2020 YAMAHA XMAX 400 maintenance

Periodic maintenance and adjustment
7-5
7
14*Steering bearings• Check bearing assemblies for
looseness.√√ √
• Moderately repack with lithium-
soap-based grease.√√
15*Chassis fasteners• Make sure that all nuts, bolts
and screws are properly tight-
ened.√√√√√
16Front and rear
brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
17Sidestand, center-
stand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
18*Sidestand switch• Check operation and replace if
necessary.√√√√√√
19*Front fork• Check operation and for oil
leakage.
• Replace if necessary.√√√√
20*Shock absorber
assemblies• Check operation and for oil
leakage.
• Replace if necessary.√√√√
21 Engine oil• Change (warm engine before
draining).
• Check oil level and vehicle for
oil leakage.At the initial interval and
when the oil change indi-
cator flashes or comes
on.√
22Engine oil filter el-
ement• Replace.√√√
23*Final transmission
oil• Check vehicle for oil leakage.√√√√√
• Change.√√√√√√
24
*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change. Every 3 years
25*V-belt• Replace.When the V-belt replacement
indicator flashes [every 20000
km (12000 mi)]
26*Front and rear
brake switches• Check operation.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
7-6
7
EAU72770
TIP
Engine air filters and V-belt air filter
• This model’s engine air filters are equipped with disposable oil-coated pa-
per 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 frequently when riding in unusually wet
or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cyl-
inders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
27*Moving parts and
cables• Lubricate.√√√√√
28*Throttle grip hous-
ing and cable• Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous-
ing and cable.√√√√√
29*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance and adjustment
7-7
7
EAU18773
Removing and installing pan-
els
The 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.
EAUM3950
Panel A
To remove the panel
Remove the screws, and then pull the
panel outward.To install the panel
Place the panel in the original position,
and then install the screws.
Panel B
To remove the panel
Remove the screws, and then pull the
panel outward and slide it forward as
shown.
1. Panel A
1. Panel B
ZAUM1024
1
ZAUM1509
1
1. Panel A
2. Screw
1. Screw
ZAUM145921
ZAUM14601
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Periodic maintenance and adjustment
7-8
7
To install the panel
Place the panel in the original position,
and then install the screws.
EAU19623
Checking the spark plug
The spark plug is an important engine
component, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
it should be removed and checked in
accordance with the periodic mainte-
nance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be operating improperly. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
1. Screw
1. Panel B
ZAUM1506
1
1
ZAUM1507
1
ZAUM1508
Specified spark plug:
NGK/CR7E
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Periodic maintenance and adjustment
7-9
7 Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the spark
plug threads.
TIP
If 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.
EAU36112
Canister
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this vehicle, make sure to check the
following:
Check each hose connection.
Check each hose and canister for
cracks or damage. Replace if
damaged.
Make sure that the canister
breather is not blocked, and if
necessary, clean it.
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 N·m (1.25 kgf·m, 9.22 lb·ft)1. Canister
2. Canister breather hose
2
1
ZAUM1458
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Periodic maintenance and adjustment
7-10
7
EAUM3940
Engine oil and oil filter ele-
ment
The 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.
TIP
The 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.
TIP
Skip 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-1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Tip of the engine oil dipstick
ZAUM1028
3
4
1
2
1. Engine oil drain bolt
2. Gasket
12
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Periodic maintenance and adjustment
7-11
7 ment cover, the compression
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.
TIP
Make 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.
TIP
Be 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
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Be sure no foreign material en-
ters the crankcase.
1. Bolt
2. Oil filter element cover
1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
Tightening torque:
Oil filter element cover bolt:
10 N·m (1.0 kgf·m, 7.4 lb·ft)
21
12
43
Tightening torque:
Engine oil drain bolt:
20 N·m (2.0 kgf·m, 15 lb·ft)
Recommended engine oil:
See page 9-1.
Oil quantity:
Oil change:
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter removal:
1.70 L (1.80 US qt, 1.50 Imp.qt)
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Periodic maintenance and adjustment
7-12
710. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
11. Reset the oil change indicator.
(See page 4-7.)
TIP
If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time.
EAU20067
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm up the final
transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the center-
stand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the fi-
nal transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
1. Final transmission oil filler cap
2. O-ring
3. Final transmission oil drain bolt
4. Gasket
2
1
3
4
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