2016 YAMAHA XMAX 125 maintenance

Table of contents
Safety information............................1-1
Further safe-riding points ................1-5
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 lights and warning
lights ............................................3-4
Multi-function meter unit .................3-6
Handlebar switches.......................3-14
Front brake lever ...........................3-15
Rear brake lever ............................3-16
ABS (for ABS models) ...................3-16
Fuel tank cap.................................3-17
Fuel................................................3-18
Catalytic converters .....................3-19
Seat ...............................................3-20
Storage compartments .................3-21
Adjusting the shock absorber
assemblies .................................3-22
Sidestand ......................................3-23
Ignition circuit cut-off system........3-24
For your safety – pre-operation
checks...............................................4-1
Operation and important riding
points.................................................5-1
Starting the engine ..........................5-2
Starting off.......................................5-3
Acceleration and deceleration.........5-3
Braking ............................................5-4
Tips for reducing fuel
consumption ................................5-5
Engine break-in ...............................5-5
Parking ............................................5-6
Periodic maintenance and
adjustment........................................6-1
Owner’s tool kit ...............................6-2Periodic maintenance chart for the
emission control system.............. 6-3
General maintenance and
lubrication chart........................... 6-4
Removing and installing panels ...... 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 and check hoses........ 6-15
Checking the throttle grip free
play ............................................ 6-17
Valve clearance ............................. 6-17
Tires .............................................. 6-18
Cast wheels .................................. 6-20
Checking the front and rear brake
lever free play ............................ 6-20
Checking the front and rear brake
pads........................................... 6-21
Checking the brake fluid level....... 6-22
Changing the brake fluid............... 6-23
Checking and lubricating the
cables ........................................ 6-24
Checking and lubricating the
throttle grip and cable ............... 6-24
Lubricating the front and rear
brake levers ............................... 6-25
Checking and lubricating the
centerstand and sidestand ........ 6-25
Checking the front fork ................. 6-26
Checking the steering ................... 6-26
Checking the wheel bearings ....... 6-27
Battery .......................................... 6-27
Replacing the fuses ...................... 6-29
Replacing a headlight bulb ........... 6-31
Auxiliary lights ............................... 6-31
Tail/brake light .............................. 6-32
Front turn signal light .................... 6-32
Replacing a rear turn signal light
bulb............................................ 6-33
Replacing the license plate light
bulb............................................ 6-34
Troubleshooting ............................ 6-34
Troubleshooting charts ................. 6-35
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1-1
1
Safety information
EAU1026B
Be a Responsible Owner
As the vehicle’s owner, you are re-
sponsible for the safe and proper oper-
ation of your scooter.
Scooters are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this scooter.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of scooter operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Never operate a scooter without
proper training or instruction. Take
a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized scooter dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks
each time you use the vehicle to make
sure it is in safe operating condition.
Failure to inspect or maintain the vehi-
cle properly increases the possibility ofan accident or equipment damage.
See page 4-1 for a list of pre-operation
checks.
This scooter is designed to carry
the operator and a passenger.
The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of auto-
mobile/scooter accidents. Many
accidents have been caused by
an automobile driver who did not
see the scooter. Making yourself
conspicuous appears to be very
effective in reducing the chance of
this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for scooter accidents to
occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a scooter with-
out proper knowledge. Contact
an authorized scooter dealer to
inform you on basic scooter
maintenance. Certain mainte-
nance can only be carried out
by certified staff.
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent driver’s license.
• Make sure that you are qualified
and that you only lend your
scooter to other qualified opera-
tors.
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Instrument and control functions
3-19
3 95 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand. Use of unleaded fuel will extend
spark plug life and reduce mainte-
nance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
EAU13447
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING
EWA10863
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust sys-
tem has cooled down before
doing any maintenance work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
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For your safety – pre-operation checks
4-1
4
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.3-18
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-10
Final transmission 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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21,
6-22
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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21,
6-22
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing.6-17,
6-24
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Periodic maintenance and adjustment
6-1
6
EAUS1824
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading todeath. See page 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA10331
This scooter is designed for use on
paved roads only. If this scooter is
operated 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.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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Periodic maintenance and adjustment
6-2
6
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and
equipped to perform these particular
services.
EAU17382
Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-20.)
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.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1.
ZAUM1020
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Periodic maintenance and adjustment
6-3
6
EAU46872
TIP
The annual checks must be performed every year, except if a kilometer-
based maintenance, or for the UK, a mileage-based maintenance, is
performed instead.
From 30000 km (17500 mi), repeat the maintenance intervals starting from
6000 km (3500 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as
they require special tools, data and technical skills.
EAU69210
Periodic maintenance chart for the emission control system
NO. ITEM
1*Fuel line• Check fuel hoses for cracks or
damage.√√√√√
2Spark plug• Check condition.
• Clean and regap.√√
• Replace.√√
3*Va l v e s• Check valve clearance.
•Adjust.√√√√
4*Fuel injection• Check engine idle speed.√√√√√
5*Muffler and ex-
haust pipe• Check the screw clamp(s) for
looseness.√√√√√X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READING
ANNUAL CHECK
1 6 12 18 24
0.6 3.5 7 10.5 14
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Periodic maintenance and adjustment
6-4
6
EAU69250
General maintenance and lubrication chart
NO. ITEM
1*Air filter element• Replace.√√
2Air filter check
hose• Clean.√√√√√
3V-belt case air fil-
ter element• Clean.√√√√√
4*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
5*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
6*Brake hoses• Check for cracks or damage.
• Check for correct routing and
clamping.√√√√√
• Replace. Every 4 years
7*Brake fluid• Change. Every 2 years
8*Wheels• Check runout and for damage.√√√√
9*Tires• Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
10*Wheel bearings• Check bearings for looseness or
damage.√√√√
11*Steering bearings• Check bearing play and steering
for roughness.√√√√√
• Lubricate with lithium-soap-
based grease.Every 24000 km (14000 mi)
12*Chassis fasteners• Make sure that all nuts, bolts
and screws are properly tight-
ened.√√√√√
13Front brake lever
pivot shaft• Lubricate with silicone grease.√√√√√X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READING
ANNUAL CHECK
16121824
0.63.5710.514
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