2020 YAMAHA XMAX 400 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
Smart key system ............................3-1
Smart key system............................3-1
Operating range of the smart key
system .........................................3-2
Handling of the smart key and
mechanical keys ..........................3-3
Smart key ........................................3-5
Replacing the smart key battery .....3-6
Main switch .....................................3-8
Instrument and control functions....4-1
Indicator lights and warning
lights ............................................4-1
Speedometer...................................4-2
Tachometer .....................................4-3
Multi-function display......................4-3
Handlebar switches.......................4-12
Front brake lever ...........................4-13
Rear brake lever ............................4-14
Rear brake lock lever ....................4-14
ABS ...............................................4-15
Traction control system.................4-16
Fuel tank cap.................................4-18
Fuel................................................4-19
Fuel tank overflow hose ................4-20
Catalytic converters .....................4-21
Storage compartments .................4-21
Windshield.....................................4-23
Handlebar position .......................4-26
Adjusting the shock absorber
assemblies .................................4-26
Sidestand ......................................4-27
Ignition circuit cut-off system........4-28
Auxiliary DC jack ..........................4-30For your safety – pre-operation
checks............................................... 5-1
Operation and important riding
points................................................. 6-1
Starting the engine.......................... 6-2
Starting off ...................................... 6-3
Acceleration and deceleration ........ 6-3
Braking............................................ 6-4
Tips for reducing fuel
consumption................................ 6-5
Engine break-in ............................... 6-5
Parking ............................................ 6-6
Periodic maintenance and
adjustment........................................ 7-1
Owner’s tool kit ............................... 7-2
Periodic maintenance chart for the
emission control system.............. 7-3
General maintenance and
lubrication chart........................... 7-4
Removing and installing panels ...... 7-7
Checking the spark plug ................. 7-8
Canister........................................... 7-9
Engine oil and oil filter element ..... 7-10
Final transmission oil .................... 7-12
Coolant ......................................... 7-13
Air filter elements and check
hoses and V-belt case air filter
element ...................................... 7-15
Checking the throttle grip free
play ............................................ 7-17
Valve clearance ............................. 7-18
Tires .............................................. 7-18
Cast wheels .................................. 7-20
Checking the front and rear brake
lever free play ............................ 7-21
Adjusting the rear brake lock
cable .......................................... 7-22
Checking the rear brake lock ........ 7-22
Checking the front and rear brake
pads........................................... 7-23
Checking the brake fluid level....... 7-23
Changing the brake fluid............... 7-24
Checking the V-belt ...................... 7-25
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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 5-1 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
4-21
4
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.
EAU78514
Storage compartments
This model is equipped with 3 storage
compartments. The front storage com-
partments and rear storage compart-
ment are located as shown.
TIP
Storage compartment A must be
opened using the smart key sys-
tem. (See page 3-9.)
The seat/rear storage compart-
ment can be opened using the
smart key system or the mechani-
cal key.
Some helmets cannot be stored in
the rear storage compartment be-
cause of their size or shape.
1. Storage compartment A
2. Storage compartment B
1. Rear storage compartment
2
1
1
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For your safety – pre-operation checks
5-1
5
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.
• Check fuel tank overflow hose for obstructions, cracks
or damage, and check hose connection.4-19,
4-20
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.7-10
Final transmission oil• Check vehicle for oil leakage. 7-12
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified
level.
• Check cooling system for leakage.7-13
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.7-21,
7-23,
7-23
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.7-21,
7-23,
7-23
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.7-17,
7-26
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Periodic maintenance and adjustment
7-1
7
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
7-2
7
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.
EAU79250
Owner’s tool kit
The owner’s tool kit is located on the
bottom of the seat. (See page 3-9.)
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.
1
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Periodic maintenance and adjustment
7-3
7
EAU71031
TIP
The annual checks must be performed every year, except if a distance-
based maintenance is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from
10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as
they require special tools, data and technical skills.
EAU71071
Periodic maintenance chart for the emission control system
NO. ITEM
1*Fuel line• Check fuel hoses for cracks or
damage.
• Replace if necessary.√√√√√
2*Spark plug• Check condition.
• Adjust gap and clean.√√
• Replace.√√
3*Valve clearance• Check and adjust. Every 40000 km (24000 mi)
4*Fuel injection• Check engine idle speed.√√√√√√
5*Exhaust system• Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary.√√√√√
6*Evaporative emis-
sion control sys-
tem• Check control system for dam-
age.
• Replace if necessary.√√
7*Air induction sys-
tem• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if
necessary.√√√√√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
7-4
7
EAU71372
General maintenance and lubrication chart
NO. ITEM
1*Diagnostic system
check• Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes.√√√√√√
2*Air filter element• Replace.√√
3Air filter case
check hose• Clean.√√√√√
4*V-belt case air fil-
ter element• Clean.
• Replace if necessary.√√√√√
5*Front brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
6*Rear brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
7*Brake hoses• Check for cracks or damage.√√√√√
• Replace. Every 4 years
8*Brake fluid• Change. Every 2 years
9Rear brake lock
cable• Check cable length.
• Adjust if necessary.At the initial interval and 4000
km (2400 mi) after the initial
1000 km (600 mi) and every
5000 km (3000 mi) thereafter.
10*Rear brake lock• Check operation.
•Adjust.√√√√√√
11*Wheels• Check runout and for damage.
• Replace if necessary.√√√√
12*Tires• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
13*Wheel bearing
s• Check bearing for looseness or
damage.√√√√
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGSANNUAL CHECK
1 10203040
0.6 6 12 18 24
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