2015 YAMAHA XMAX 400 check engine

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the speci-
fied torque.
7. Refill with the specified amount of
the recommended final transmis-
sion oil. WARNING! Make surethat no foreign material enters
the final transmission case.
Make sure that no oil gets on
the tire or wheel.
[EWA11312]
8. Install the final transmission oil fill-
er cap and its new O-ring, and
then tighten the oil filler cap.
9. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20071
CoolantThe coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUM3043
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
2. Open the front storage compart-
ment A. (See page 3-16.)TIPThe coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.3. Check the coolant level through
the check window.
1. Final transmission oil filler cap
2. O-ring
3. Final transmission oil drain bolt
4. GasketTightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
21
34
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
U1SDE1E0.book Page 16 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
TIPThe coolant should be between the mi-
nimum and maximum level marks.4. If the coolant is at or below the mi-
nimum level mark, remove panel
B. (See page 6-8.)
5. Open the reservoir cap, and then
add coolant to the maximum level
mark. WARNING! Remove only
the coolant reservoir cap. Never
attempt to remove the radiator
cap when the engine is hot.
[EWA15162]
NOTICE: If coolant is not
available, use distilled water or
soft tap water instead. Do not
use hard water or salt watersince it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10473]
6. Close the reservoir cap, and then
install the panel.7. Close the front storage compart-
ment.
EAU33032
Changing the coolant
The coolant must be changed at the in-
tervals specified in the periodic main-
tenance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING! Never attempt to remove
the radiator cap when the engine is
hot.
[EWA10382]
1. Maximum level mark
2. Minimum level markZAUM1029
2 1
Coolant LevelCoolant L
evelH
ighH
igh
LowLo
w
1. Coolant reservoir capCoolant reservoir capacity:
0.31 L (0.33 US qt, 0.27 Imp.qt)ZAUM10301
U1SDE1E0.book Page 17 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6case. Always replace both air fil-
ter elements at the same time,
otherwise poor engine perfor-
mance or damage to the engine
may result. The engine should
never be operated without the
filter elements installed, other-
wise the piston(s) and/or cylin-
der(s) may become excessively
worn.
[ECA12924]
6. Install the rubber caps.
To clean the air filter check hoses
1. Check the hose at the bottom of
both air filter cases for accumulat-
ed dirt or water.
LeftRight
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
Cleaning the V-belt case air filter el-
ement
1. Remove panel A. (See page 6-8.)
2. Remove the left air filter case cov-
er.
3. Remove the V-belt air filter case
cover by removing the screws.4. Remove the V-belt case air filter
element by removing the screws.1. Air filter check hose
1
1. Air filter check hose
1
1. Screw
2. V-belt air filter case cover
1. Screw
2. V-belt case air filter elementZAUM10312
11
2
1 1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6 5. Lightly tap the V-belt case air filter
element to remove most of the
dust and dirt, and then blow out
the dirt with compressed air as
shown.
6. Check the V-belt case air filter ele-
ment for damage and replace it if
necessary.
7. Install the V-belt case air filter ele-
ment by installing the screws.
NOTICE: Make sure that the V-
belt filter element is properly
seated in its case.
[ECA12942]
8. Install the V-belt air filter case cov-
er by installing the screws.
9. Install the left air filter case cover.
10. Install the panel.
EAU21385
Checking the throttle grip free
playThe throttle grip free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er adjust it.
EAU21402
Valve clearanceThe 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.
1. Throttle grip free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
6
EAU42706
Troubleshooting chartsStarting problems or poor engine performance
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the battery.
Supply fuel.
The engine does not start.
Check the battery.
Operate the electric starter.4. Compression
There is compression.
There is no compression.
The engine does not start.
Have a Yamaha dealer check the vehicle.Have a Yamaha dealer check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the compression.
Operate the electric starter.2. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.
DryWet
Operate the electric starter.
Check the battery lead connections,
and have a Yamaha dealer charge
the battery if necessary.
The engine does not start.
Check the ignition.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
6Engine overheating
WARNING
EWAT1041
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the
detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap
while turning it counterclockwise, and then remove the cap.TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended cool-
ant as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U1SDE1E0.book Page 37 Monday, September 23, 2013 3:55 PM

SCOOTER CARE AND STORAGE
7-4
7
EAU36564
StorageShort-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the
scooter.NOTICE
ECA10821
Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.
[EWA10952]
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. 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.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully char-
ge it. Store it in a cool, dry place
and charge it once a month. Do
not store the battery in an exces-
sively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-29.TIPMake any necessary repairs before
storing the scooter.
U1SDE1E0.book Page 4 Monday, September 23, 2013 3:55 PM

10-1
10
INDEX
AABS (for ABS models) .......................... 3-12
ABS warning light (for ABS models) ....... 3-4
Acceleration and deceleration ................ 5-3
Air filter elements and check hoses
and V-belt case air filter element ....... 6-18
Anti-theft alarm (optional) ..................... 3-10
Auxiliary light ........................................ 6-35BBattery .................................................. 6-29
Brake fluid, changing............................ 6-26
Brake fluid level, checking.................... 6-24
Brake lever, front .................................. 3-11
Brake lever, rear ................................... 3-12
Brake levers, lubricating ....................... 6-27
Braking ................................................... 5-3CCables, checking and lubricating ......... 6-26
Care ........................................................ 7-1
Catalytic converters.............................. 3-15
Centerstand and sidestand, checking
and lubricating ................................... 6-27
Coolant ................................................. 6-16DDimmer switch...................................... 3-11EEngine break-in ...................................... 5-4
Engine oil and oil filter element............. 6-13
Engine trouble warning light ................... 3-4FFinal transmission oil ............................ 6-15
Front and rear brake lever free play,
checking ............................................. 6-23
Front and rear brake pads, checking ... 6-24Front fork, checking ............................. 6-28
Front turn signal light ........................... 6-33
Fuel ...................................................... 3-14
Fuel consumption, tips for reducing ...... 5-4
Fuel tank cap........................................ 3-13
Fuses, replacing ................................... 6-31
HHandlebar switches ............................. 3-10
Hazard switch ...................................... 3-11
Headlight bulb, replacing ..................... 6-32
High beam indicator light ....................... 3-4
Horn switch .......................................... 3-11IIdentification numbers ........................... 9-1
Ignition circuit cut-off system .............. 3-19
Immobilizer system ................................ 3-1
Immobilizer system indicator light ......... 3-4
Indicator lights and warning lights ......... 3-3LLicense plate light bulb, replacing ....... 6-34MMain switch/steering lock ...................... 3-2
Maintenance and lubrication, periodic... 6-4
Maintenance, emission control
system ................................................. 6-3
Matte color, caution ............................... 7-1
Model label............................................. 9-1
Multi-function display............................. 3-6PPanels, removing and installing ............. 6-8
Parking ................................................... 5-5
Part locations ......................................... 2-1
Pass switch .......................................... 3-11
SSafe-riding points ................................... 1-5
Safety information................................... 1-1
Seat....................................................... 3-16
Shock absorber assemblies,
adjusting ............................................. 3-18
Sidestand.............................................. 3-18
Spark plug, checking ............................ 6-11
Specifications ......................................... 8-1
Speedometer .......................................... 3-5
Starting off .............................................. 5-2
Starting the engine ................................. 5-1
Start switch ........................................... 3-11
Steering, checking ................................ 6-29
Storage ................................................... 7-4
Storage compartments ......................... 3-16TTachometer............................................. 3-6
Tail/brake light ...................................... 6-33
Throttle grip and cable, checking and
lubricating ........................................... 6-26
Throttle grip free play, checking ........... 6-20
Tires ...................................................... 6-21
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-35
Troubleshooting charts ......................... 6-36
Turn signal indicator lights...................... 3-3
Turn signal light bulb (rear),
replacing ............................................. 6-33
Turn signal switch ................................. 3-11VValve clearance..................................... 6-20
Vehicle identification number ................. 9-1
U1SDE1E0.book Page 1 Monday, September 23, 2013 3:55 PM