maintenance YAMAHA TMAX 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU21380
Adjusting the throttle cable
free play
The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21400
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU33600
Tires
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10500

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
1. Throttle cable free play
1

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WARNING

EWA11200
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your vehicle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE VEHI-
CLE! Operation of an overload-
ed vehicle may result in tiredamage, loss of control, or se-
vere injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.

Do not carry along loosely
packed items, which can shift
during a ride.

Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.

Adjust the tire air pressure with
regard to the load.

Check the tire condition and air
pressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire air pressure (measured on
cold tires):
0–90 kg (0–198 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
90–190 kg (198–419 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
280 kPa (41 psi) (2.80 kgf/cm
2
)
Maximum load*:
190 kg (419 lb)
* Total weight of rider, passenger,
cargo and accessories
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
12

PERIODIC MAINTENANCE AND MINOR REPAIR
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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

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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)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22492
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.
2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the rear brake caliper by in-
stalling the bolts, then tightening
them to the specified torque.
CAUTION:

ECA12821
Do not apply the rear brake or park-
ing brake after the brake caliper has
been removed, otherwise the brake
caliper piston will be forced out.
1. Brake pad wear indicator groove
1 1

1. Bolt
2. Lining thickness
1
2

Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)

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EAU22580
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the brake fluid reservoir whenrefilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23170
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23210
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and met-
al-to-metal contact surfaces should be
lubricated if necessary.
WARNING

EWA10740
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

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CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

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EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23411
Battery
This model is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
To access the battery
1. Open the seat. (See page 3-13.)
2. Remove the battery cover by re-
moving the screws.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
WARNING

EWA10760

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
1. Screw
2. Battery cover
1
2

1. Battery
1