1
1. Grab bar
ab
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
EAU01128
Engine break-inEngine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
EAU03845*
0–1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000–1,600 km
Avoid prolonged operation above 1/2
throttle.
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After 1,000 km of operation, the
engine oil must be changed, and
the oil filter cartridge replaced.
1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
cC
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU00460
ParkingParking
When parking, stop the engine, and
then remove the key from the main
switch.
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8 8
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
8 8
Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
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