2004 YAMAHA TMAX check engine

PRE-OPERATION CHECKS
4-2
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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

OPERATION AND IMPORTANT RIDING POINTS
5-1
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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!

OPERATION AND IMPORTANT RIDING POINTS
5-2
1
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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)

OPERATION AND IMPORTANT RIDING POINTS
5-4
1
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EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17021
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:

ECA11281
After 1000 km (600 mi) of operation,
the engine oil must be changed, andthe oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17211
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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10

*
Brake hoses

Check for cracks or damage.
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Replace. Every 4 years
11

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Wheels

Check runout and for damage.
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12

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Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
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13

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Wheel bearings

Check bearing for looseness or damage.
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14

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Steering bearings

Check bearing play and steering for roughness.
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Lubricate with lithium-soap-based grease. Every 20000 km
15

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
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16

Sidestand, centerstand

Check operation.

Lubricate.
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17

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Sidestand switch

Check operation.
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18

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Front fork

Check operation and for oil leakage.
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19

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
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20

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Electronic fuel injection

Adjust engine idling speed and synchronization.
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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
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22

Engine oil filter cartridge

Replace.
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23

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Cooling system

Check coolant level and vehicle for coolant leakage.
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Change. Every 3 years
24

Chain drive oil

Check vehicle for oil leakage.

Change.
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25

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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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
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EAU19592
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs 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.
To remove a spark plug
1. Remove cowling B. (See
page 6-6.)
2. Remove the spark plug cover by
pulling it out as shown.3. Remove the spark plug cap.
4. Remove the spark plug as shown
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulatoraround the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:

If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cover
1

1. Spark plug cap
1. Spark plug wrench
11

Specified spark plug:
NGK/CR7E

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
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2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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.
4. Install the spark plug cap.
5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
EAU19852
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-
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
1

1. Spark plug cover
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
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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. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:

Skip steps 4–6 if the oil filter cartridge is
not being replaced.
4. Remove the oil filter cartridge with
an oil filter wrench.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1
32

1. Engine oil filler cap
1

1. Engine oil drain bolt
1