air filter 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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
2
3
4
5
67
8
9

EAU17280
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
WARNING

EWA10330
This scooter is designed for use on
paved roads only. If this scooter isoperated in abnormally dusty, mud-
dy or wet conditions, the air filter el-
ement should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result. Con-
sult a Yamaha dealer for proper
maintenance intervals.
EAU17390
Owner’s tool kit
The owner’s tool kit is located under the
seat. (See page 3-13.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
1. Helmet holding cable
2. Owner’s tool kit
2 1

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

EAU18670
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
26

*
Front and rear brake
switches

Check operation.
√

√

√

√

√

√


27

Moving parts and cables

Lubricate.
√

√

√

√

√


28

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√

√

√

√

√


29

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√

√

√

√

√

√

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1
2
3
4
5
6
7
8
9
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
2
3
4
5
67
8
9
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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
1
2
3
4
5
6
7
8
9
NOTE:

An oil filter wrench is available at a
Yamaha dealer.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:

Make sure that the O-ring is properly
seated.
6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
1. Oil filter wrench
2. Oil filter cartridge
2
1

1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12.3 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31.1 ft·lbf)
1

Recommended engine oil:
SAE 10W-30 or SAE
10W-40(API SE, SF, SG or
higher)
Oil quantity:
Without oil filter cartridge re-
placement:
2.80 L (2.96 US qt)
(2.46 Imp.qt)
With oil filter cartridge replace-
ment:
2.90 L (3.07 US qt)
(2.55 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1
2
3
4
5
6
7
8
9ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
5. Install the coolant reservoir cover
by installing the screw.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-32 for further instructions.
EAU21120
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove cowling A. (See
page 6-6.)
2. Remove the windshield by remov-
ing the screws.
3. Remove the air filter case cover by
removing the screws, and then pull
the air filter element out.4. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
1. Screw
1
1(×5)

1. Air filter case cover
2. Screw
1. Air filter element
1
2
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
2
3
4
5
67
8
9
replace it.
5. Insert the air filter element into the
air filter case.
CAUTION:

ECA10480

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
6. Install the air filter case cover by in-
stalling the screws.
7. Install the windshield and the cowl-
ing.
EAU33481
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
NOTE:

The engine is warm when it quickly re-
sponds to the throttle.
1. Remove panel B. (See page 6-6.)
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the idle adjust-
ing screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
NOTE:

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
3. Install the panel.
1. Idle adjusting screw
Engine idling speed:
1150–1250 r/min
1(a)
(b)

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

EAU26333
Dimensions:
Overall length:
2235 mm (88.0 in)
Overall width:
775 mm (30.5 in)
Overall height:
1410 mm (55.5 in)
Seat height:
795 mm (31.3 in)
Wheelbase:
1575 mm (62.0 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
2800 mm (110.2 in)
Weight:
With oil and fuel:
225.0 kg (496 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
499.0 cm
3

(30.45 cu.in)
Bore
×
stroke:
66.0
×
73.0 mm (2.60
×
2.87 in)
Compression ratio:
11.00 :1
Starting system:
Electric starter
Lubrication system:
Dry sump

Engine oil:
Type:
SAE10W30 or SAE10W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 US qt) (2.55 Imp.qt)
Chain drive oil:
Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.6–0.7 L (0.63–0.74 US qt) (0.53–0.62
Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.35 L (0.37 US qt) (0.31 Imp.qt)
Radiator capacity (including all routes):
1.50 L (1.59 US qt) (1.32 Imp.qt)
Air filter:
Air filter element:
Dry element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Electronic fuel injection:
Manufacturer:
AISAN
Model:
1100-87B60/1100-87B70
Spark plug(s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Primary reduction system:
Spur gear/helical gear
Primary reduction ratio:
52/32
×
36/22 (2.659)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
41/25
×
40/29 (2.262)
Transmission type:
V-belt automatic