2004 YAMAHA TMAX parking brake

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

SAFETY INFORMATION
1-4
1
sories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
scooter in an area that has ade-
quate ventilation.

Always turn the engine off before
leaving the scooter unattended
and remove the key from the mainswitch. When parking the scooter,
note the following:

The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedes-
trians or children are not likely to
touch these hot areas.

Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.

Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
EAU10370
Further safe-riding points

Be sure to signal clearly when
making turns.

Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when
stopping on a wet surface.

Slow down as you approach a cor-
ner or turn. Once you have com-
pleted a turn, accelerate slowly.

Be careful when passing parked
cars. A driver might not see you
and open a door in your path.

Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers be-
come extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter up-
right, otherwise it could slide out
from under you.

The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
5
4
2
3
6
7
8
1
109

1. Rear brake lever (page 3-10)
2. Left handlebar switches (page 3-8)
3. Parking brake lever (page 3-10)
4. Speedometer (page 3-4)
5. Multi-function display (page 3-5)
6. Tachometer (page 3-4)
7. Right handlebar switches (page 3-8)
8. Front brake lever (page 3-10)9. Throttle grip (page 6-18)
10. Main switch/steering lock (page 3-2)

INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9

EAU12900
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle-
bar grip.
EAU12950
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
EAU12961
Parking brake
This vehicle is equipped with a parking
brake to lock the rear wheel when the
vehicle is parked.
To lock the parking brake
Push the parking brake lever to the left
until it snaps into place.
To unlock the parking brake
Push the parking brake lever back to
the original position.
NOTE:

Be sure to check that the rear wheel
does not move when the parking brake
is applied.
1. Front brake lever
1

1. Rear brake lever1

1. Parking brake lever
1

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9
WARNING

EWA12360
Never move the parking brake lever
to the left while the scooter is mov-
ing, otherwise loss of control or an
accident may result. Make sure that
the scooter is stopped before mov-
ing the parking brake lever to the
left.
EAU13171
Fuel tank cap
To remove the fuel tank cap
1. Open the lid by pulling the lever up.
2. Insert the key into the lock and turn
it clockwise. The lock will be re-
leased and the fuel tank cap can
be removed.
To install the fuel tank cap
1. Align the match marks, insert the
fuel tank cap into the tank opening,
and then push down on the cap.
2. Turn the key counterclockwise to
the original position, and then re-
move it.
3. Close the lid.
WARNING

EWA11260
Make sure that the fuel tank cap is
properly installed and locked in
place before riding the scooter.
1. Lid1
1. Match marks
1

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.
√

√

√

√

√

√

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
2
3
4
5
67
8
9

EAU33451
Front and rear brake lever free
play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
EAU33472
Adjusting the parking brake
cable
Parking brake adjustment may be re-
quired if the parking brake does not
hold properly. When the parking
brake is not in use, the parking brake
cable length should measure 46 mm
to 48 mm (1.81 in to 1.89 in) at the
rear brake caliper. Periodically check
the parking brake cable length and, if
necessary, adjust it as follows.
To increase the parking brake cable
length, turn the adjusting nut at the rear
brake caliper in direction (a). To de-crease the parking brake cable length,
turn the adjusting nut in direction (b).
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
1. Adjusting nut
2. Parking brake cable length2
1
(b)
(a)

SPECIFICATIONS
8-3
1
2
3
4
5
6
7
8
9Headlight:

Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60 W/55.0 W
×
1
Headlight:
12 V, 55.0 W
×
1
Tail/brake light:
12 V, 5.0/21.0 W
×
2
Front turn signal/position light:
12 V, 21 W/5.0 W
×
2
Rear turn signal light:
12 V, 21.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
2
Licence plate light:
12 V, 5.0 W
×
1
Meter lighting:
14 V, 2.0 W
×
3
High beam indicator light:
14 V, 1.4 W
×
1
Turn signal indicator light:
14 V, 1.4 W
×
1
Engine trouble warning light:
14 V, 1.4 W
×
1
Immobilizer system indicator light:
LED

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