maintenance YAMAHA VMAX 2009 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU36771
TIP


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 and clutch service

Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.

Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master
and release cylinders, and change the brake and clutch fluids.

Replace the brake and clutch hoses every four years and if cracked or damaged.
31

*
Air induction system

Check the air cut-off valve, reed
valve, and hose for damage.

Replace any damaged parts if
necessary.
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32

*
Mufflers and exhaust
pipes

Check the screw clamps for
looseness.
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√

√

√

√

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33

*
EXUP system

Check operation, cable free play
and pulley position.
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34

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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 ADJUSTMENT
6-6
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EAU18722
Removing and installing the
cowling and panels
The cowling and panels shown need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
the cowling or a panel needs to be re-
moved and installed.
EAU46430
Cowling A
To remove the cowling
1. Remove the rider seat. (See page
3-22.)
2. Remove panel C. (See page 6-7.)
3. Remove the bolts, and then pull
the cowling off.To install the cowling
1. Place the cowling in the original
position, and then install the bolts.
2. Install the panel.
3. Install the rider seat.

1. Cowling A
2. Panel A
1
2

1. Panel B
2. Panel C
1
2
1. Bolt
11 1
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46471
Panel A
To remove the panel
1. Insert the key into the lock, and
then turn it 1/4 turn clockwise.
2. Pull the panel outward.
To install the panel1. Place the panel in the original po-
sition.2. Turn the key counterclockwise to
the original position, and then re-
move it.
Panel B
To remove the panel
1. Remove the bolt.2. Pull the panel outward.
To install the panel
Place the panel in the original position,
and then install the bolt.

1. Unlock.
2. Panel A
2
1

1. Bolt
2. Panel B
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
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9Panel C
To remove the panel
1. Remove the bolt.
2. Pull the panel upward.
To install the panelPlace the panel in the original position,
and then install the bolt.

EAU46680
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 replaced if
out of specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
1. Panel C
2. Bolt
1 2

Specified spark plug:
NGK/CR9EIA
DENSO/IU27D
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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TIP

If a torque wrench is not available when
installing 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.
NOTICE

ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.
EAU19907
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 a level sur-
face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
TIP

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.
Tightening torque:
Spark plug:
12.5 Nm (1.3 m·kgf, 9 ft·lbf)
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
TIP

Skip steps 5–7 if the oil filter cartridge is
not being replaced.
5. Remove the oil filter cartridge with
an oil filter wrench.
TIP

An oil filter wrench is available at a
Yamaha dealer.
6. Apply a thin coat of clean engine
oil to the O-ring of the new oil filter
cartridge.
TIP

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

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

1. O-ring

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
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8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP

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

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.
10. 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.
TIP

After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.
NOTICE

ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealer
check the vehicle.
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 30 ft·lbf)
1

Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
4.30 L (4.55 US qt, 3.78 Imp.qt)
With oil filter cartridge replacement:
4.70 L (4.97 US qt, 4.14 Imp.qt)
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
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11. Turn the engine off, and then
check the oil level and correct it if
necessary.

EAU46572
Final gear oil
The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In addi-
tion, the final gear oil must be checked
and changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
WARNING

EWA10370

Make sure that no foreign mate-
rial enters the final gear case.

Make sure that no oil gets on the
tire or wheel.
To check the final gear oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The final gear oil level must be
checked on a cold engine.

Make sure that the vehicle is posi-
tioned straight up when checking
the oil level.2. Loosen the final gear oil check bolt
until oil flows out.
3. If no oil flows out, remove the final
gear oil filler bolt. (See steps 3–4
under “To change the final gear oil”
for oil filler bolt removal.)
4. Pour the recommended type of oil
in the final gear oil filler hole until it
flows out of the oil check bolt hole.
5. Install the final gear oil filler bolt
and final gear oil check bolt, and
then tighten them to their specified
torques.
1. Final gear oil drain bolt
2. Final gear oil check bolt
3. Final gear oil drain bolt washer
12
3

PERIODIC MAINTENANCE AND ADJUSTMENT
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67
8
9 To change the final gear oil
1. Place the vehicle on a level sur-
face.
2. Place an oil pan under the final
gear case to collect the used oil.
3. Remove the final gear case
breather cap by removing the bolt
and washer.4. Remove the oil drain bolt and the
filler bolt to drain the oil from the fi-
nal gear case.
5. Replace the final gear oil drain bolt
washer, and then install the final
gear oil drain bolt.
6. Tighten the final gear oil drain bolt
to the specified torque.
7. Refill with the recommended final
gear oil.
8. Install the oil filler bolt, and then
tighten it to the specified torque.
9. Install the final gear case breather
cap by installing the washer andbolt, and then tighten the bolt to the
specified torque.
10. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.

Tightening torques:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
Final gear oil check bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1. Final gear oil filler bolt
2. Final gear case breather cap
3. Washer
4. Final gear case breather cap bolt
2 3 41

Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
Recommended final gear oil:
Shaft drive gear oil (Part No.:
9079E-SH001-00)
Oil quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)

Tightening torque:
Final gear case breather cap bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
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EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU46690
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
TIP

The coolant should be between the
minimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir cap guard by re-
moving the bolt, and then remove
the reservoir cap.
4. Add coolant to the maximum level
mark, and then install the reservoir
cap.
WARNING! Remove only
the coolant reservoir cap. Never
attempt to remove the radiator
cap when the engine is
hot.
[EWA15161]

NOTICE:
If coolant is
not available, use distilled wateror soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10472]

5. Install the coolant reservoir cap
guard by installing the bolt.
EAU46422
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.
2. Remove cowling A. (See
page 6-6.)
1. Coolant reservoir cap
2. Coolant reservoir cap guard
3. Bolt
4. Maximum level mark
5. Minimum level mark2
1
5 4
3

Coolant reservoir capacity (up to the
maximum level mark):
0.27 L (0.29 US qt, 0.24 Imp.qt)