tires YAMAHA TMAX 2004 Owners Manual

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

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

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
1
2
3
4
5
6
7
8
9

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
2
3
4
5
67
8
9
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
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

SCOOTER CARE AND STORAGE
7-2
2
3
4
5
6
78
9 scratched, use a quality plastic
polishing compound after

washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-gine has cooled down.
CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be-
fore storing or covering it.
WARNING

EWA10940

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.

Before operating the scooter
test its braking performance
and cornering behavior.
CAUTION:

ECA10800

Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.

Never apply oil or wax to any
rubber and plastic parts, but

SCOOTER CARE AND STORAGE
7-4
2
3
4
5
6
78
9
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more in-
formation on storing the battery,
see page 6-27.
NOTE:

Make any necessary repairs before
storing the scooter.

SPECIFICATIONS
8-2
2
3
4
5
6
7
89

Operation:
Centrifugal automatic type
Chassis:
Frame type:
Diamond
Caster angle:
28.0 °
Trail:
95.0 mm (3.74 in)
Front tire:
Type:
Tubeless
Size:
120/70R-14M/C 55H
Manufacturer/model:
DUNLOP/D252F
Manufacturer/model:
BRIDGESTONE/TH01F
Rear tire:
Type:
Tubeless
Size:
160/60R-15M/C 67H
Manufacturer/model:
DUNLOP/D252
Manufacturer/model:
BRIDGESTONE/TH01R
Loading:
Maximum load:
190 kg (419 lb)
* (Total weight of rider, passenger, cargo
and accessories)

Tire air pressure (measured on cold
tires):
Loading condition:
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

)
Loading condition:
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

)
Front wheel:
Wheel type:
Cast wheel
Rim size:
14M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
15M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)
Rear suspension:
Type:
Swingarm
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
117.0 mm (4.61 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 Ah