2016 YAMAHA XMAX 400 seat adjustment

TABLE OF CONTENTSSAFETY 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............................................ 3-3
Speedometer .................................. 3-5
Tachometer .................................... 3-6
Multi-function display ..................... 3-6
Anti-theft alarm (optional) ............. 3-10
Handlebar switches ...................... 3-10
Front brake lever .......................... 3-11
Rear brake lever ........................... 3-12
ABS (for ABS models) .................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-14
Catalytic converters...................... 3-15
Seat .............................................. 3-16
Storage compartments................. 3-16
Adjusting the shock absorber
assemblies ................................ 3-18
Sidestand ..................................... 3-18
Ignition circuit cut-off system ....... 3-19FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting the engine .......................... 5-1
Starting off ...................................... 5-2
Acceleration and deceleration ........ 5-3
Braking ............................................ 5-3
Tips for reducing fuel
consumption ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and
lubrication chart ........................... 6-4
Removing and installing panels ...... 6-8
Checking the spark plug ............... 6-11
Engine oil and oil filter element ..... 6-13
Final transmission oil..................... 6-15
Coolant.......................................... 6-16
Air filter elements and check
hoses and V-belt case air filter
element ...................................... 6-18
Checking the throttle grip free
play ............................................ 6-20Valve clearance............................. 6-20
Tires .............................................. 6-21
Cast wheels .................................. 6-22
Checking the front and rear brake
lever free play ............................ 6-23
Checking the front and rear brake
pads .......................................... 6-24
Checking the brake fluid level ...... 6-24
Changing the brake fluid .............. 6-26
Checking and lubricating the
cables ........................................ 6-26
Checking and lubricating the
throttle grip and cable ............... 6-26
Lubricating the front and rear
brake levers ............................... 6-27
Checking and lubricating the
centerstand and sidestand........ 6-27
Checking the front fork ................. 6-28
Checking the steering................... 6-29
Checking the wheel bearings ....... 6-29
Battery .......................................... 6-29
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-32
Tail/brake light .............................. 6-33
Front turn signal light .................... 6-33
Replacing a rear turn signal light
bulb ........................................... 6-33
Replacing the license plate light
bulb ........................................... 6-34
Auxiliary light ................................ 6-35
Troubleshooting............................ 6-35U1SDE1E0.book Page 1 Monday, September 23, 2013 3:55 PM

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 kitThe owner’s tool kit is located under
the seat. (See page 3-16.)
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.TIPIf 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
6-11
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
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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
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6 spring will fall out. Take care not
to lose the compression spring.
[ECA12912]
6. Remove and replace the oil filter
element and O-rings.7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
TIPMake sure that the O-rings are properly
seated.8. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA11671
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
1. Bolt
2. Oil filter element cover
21
1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
24
3
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element replacement:
1.70 L (1.80 US qt, 1.50 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
EAUM3051
Air filter elements and check
hoses and V-belt case air filter
elementThe air filter elements and the V-belt
case air filter element should be ser-
viced at the intervals specified in the
periodic maintenance and lubrication
chart. Service all air filter elements
more frequently if you are riding in un-
usually wet or dusty areas.
Replacing the air filter elements
1. Place the scooter on the center-
stand.TIPContinue as follows for each air filter el-
ement.2. Remove the air filter case cover by
removing the rubber caps and
screws.Left
Right
3. Pull the air filter element out.Left
Right
4. Insert a new air filter element into
the air filter case.
5. Install the air filter case cover by
installing the screws. NOTICE:
Make sure that each filter ele-
ment is properly seated in its
1. Screw
2. Air filter case cover
3. Rubber cap
1. Screw
2. Air filter case cover
3. Rubber cap
1
21
13
3
1
1
23
1. Air filter element
1. Air filter element
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
6-33
6
EAU24182
Tail/brake lightThis model is equipped with an LED-
type tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU39881
Front turn signal lightIf a front turn signal light does not
come on, have a Yamaha dealer check
its electrical circuit or replace the bulb.
EAUM3062
Replacing a rear turn signal
light bulb1. Place the scooter 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 socket (together with
the turn signal light bulb) by turn-
ing it counterclockwise.
5. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.1. Bolt
2. Storage compartmentZAUM1052
1
2
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