2007 YAMAHA XMAX 125 air filter

SAFETY INFORMATION.....................1-1
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
Indicators, indicator lights and
warning light ..................................3-3
Speedometer ....................................3-4
Fuel gauge ........................................3-4
Coolant temperature gauge..............3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) .................3-7
Handlebar switches ..........................3-8
Front brake lever...............................3-9
Rear brake lever................................3-9
Fuel tank cap ..................................3-10
Fuel .................................................3-10
Catalytic converter..........................3-11
Seat.................................................3-11
Front storage compartment............3-12
Storage compartment.....................3-12
Adjusting the shock absorber
assemblies...................................3-13
Sidestand ........................................3-13PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT
RIDING POINTS..................................5-1
Starting a cold 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.................................5-3
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 plug ..................6-7
Engine oil ..........................................6-8
Final transmission oil ......................6-10
Coolant ...........................................6-11
Air filter and V-belt case air filter
elements ......................................6-12
Adjusting the throttle cable
free play .......................................6-14
Valve clearance ...............................6-15
Tires ................................................6-15
Cast wheels ....................................6-17Front and rear brake lever free
play ..............................................6-17
Checking the front and rear brake
pads.............................................6-17
Checking the brake fluid level ........6-18
Changing the brake fluid ................6-19
Checking and lubricating the
throttle grip and cable .................6-19
Lubricating the front and rear
brake levers .................................6-20
Checking and lubricating the
centerstand and sidestand .........6-20
Checking the front fork ...................6-20
Checking the steering.....................6-21
Checking the wheel bearings .........6-22
Battery ............................................6-22
Replacing the fuses ........................6-23
Replacing a headlight bulb .............6-24
Replacing a front turn signal
light bulb......................................6-25
Replacing the tail/brake light bulb
or a rear turn signal light bulb .....6-25
Replacing the license plate light
bulb .............................................6-26
Replacing the auxiliary light bulb ...6-27
Troubleshooting ..............................6-27
Troubleshooting charts ...................6-28
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage .............................................7-3
TABLE OF CONTENTS
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EAU10410
Left view
DESCRIPTION
2-1
21
2345
1. Storage compartment (page 3-12)
2. Spring preload (page 3-13)
3. Air filter (page 6-12)4. V-Belt filter (page 6-12)
5. Sidestand (page 3-13)
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
EAU17705
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ODOMETER READING (x 1000 Km)
ANNUAL
CHECKNO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24
1*Fuel line• Check fuel and vacuum hoses for cracks or damage.√√√√ √
• Check condition.
2Spark plug• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4Air filter element• Replace. Every 20000 Km
5*V-Belt• Replace. Every 20000 Km
6*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
7*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
• Replace brake pads. Whenever worn to the limit
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
ODOMETER READING (x 1000 Km)
ANNUAL
CHECKNO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24
8*Brake hoses• Check for cracks or damage.√√√√ √• Replace. Every 4 years
9*Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
10 *Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
11 *Wheel bearings• Check bearing for looseness or damage.√√√√
12 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 20000 km
13 *Chassis fasteners• Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
15 *Sidestand switch• Check operation.√√ √ √√ √
16 *Front fork• Check operation and for oil leakage.√√√√
17 *Shock absorber
• Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 *Fuel injection• Check engine idle speed.√√ √ √√ √
• Change. (See page 6-8)√When the oil change
19Engine oilindicator light comes on (every 6000 km)• Check oil level/top up.√Every 3000 km
20Engine oil filter element• Replace.√√√
21 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
ODOMETER READING (x 1000 Km)
ANNUAL
CHECKNO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24
22Final gear oil• Check vehicle for oil leakage.√√ √• Change.√√√
23*
V-belt case air filter • Clean. Every 6000 kmelements
• Replace. Every 20000 km
24 *Front and rear brake
• Check operation.√√ √ √√ √
switches
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
26 *
and cable• Adjust the throttle cable free play if necessary.√√√√ √
• Lubricate the throttle grip housing and cable.
27 *Muffler and exhaust pipe• Check the screw clamp for looseness.√√ √ √√
28 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
EAU18660
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 cylinder and caliper, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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3. If the coolant is at or below the
minimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION:
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted 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 possi-
ble, otherwise the effective-ness of the coolant will be
reduced.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Close the reservoir cap.
6. Place the floorboard mat in the
original position and push it
downward to secure it.
EAU33030
Changing the coolantEWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAUM1320
Air filter and V-belt case air
filter elements
The air filter and the V-belt case air fil-
ter elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.
Replace the air filter element
1. Place the scooter on the centers-
tand.
2. Remove the air filter case cover
by removing the screws.
1. Air filter case cover
2. Screw
1
2
Coolant reservoir capacity:
0.26 L (0.28 US qt) (0.23 Imp.qt)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
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3. 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.
5. Check the air filter element for
damage and replace it if neces-
sary.
6. Insert the air filter element into
the air filter case.
7. Install the air filter case cover by
installing the screws.Cleaning the V-belt case air filter
element
1. Remove the V-belt case air filter
cover by removing the screws.
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.3. Check the air filter element for
damage and replace it if neces-
sary.
4. Install the air filter element with
the colored side facing outward.
5. Install the V-belt case air filter
cover by installing the screws.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
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ECA10530
CAUTION:
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
EAUS1290
Adjusting the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 4 ~ 6 mm (0.16 ~ 0.24) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Remove cowling A (See page
6-6).2. Loosen the locknut.
3. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
4. Tighten the locknut.
5. Install the cowling.
(a)
(b)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
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