YAMAHA VMAX 2011 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
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 cowling1. Remove the rider seat. (See page
3-25.)
2. Remove panel C. (See page 6-9.)
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. Bolt11 1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6
EAU46471
Panel A
To remove the panel1. 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 posi-
tion.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.
Panel C
To remove the panel1. Remove the bolt.
2. Pull the panel upward.
1. Unlock.
2. Panel A
2
1
1. Bolt
2. Panel B1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6To install the panel
Place 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/IU27D1. Spark plug gapSpark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
TIPIf 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.
EAU19908
Engine oil and oil filter car-
tridge 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.TIPThe 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:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
64. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIPSkip steps 5–7 if the oil filter cartridge is
not being replaced.5. Remove the oil filter cartridge with
an oil filter wrench.TIPAn 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.
TIPMake 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
2. Gasket
1
12
1. Oil filter wrench
2. Oil filter cartridge
1
2
1. O-ring
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6 8. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe 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.TIPAfter the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.NOTICE
ECA10401
If the oil level warning light flickers
or remains on even if the oil level is
correct, immediately turn the engine
off and have a Yamaha dealer check
the vehicle.11. Turn the engine off, wait a few min-
utes until the oil settles, and then
check the oil level and correct it if
necessary.
1. Torque wrenchTightening 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, 31 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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAU46577
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.TIPMake sure that the vehicle is positioned
straight up when checking the oil level.2. Remove the final gear oil check
bolt and its gasket, and check that
oil flows out.3. If no oil flows out, remove the final
gear case breather cap by remov-
ing the bolt and washer and then
remove the final gear oil filler bolt
and its gasket.4. Check the gaskets for damage,
and replace them if necessary.
5. Pour the recommended type of oil
in the final gear oil filler hole until it
flows out of the oil check bolt hole.
6. Install the oil check bolt, the oil filler
bolt and their gasket, and then
tighten the bolts to the specified
torques.
1. Final gear oil check bolt
2. Gasket
1
2
1. Final gear case breather cap bolt
2. Washer
3. Final gear case breather cap
4. Final gear oil filler bolt
5. GasketTightening torques:
Final gear oil check bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)3 2 145
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6 7. Install the final gear case breather
cap by installing the washer and
bolt, and then tighten the bolt to the
specified torque.
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 final gear oil filler bolt,
the final gear oil drain bolt and their
gasket to drain the oil from the final
gear case.5. Install the drain bolt and its new
gasket, and then tighten the bolt to
the specified torque.
6. Remove the final gear oil check
bolt and its gasket.
7. Check the oil check bolt gasket
and the oil filler bolt gasket for
damage, and replace them if nec-
essary.
8. Refill with the recommended final
gear oil until it flows out of the oil
check bolt hole.
Tightening torque:
Final gear case breather cap bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1. Final gear case breather cap bolt
2. Washer
3. Final gear case breather cap
4. Final gear oil filler bolt
5. Gasket
3 2 145
1. Final gear oil drain bolt
2. Gasket
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
69. Install the oil check bolt, the oil filler
bolt and their gasket, and then
tighten the bolts to the specified
torques.
10. Install the final gear case breather
cap by installing the washer and
bolt, and then tighten the bolt to the
specified torque.
11. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
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.
EAU46691
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.TIPThe 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 water or
soft tap water instead. Do not
Recommended final gear oil:
Yamaha genuine shaft drive gear oil
SAE 80 API GL-5
Oil quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
Tightening torques:
Final gear oil check bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Final gear case breather cap bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1. Coolant reservoir cap
2. Coolant reservoir cap guard
3. Bolt
4. Maximum level mark
5. Minimum level mark
2
1
5 4
3
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