YAMAHA TMAX 2008 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9

9*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years
10

*
Wheels

Check runout and for damage.
√√√√
11

*
Tires

Check tread depth and for
damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√√
12

*
Wheel bearings

Check bearing for looseness or
damage.
√√√√
13

*
Steering bearings

Check bearing play and steer-
ing for roughness.
√√√√√

Lubricate with lith-
ium-soap-based grease.Every 20000 km (12000 mi)
14

*
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly tight-
ened.
√√√√√
15

Front brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
16

Rear brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
17

Sidestand, center-
stand

Check operation.

Lubricate.
√√√√√
18

*
Sidestand switch

Check operation.
√√√√√√
19

*
Front fork

Check operation and for oil
leakage.
√√√√
20

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
1
2
3
4
5
6
7
8
9

21

*
Fuel injection

Adjust engine idling speed and
synchronization.
√√√√√√
22

Engine oil

Change. (See page 3-6.)
√
When the oil change indicator flashes

Check oil level and vehicle for
oil leakage.Every 5000 km (3000 mi)
√
23

Engine oil filter car-
tridge

Replace.
√√√
24

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
25

Chain drive oil

Check vehicle for oil leakage.

Change.
√√√√
26

*
V-belt

Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
27

*
Front and rear brake
switches

Check operation.
√√√√√√
28

Moving parts and
cables

Lubricate.
√√√√√
29

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
2
3
4
5
67
8
9

EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
3
4
5
6
7
8
9

EAU18771
Removing and installing
panels
The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAU45012
Panel A
To remove the panel
1. Remove the quick fasteners.2. Remove the upper left and right
side of the panel by pulling them
upward, and then pull the panel
downward as shown.
To install the panel
Place the panel in the original position,
and then install the quick fasteners.

1. Panel A
2. Panel B
3. Panel C
4. Panel D
5. Panel E
34
5
12

1. Panel F
1. Panel A
2. Quick fastener
1
2
1

1. Panel A
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
2
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5
67
8
9 Panel B
To remove the panel
1. Remove panel A.
2. Pull the rear view mirror rubber
cover on each mirror upward, and
then remove the rear view mirrors
by removing the nuts.
3. Remove the screws, and then pull
the panel outward.To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Install the rear view mirrors by in-
stalling the nuts, and then place
the rubber cover on each mirror in
the original position.
3. Install panel A.
Panel C
To remove the panelRemove the screws, and then pull the
panel upward.To install the panel
Place the panel in the original position,
and then install the screws.
Panel D
To remove the panel1. Remove panel C.
2. Remove the screws, and then pull
the panel backward and upward.

1. Nut
2. Rubber cover
3. Rear view mirror
1
32

1. Screw
2. Panel B
21
1

1. Screw
2. Panel C
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1
2
3
4
5
6
7
8
9
To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Install panel C.
Panel E
To remove the panelRemove the screws, and then pull the
panel outward.To install the panel
Place the panel in the original position,
and then install the screws.
Panel F
To remove the panelRemove the screws, and then pull the
panel outward.To install the panel
Place the panel in the original position,
and then install the screws.

1. Screw
2. Panel D
2
1

1. Screw1
1. Screw
1
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9

EAU19642
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:

If a torque wrench is not available wheninstalling a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (12.5 m·kgf, 9 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9

EAU19858
Engine oil and oil filter
cartridge
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on the center-
stand.
CAUTION:

ECA11290
The engine must be cold before pro-
ceeding with the oil level check, oth-
erwise the check will result in a false
reading.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for two
minutes, and then turn it off.
3. Wait two minutes until the oil set-tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Place the vehicle on a level sur-
face.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
32

1. Engine oil filler cap
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
2
3
4
5
67
8
9
5. Check the washer and O-ring for
damage and replace them if nec-
essary.
NOTE:

Skip steps 6–8 if the oil filter cartridge is
not being replaced.
6. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:

An oil filter wrench is available at a
Yamaha dealer.
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:

Make sure that the O-ring is properly
seated.
8. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
1. Engine oil drain bolt
1

1. Engine oil drain bolt
2. O-ring
3. Washer
12
3

1. Oil filter wrench
2. Oil filter cartridge
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9
9. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
10. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
NOTE:

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
11. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
12. Turn the engine off, and then
check the oil level and correct it if
necessary.
13. Reset the oil change indicator.
(See page 3-9.)
NOTE:

If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12.3 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31.1 ft·lbf)
1

Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2