YAMAHA VMAX 2016 Repair Manual

Periodic maintenance an d a djustment
6-6
6
21 *Rear suspension re-
lay arm an
d con-
nectin g arm
pivotin g points • Check operation.
√√√√
22 En gine oil • Change.
• Check oil level and vehicle for oil
leakage. √√√√√√
23 En
gine oil filter car-
tri dg e •Replace.
√√√
24 *Coolin g system • Check coolant level and vehicle
for coolant leakage. √√√√√
• Change coolant. Every 3 years
25 *EXUP system • Check operation, cable free play
and pulley position. √√√
26 Final gear oil • Check oil level and vehicle for oil
leakage. √√ √
• Change. √√√
27 *Front an
d rear
b rake switches • Check operation.
√√√√√√
28 Movin
g parts an d
ca bles • Lubricate.
√√√√√
29 *Throttle g rip • Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing. √√√√√
30 *Li
ghts, si gnals an d
switches • Check operation.
• Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 k
m

(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
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Periodic maintenance an d a djustment
6-7
6
EAU36773
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 an d a djustment
6-8
6
EAU18724
Removin g an d installin g the
cowlin g an d panelsThe 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.
EAU46431
Cowlin g 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. Bolt1 1
1
1
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Periodic maintenance an d a djustment
6-9
6
EAU46472
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 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.
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 an d a djustment
6-10
6
To install the panel
Place the panel in the original position,
and then install the bolt.
EAU46681
Checkin
g the spark plug sThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and depos-
its will cause any spark plug to slowly
erode, they should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition of
the engine.
The porcelain insulator around the
center 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 engine should have the same
color. If any spark plug shows a dis-
tinctly different color, the engine could
be operating improperly. Do not at-
tempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of elec-
trode 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 re-
placed 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 plu g:
NGK/CR9EIA
DENSO/IU27D
1. Spark plug gap
Spark plu g g ap:
0.8–0.9 mm (0.031–0.035 in)
1
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Periodic maintenance an d a djustment
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
specified torque as soon as possible.NOTICE
ECA10841
Do not use any tools to remove or in-
stall the spark plu g cap, otherwise
the i gnition coil coupler may get
d amag ed . The spark plu g cap may
b e difficult to remove b ecause the
ru bber seal on the en d of the cap fits
ti g htly. To remove the spark plu g
cap, simply twist it b ack and forth
while pullin g it out; to install it, twist
it back an d forth while pushin g it in.
EAU1990A
En gine oil an d oil filter car-
tri dgeThe 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 en gine oil level
1. Place the vehicle on a level surfa- ce 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 locat-
ed 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 chan ge the en gine oil (with or
without oil filter cartri dge replace-
ment) 1. Place the vehicle on a level surfa- ce.
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.
Tightenin g 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
23
1
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Periodic maintenance an d a djustment
6-12
6
4. 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 withan oil filter wrench.TIPAn oil filter wrench is available at a
Yamaha dealer.6. Apply a thin coat of clean engineoil 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 cartridgewith 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
2
1
1. Oil filter wrench
2. Oil filter cartridge
1
2
1. O-ring
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Periodic maintenance an d a djustment
6-13
6
8. Install the engine oil drain bolt andits 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
ECA11621
In or der to prevent clutch slip-
pa ge (since the en gine oil also
lu bricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a hi gh-
er quality than specifie d. In
a ddition, do not use oils la beled
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn 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,
immediately 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
ECA10402
If the oil level warnin g lig ht flickers
or remains on even if the oil level is
correct, immed iately turn the en gine
off an d have a Yamaha d ealer check
the vehicle.11. Turn the engine off, wait a few mi- nutes until the oil settles, and then
check the oil level and correct it if
necessary.
1. Torque wrenchTightenin g torque:
Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)
Ti ghtenin g torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
1
Recommen ded en gine oil:
See page 8-1.
Oil quantity: Oil change:
4.30 L (4.55 US qt, 3.78 Imp.qt)
With oil filter removal: 4.70 L (4.97 US qt, 4.14 Imp.qt)
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Periodic maintenance an d a djustment
6-14
6
EAU46578
Final gear oilThe 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 ad-
dition, the final gear oil must be
checked and changed as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
WARNING
EWA10371
 Make sure that no forei gn 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 surfa- ce and hold it in an upright posi-
tion.TIPMake sure that the vehicle is posi-
tioned straight up when checking the
oil level.2. Remove the final gear oil checkbolt 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 fill- er bolt and their gasket, and then
tighten the bolts to the specified
torques.
1. Final gear oil check bolt
2. Gasket
2
1
1. Final gear case breather cap bolt
2. Washer
3. Final gear case breather cap
4. Final gear oil filler bolt
5. Gasket
Tightenin g 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 an d a djustment
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 chan ge the final gear oil
1. Place the vehicle on a level surfa- ce.
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.
Tightenin g 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. GasketTightenin g torque:
Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
2
1
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