2004 YAMAHA TMAX brake
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PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9
EAU15602
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-12
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
Chain drive oil
Check vehicle for oil leakage. 6-13
Coolant
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-14
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
Rear brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-24
Page 36 of 84
PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9
Wheels and tires
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-18, 6-20
Brake levers
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-24
Centerstand, sidestand
Make sure that operation is smooth.
Lubricate pivots if necessary.6-25
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switches
Check operation.
Correct if necessary.—
Sidestand switch
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-16
ITEM CHECKS PAGE
Page 37 of 84
OPERATION AND IMPORTANT RIDING POINTS
5-1
2
3
4
56
7
8
9
EAU15970
WARNING
EWA11250
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
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.
For safety, always start the en-
gine with the centerstand down.
When the centerstand is down
and the engine is idling, keep
your hands and feet away from
the rear wheel.
EAU27060
Starting the engine
CAUTION:
ECA10250
See page 5-4 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-16.
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 possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. If the engine does not start, try
with the throttle open 1/8 turn.
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!
Page 38 of 84
OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9
EAU16760
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 centerstand.
2. Sit astride the seat, and then ad-
just 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.
EAU16780
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throt-
tle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
Front
1. Grab bar
1
(a)(b)
Page 43 of 84
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9
EAU17701
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line
Check fuel hoses for cracks or damage.
√
√
√
√
√
2*
Fuel filter
Check condition.
√
√
3
Spark plugs
Check condition.
Clean and regap.
√
√
Replace.
√
√
4*
Valves
Check valve clearance.
Adjust.Every 40000 km
5
Air filter element
Clean.
√
√
Replace.
√
√
6*
V-belt case air filter ele-
ments
Clean.
√
√
Replace.
√
√
7*
Front brake
Check operation, fluid level and vehicle for fluid leak-
age.
√
√
√
√
√
√
Replace brake pads. Whenever worn to the limit
8*
Rear brake
Check operation, fluid level and vehicle for fluid leak-
age.
√
√
√
√
√
√
Replace brake pads. Whenever worn to the limit
9
Parking brake
Check operation.
Adjust.
√
√
√
√
√
√
Page 44 of 84
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9
10
*
Brake hoses
Check for cracks or damage.
√
√
√
√
√
Replace. Every 4 years
11
*
Wheels
Check runout and for damage.
√
√
√
√
12
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
13
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
14
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 20000 km
15
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√
√
√
√
√
16
Sidestand, centerstand
Check operation.
Lubricate.
√
√
√
√
√
17
*
Sidestand switch
Check operation.
√
√
√
√
√
√
18
*
Front fork
Check operation and for oil leakage.
√
√
√
√
19
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
20
*
Electronic fuel injection
Adjust engine idling speed and synchronization.
√
√
√
√
√
√
21
Engine oil
Change. (See pages 3-5 and 6-10.)
√
When the oil change indicator flashes
(every 5000 km)
Check oil level and vehicle for oil leakage. Every 5000 km
√
22
Engine oil filter cartridge
Replace.
√
√
√
23
*
Cooling system
Check coolant level and vehicle for coolant leakage.
√
√
√
√
√
Change. Every 3 years
24
Chain drive oil
Check vehicle for oil leakage.
Change.
√
√
√
√
25
*
V-belt
Replace.When the V-belt replacement indicator flashes
(every 20000 km)
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
Page 45 of 84
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
8
9
EAU18670
NOTE:
The air filter needs more frequent service if you are 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.
26
*
Front and rear brake
switches
Check operation.
√
√
√
√
√
√
27
Moving parts and cables
Lubricate.
√
√
√
√
√
28
*
Throttle grip housing
and cable
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
√
√
√
√
√
29
*
Lights, signals and
switches
Check operation.
Adjust headlight beam.
√
√
√
√
√
√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
Page 60 of 84
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
1
2
3
4
5
6
7
8
9Tire information
This model is equipped with tubeless
tires.
WARNING
EWA10470
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to aYamaha dealer, who has the
necessary professional knowl-
edge and experience.
EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
120/70R-14M/C 55H
Manufacturer/model:
DUNLOP/D252F
BRIDGESTONE/TH01F
Rear tire:
Size:
160/60R-15M/C 67H
Manufacturer/model:
DUNLOP/D252
BRIDGESTONE/TH01R