2008 YAMAHA XMAX 125 transmission

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
Self-diagnosis device .......................3-4
Speedometer ....................................3-4
Fuel gauge ........................................3-5
Coolant temperature gauge..............3-5
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Front brake lever.............................3-10
Rear brake lever..............................3-11
Fuel tank cap ..................................3-11
Fuel .................................................3-12
Catalytic converters ........................3-13
Seat.................................................3-14
Storage compartments ...................3-14
Front storage compartment............3-15
Rear storage compartment.............3-16
Adjusting the shock absorber
assemblies...................................3-17
Sidestand ........................................3-18Ignition circuit cut-off system .........3-18
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..............................................5-3
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 the
cowlings and panel .......................6-7
Checking the spark plug ..................6-9
Engine oil ........................................6-10
Final transmission oil ......................6-13
Coolant ...........................................6-14
Air filter and V-belt case air filter
elements ......................................6-15
Adjusting the throttle cable free
play ..............................................6-17
Valve clearance ...............................6-17Tires ................................................6-18
Cast wheels ....................................6-20
Front and rear brake lever free
play ..............................................6-20
Checking the front and rear brake
pads.............................................6-21
Checking the brake fluid level ........6-21
Changing the brake fluid ................6-22
Checking and lubricating
the cables ....................................6-23
Checking and lubricating the
throttle grip and cable .................6-23
Lubricating the front and rear
brake levers .................................6-23
Checking and lubricating the
centerstand and sidestand .........6-24
Checking the front fork ...................6-24
Checking the steering.....................6-25
Checking the wheel bearings .........6-26
Battery ............................................6-26
Replacing the fuses ........................6-27
Replacing a headlight bulb .............6-29
Replacing a front turn signal light
bulb .............................................6-30
Replacing a tail/brake light bulb
or a rear turn signal light bulb .....6-30
Replacing the license plate light
bulb .............................................6-32
Replacing an auxiliary light bulb.....6-32
Troubleshooting ..............................6-32
Troubleshooting charts ...................6-33
TABLE OF CONTENTS
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EAU10410
Left view
DESCRIPTION
2-1
2
1. Fuel tank cap (page 3-11)
2. Owner’s tool kit (page 6-1)
3. V-belt case air filter cover (page 6-15)
4. Rear storage compartment (page 3-16)
5. Air filter case cover (page 6-15)6. Spring preload adjusting ring (page 3-17)
7. Final transmission oil filler cap (page 6-13)
8. Engine oil drain bolt (page 6-10)
9. Sidestand (page 3-18)
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EAU15605
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-11, 3-12
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-10
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-13
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-10, 6-20 ~ 6-23
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 3-11, 6-20 ~ 6-23
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
5-2, 6-17, 6-23
• If necessary, have Yamaha dealer adjust cable free play and
lubricate cable and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-18 ~ 6-20
• Check air pressure.
• Correct if necessary.
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
√When the oil change indicator light
20Engine oil• Change. (See pages 6-10)comes on (5000 km (2920 mi) after the initial
1000 km (600 mi) and every
6000 km (3500 mi) thereafter)
• Check oil level and vehicle for oil leakage. Every 3000 km (1800 mi)√
21Engine oil filter
element• Replace.√√√
22Final transmission oil• Check vehicle for oil leakage.√√ √• Change.√√√
23 *V-belt• Replace. Every 18000 km (10500 mi)
24 *Front and rear brake
switches• Check operation.√√√√√ √
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing • Check operation and free play.
26 * • Adjust the throttle cable free play if necessary.√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
27 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√√√√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
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EAU20061
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final trans-
mission oil must be changed as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm up the
final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil filler cap
2. O-ring
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1. Final transmission oil drain bolt
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
●Make sure that no foreign
material enters the final trans-
mission case.
●Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.21 L (0.22 US qt) (0.18 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
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Dimensions:Overall length:
2210 mm (87.0 in)
Overall width:
790 mm (31.1 in)
Overall height:
1380 mm (54.3 in)
Seat height:
785 mm (30.9 in)
Wheelbase:
1545 mm (60.8 in)
Ground clearance:
112 mm (4.44 in)
Minimum turning radius:
3650 mm (143.7 in)
Weight:With oil and fuel:
166 kg (366 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
124.6 cm
3
Bore x stroke:
52.0 x 58.6 mm (2.05 x 2.31 in)
Compression ratio:
11.20 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Without oil filter cartridge replacement:
1.40 L (1.48 US qt) (1.23 Imp.qt)
With oil filter element replacement:
1.50 L (1.59 US qt) (1.32 Imp.qt)
Final transmission oil:Type:
SAE 10W-30 type SE motor oil
Quantity:
0.21 L (0.22 US qt) (0.18 Imp.qt)
Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.26 L (0.27 US qt) (0.23 Imp.qt)Radiator capacity (including all routes):
1.40 L (1.48 US qt) (1.23 Imp.qt)
Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
12.5 L (3.30 US gal) (2.75 Imp.gal)
Fuel reserve amount:
2 L (0.53 US gal) (0.44 Imp.gal)
Throttle body:Type/quantity:
EFI (1B9) / 1
Manufacturer:
AISAN
Spark plug (s):Manufacturer/model:
NGK/ CPR 9EA-9
Spark plug gap:
0.8-0.9 mm (0.031-0.035 in)
Clutch:Clutch type:
Dry, centrifugal automatic
Transmission:Primary reduction system:
Helical gear
Primary reduction ratio:
41/14 (2.929)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
44/13 (3.384)
SPECIFICATIONS
8-1
8
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Transmission type:
V-belt automatic
Chassis:Frame type:
Steel tube underbone
Caster angle:
28.00 degree
Trail:
100.0 mm (3.94 in)
Front tire:Type:
Tubeless
Size:
120/70-15 M/C 56S(Michelin -
Continental)
120/70-15 M/C 56P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Manufacturer/model:
Continental/ContiTwist TL
Manufacturer/model:
Pirelli/GTS23
Rear tire:Type:
Tubeless
Size:
140/70-14 M/C 68S(Michelin -
Continental)
140/70-14 M/C 68P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Manufacturer/model:
Continental/ContiTwist TL
Manufacturer/model:
Pirelli/GTS24
Loading:Maximum load:
189 kg (417 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0-90 kg
Front:
190 kPa (28 psi) (1.90 kgf/cm
2) (1.90 bar)
Rear:
220 kPa (32 psi) (2.20 kgf/cm
2) (2.20 bar)
Loading condition:
90 kg - maximum load
Front:
210 kPa (30 psi) (2.10 kgf/cm
2) (2.10 bar)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2) (2.50 bar)
High-speed riding:
Front:
210 kPa (30 psi) (2.10 kgf/cm
2) (2.10 bar)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2) (2.50 bar)
Front wheel:Wheel type:
Cast wheel
Rim size:
15 x MT3.5
Rear wheel:Wheel type:
Cast wheel
Rim size:
14 x MT3.75
Front brake:Type:
Single 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:
94.0 mm (3.70 in)
Rear suspension:Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
83.0 mm (3.27 in)
Electrical system:Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magneto
Battery:Model:
YTX9-BS
SPECIFICATIONS
8-2
8
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INDEX
AAcceleration and deceleration ...................5-2
Air filter and V-belt case air filter
elements ................................................6-15
Anti-theft alarm (optional) ..........................3-9
Auxiliary light bulb, replacing ...................6-32
BBattery......................................................6-26
Brake fluid level, checking .......................6-21
Brake fluid, changing ...............................6-22
Brake lever, front ......................................3-10
Brake lever, rear .......................................3-11
Brake levers, lubricating ..........................6-23
Braking .......................................................5-3
CCables, checking and lubricating ............6-23
Care............................................................7-1
Catalytic converters .................................3-13
Centerstand and sidestand, checking
and lubricating .......................................6-24
Coolant.....................................................6-14
Coolant temperature gauge .......................3-5
Cowlings and panel, removing and
installing ...................................................6-7
DDimmer switch ...........................................3-9
Display, multi-function ...............................3-6
EEngine break-in ..........................................5-4
Engine oil .................................................6-10
Engine trouble warning light ......................3-3
FFinal transmission oil ...............................6-13
Front and rear brake lever free play.........6-20Front and rear brake pads, checking ......6-21
Front fork, checking .................................6-24
Fuel ..........................................................3-12
Fuel consumption, tips for reducing ..........5-3
Fuel gauge .................................................3-5
Fuel level warning light ..............................3-3
Fuel tank cap ...........................................3-11
Fuses, replacing .......................................6-27
HHandlebar switches ...................................3-9
Hazard switch ............................................3-9
Headlight bulb, replacing .........................6-29
High beam indicator light...........................3-3
Horn switch ................................................3-9
I
Identification numbers ...............................9-1
Ignition circuit cut-off system ..................3-18
Immobilizer system ....................................3-1
Immobilizer system indicator light .............3-3
Indicator and warning lights ......................3-3
KKey identification number ..........................9-1
LLicense plate light bulb, replacing ...........6-32
MMain switch/steering lock ..........................3-2
Matte color, caution ...................................7-4
Model label ................................................9-2
PParking .......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart .........................................................6-3
Pre-operation check list .............................4-2
SSafe-riding points.......................................1-1
Safety information ......................................1-1
Seat ..........................................................3-14
Self-diagnosis device.................................3-4
Shock absorber assemblies, adjusting....3-17
Sidestand .................................................3-18
Spark plug, checking .................................6-9
Specifications.............................................8-1
Speedometer .............................................3-4
Start switch ................................................3-9
Starting off .................................................5-2
Starting the engine.....................................5-1
Steering, checking ...................................6-25
Storage.......................................................7-3
Storage compartment (front) ...................3-15
Storage compartment (rear) .....................3-16
Storage compartments ............................3-14
TTail/brake light bulb or rear turn signal
light bulb, replacing ...............................6-30
Throttle cable free play, adjusting ............6-17
Throttle grip and cable, checking and
lubricating ..............................................6-23
Tires .........................................................6-18
Tool kit ........................................................6-1
Troubleshooting .......................................6-32
Troubleshooting charts ............................6-33
Turn signal indicator lights .........................3-3
Turn signal light bulb (front), replacing ....6-30
Turn signal switch ......................................3-9
VValve clearance ........................................6-17
Vehicle identification number .....................9-1
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