2004 YAMAHA TMAX ignition

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
Further safe-riding points .......... 1-4
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Immobilizer system ................... 3-1
Main switch/steering lock .......... 3-2
Indicator and warning lights ...... 3-3
Speedometer ............................. 3-4
Tachometer ............................... 3-4
Multi-function display ................. 3-5
Anti-theft alarm (optional) .......... 3-8
Handlebar switches ................... 3-8
Front brake lever ..................... 3-10
Rear brake lever ...................... 3-10
Parking brake .......................... 3-10
Fuel tank cap ........................... 3-11
Fuel ......................................... 3-12
Catalytic converter .................. 3-12
Seat ......................................... 3-13
Adjusting the rider backrest ..... 3-13
Helmet holder .......................... 3-14
Storage compartments ............ 3-15Shock absorber ....................... 3-15
Sidestand ................................ 3-16
Ignition circuit cut-off system ... 3-16
PRE-OPERATION CHECKS ....... 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting the engine .................... 5-1
Starting off ................................. 5-2
Acceleration and
deceleration ............................ 5-2
Braking ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR ................... 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-3
Removing and installing
cowlings and panels ................ 6-6
Checking the spark plugs .......... 6-9Engine oil and oil filter
cartridge ................................ 6-10
Chain drive oil ......................... 6-13
Coolant .................................... 6-14
Cleaning the air filter
element ................................. 6-16
Adjusting the engine idling
speed .................................... 6-17
Adjusting the throttle cable free
play ....................................... 6-18
Adjusting the valve
clearance .............................. 6-18
Tires ........................................ 6-18
Cast wheels ............................ 6-20
Front and rear brake lever
free play ................................ 6-21
Adjusting the parking brake
cable ..................................... 6-21
Checking the front and rear
brake pads ............................ 6-22
Checking the brake fluid
level ....................................... 6-23
Changing the brake fluid ......... 6-24
Checking and lubricating the
throttle grip and cable ........... 6-24
Lubricating the front and rear
brake levers .......................... 6-24

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9keys away from the main switch
as they may cause signal inter-

ference.
EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.
NOTE:

Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code
re-registering key (red bow), keep it in a
safe place and only use it for code
re-registering.
EAU10560
ON
All electrical circuits are supplied with
power; the meter lighting, taillight, li-
cense plate light and auxiliary light
come on, and the engine can be start-ed. The key cannot be removed.
NOTE:

The headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF” or the
sidestand is moved down.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to
“OFF” while still pushing it.

INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9

EAU15300
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
WARNING

EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the
ground and distract the operator,
resulting in a possible loss of con-
trol. Yamaha’s ignition circuit
cut-off system has been designed
to assist the operator in fulfilling
the responsibility of raising the sid-
estand before starting off. There-fore, check this system regularly
as described below and have a
Yamaha dealer repair it if it does
not function properly.
EAU15371
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch and brake
light switches) has the following func-
tions.

It prevents starting when the side-
stand is up, but neither brake is ap-
plied.

It prevents starting when either
brake is applied, but the sidestand
is still down.

It cuts the running engine when the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
WARNING

EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.

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

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!

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
2
3
4
5
67
8
9
der the battery cover and can be ac-
cessed as follows.
1. Open the seat. (See page 3-13.)
2. Remove the battery cover.
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:

ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
1. Signaling system fuse
2. Headlight fuse
3. Ignition fuse
4. Radiator fan fuse
5. Electronic fuel injection fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
7
123456

Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
20.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 A
Radiator fan fuse:
15.0 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
10.0 A

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
2
3
4
5
67
8
9 the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-

cohol or thinner.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU25880
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your scooter re-
quire any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter prop-
erly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Do not touch the glass part of the bulb.
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
1
2
3
4
5
6
7
8
9

EAU25911
Troubleshooting charts
Starting problems or poor engine
performance
WARNING

EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.