2016 YAMAHA XMAX 400 Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
EAU34492
TIPEngine air filters and V-belt air filter
• This model’s engine air filters are equipped with disposable oil-coated paper elements, which must not be cleaned
with compressed air to avoid damaging them.
• The engine air filter elements need to be replaced and the V-belt air filter element needs to be serviced more fre-
quently when riding in unusually wet or dusty areas.21*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
22Final transmission
oil• Check vehicle for oil leakage.√√ √
• Change.√√√√√√
23*V-belt• Replace. When the V-belt replacement indicator flashes [every 20000 km (12500 mi)]
24*Front and rear
brake switches• Check operation.√√√√√√
25Moving parts and
cables• Lubricate.√√√√√
26*Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing.√√√√√
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U1SDE1E0.book Page 6 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
• Replace the brake hoses every four years and if cracked or damaged.
U1SDE1E0.book Page 7 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU18772
Removing and installing pan-
elsThe panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAUM3101
Panel A
To remove the panelRemove the screws, and then pull the
panel outward.
To install the panelPlace the panel in the original position,
and then install the screws.
1. Panel AZAUM1024
1
1. Panel B
2. Panel C
1. Panel DZAUM10221
2
ZAUM1021
1
1. Panel A
2. Screw
21
U1SDE1E0.book Page 8 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6Panel B
To remove the panel
1. Open the front storage compart-
ment A. (See page 3-16.)
2. Remove the screw, and then pull
the panel off.To install the panel
Place the panel in the original position,
and then install the screw.
Panel C
To remove the panel1. Open the front storage compart-
ment B. (See page 3-16.)
2. Remove the screw, and then pull
the panel off.To install the panel
Place the panel in the original position,
and then install the screw.
Panel D
To remove the panel1. Remove the quick fastener, and
then pull the under cowling off as
shown.TIPThe quick fastener is removed by
pushing the center pin in with a screw-
driver, and then pulling the fastener
out.
1. Screw1
1. Panel B
2. ScrewZAUM1046
12
1. Panel C
2. ScrewZAUM104712
U1SDE1E0.book Page 9 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 2. Remove the cowling screws, and
then pull it off.
3. Remove the battery bracket bolts,
and then pull it off.4. Remove the battery bracket and
panel assembly by pulling it off as
shown.
To install the panel
1. Place the battery bracket and
panel assembly in the original po-
sition, and then install the bolts.
2. Place the cowling in the original
position, and then install the
screws.
3. Place the under cowling in the
original position, and then install
the quick fastener.
TIPTo install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the under cowling, and then
push the protruding pin in until it is
flush with the fastener head.
1. Cowling
2. Quick fastener
1. Screw
2. CowlingZAUM104212ZAUM10432
1
1
1. Panel D
2. Bracket
3. BoltZAUM1045
1
32
3
U1SDE1E0.book Page 10 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
EAUM3021
Checking the spark plugThe spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plug
1. Place the vehicle on the center-
stand
2. Open the seat. (See page 3-16.)
3. Remove the rear storage com-
partment by removing the bolts.4. Remove the spark plug cap.
5. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
1. Storage compartment
2. BoltZAUM1040
2
1
1. Spark plug cap
1. Spark plug wrenchZAUM1025
1
ZAUM1026
1
Specified spark plug:
NGK/CR7E
U1SDE1E0.book Page 11 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
To install the spark plug
1. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
2. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4…
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.3. Install the spark plug cap.TIPMake sure the spark plug wire is fas-
tened in the clamp as shown.4. Place the rear storage compart-
ment in the original position and
install the bolts.5. Close the seat.
1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.04 ft·lbf)
1
1. Spark plug cap
2. Spark plug lead clamp
3. Spark plug lead
ZAUM1027
1
2 3
U1SDE1E0.book Page 12 Monday, September 23, 2013 3:55 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
EAUM3031
Engine oil and oil filter ele-
mentThe engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart and when the oil change
indicator comes on.
To check the engine oil level
1. Place the vehicle on the center-
stand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.TIPThe engine oil should be between the
tip of the dipstick and the maximum
level mark.
4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Place the vehicle on the center-
stand.2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIPSkip steps 5…7 if the oil filter element is
not being replaced.5. Remove the oil filter element cover
by removing the bolts. NOTICE:
When removing the oil filter ele-
ment cover, the compression
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Tip of the engine oil dipstickZAUM102834
1
2
1. Engine oil drain bolt
2. Gasket
12
U1SDE1E0.book Page 13 Monday, September 23, 2013 3:55 PM