2020 YAMAHA XMAX 400 Owners Manual

Periodic maintenance and adjustment
7-17
7 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.
EAU21386
Checking the throttle grip free
play
Measure the throttle grip free play as
shown.
Periodically check the throttle grip free
play and, if necessary, have a Yamaha
dealer adjust it.
1. Screw
2. V-belt case air filter element
2
1 1
1. Throttle grip free play
Throttle grip free play:
3.0–5.0 mm (0.12–0.20 in)
UBL1E0E0.book Page 17 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-18
7
EAU21402
Valve clearance
The 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.
EAU69760
Tires
Tires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
EWA10504
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
UBL1E0E0.book Page 18 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-19
7
WARNING
EWA10512
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
TIP
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
WARNING
EWA10472
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience to do so.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
Tire information
This model is equipped with tubeless
tires and rubber tire air valves.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
Tire air pressure (measured on cold
tires):
1 person:
Front:
220 kPa (2.20 kgf/cm², 32 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
2 persons:
Front:
220 kPa (2.20 kgf/cm², 32 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Maximum load*:
184 kg (406 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depth
12
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
UBL1E0E0.book Page 19 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-20
7
WARNING
EWA10462
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.
EAU21995
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
The wheel rims should be
checked for cracks, bends, warp-
age or other damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
After repairing or replacing the
rear tire, tighten the valve stem nut
and locknut to the specified
torques.
Front tire:
Size:
120/70-15 M/C 56S
Manufacturer/model:
MICHELIN/CITY GRIP
Rear tire:
Size:
150/70-13 M/C 64S
Manufacturer/model:
MICHELIN/CITY GRIP
1. Valve stem nut
2. Valve stem locknut
Tightening torques:
Valve stem nut:
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
Valve stem locknut:
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
1
2
UBL1E0E0.book Page 20 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-21
7
EAU50861
Checking the front and rear
brake lever free play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish thebraking performance, which may re-
sult in loss of control and an acci-
dent.
1. No brake lever free play
1. No brake lever free play
ZAUM1049
ZAUM1050
UBL1E0E0.book Page 21 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-22
7
EAU53033
Adjusting the rear brake lock
cable
Periodically check the rear brake lock
cable length and adjust if necessary.
1. Release the rear brake lock lever.
2. To increase the rear brake lock ca-
ble length, turn the adjusting nut at
the rear brake caliper in direction
(a). To decrease the rear brake
lock cable length, turn the adjust-
ing nut in direction (b).
3. Confirm that the rear brake lock
lever (page 4-14) functions prop-
erly and that the rear wheel rotates
freely when unlocked.
WARNING
EWA20290
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAUM3970
Checking the rear brake lock
The rear brake lock must be checked
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Adjust the rear brake lock cable.
2. Apply the rear brake lock, and
then try to push the vehicle to con-
firm that the rear brake lock func-
tions properly.
3. The rear brake lock caliper is pro-
vided with wear pad indicator
grooves, which allow you to check
the brake pad wear without having
to disassemble the brake. To
check the brake pad wear, check
the wear indicator grooves. If a
brake pad has worn to the point
that the wear indicator grooves
have almost disappeared, have a
Yamaha dealer replace the brake
pads as a set and check the rear
brake lock.
1. Adjusting nut
2. Rear brake lock cable length
Rear brake lock cable length:
66.5–67.5 mm (2.62–2.66 in)
ZAUM1515
2
(b) (a)
1
2
(b) (a)
1. Brake pad wear indicator groove
ZAUM1514
UBL1E0E0.book Page 22 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-23
7
EAU22393
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22432Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU34211Rear brake pads
Have a Yamaha dealer check each rear
brake pad for damage and measure
the lining thickness and if necessary,
replace them as a set.
EAU40262
Checking the brake fluid level
Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA16011
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
1. Wear indicator groove
ZAUM15011. Minimum level mark
1. Minimum level mark
Specified brake fluid:
DOT 4
1
ZAUM1057
ZAUM1032
1
UBL1E0E0.book Page 23 Thursday, May 11, 2017 8:51 AM

Periodic maintenance and adjustment
7-24
7Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-
sult in vapor lock, and dirt may
clog the ABS hydraulic unit
valves.NOTICE
ECA17641
Brake fluid may damage painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22734
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid every 2 years. In addition,
have the seals of the master cylinders
and brake calipers, as well as the brake
hoses replaced at the intervals listed
below or sooner if they are damaged or
leaking.
Brake seals: every 2 years
Brake hoses: every 4 years
UBL1E0E0.book Page 24 Thursday, May 11, 2017 8:51 AM