brake 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

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
3-9
2
34
5
6
7
8
9 Right

EAU12360
Pass switch “PASS”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “/”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
position. To cancel the turn signallights, push the switch in after it has re-
turned to the center position.
EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12660
Engine stop switch “/”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12720
Start switch “”
With the sidestand up, push this switch
while applying the front or rear brake to
crank the engine with the starter.
CAUTION:

ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12731
Hazard switch “”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard light (simultaneous flashing of all
turn signal lights).
The hazard light is used in case of anemergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.
CAUTION:

ECA10060
Do not use the hazard light for an ex-
tended length of time, otherwise the
battery may discharge.
1. Engine stop switch “ / ”
2. Hazard switch “ ”
3. Start switch “ ”
123

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

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.

INSTRUMENT AND CONTROL FUNCTIONS
3-17
2
34
5
6
7
8
9
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
The system is OK. The scooter can be ridden.
This check is most reliable if performed with
a warmed-up engine.The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO NO YESNOTE:

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15602
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-12
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-10
Chain drive oil

Check vehicle for oil leakage. 6-13
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-14
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 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