YAMAHA XCITY 125 2009 Service Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU17715
Periodic maintenance and lubrication chart TIP

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
1*Fuel lineCheck fuel hoses for cracks or
damage.√√√√√
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√√√
4*Air filter elementReplace.√√
5V-belt case air filter
elementClean.√√√√
6*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
U16PE1E0.book Page 2 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
8*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
11*Wheel bearingsCheck bearing for looseness or
damage.√√√√
12*Steering bearingsCheck bearing play and steering
for roughness.√√√√√
Lubricate with lithium-soap-based
grease.Every 24000 km (14000 mi)
13*Chassis fastenersMake sure that all nuts, bolts and
screws are properly tightened.√√√√√
14Sidestand, center-
standCheck operation.
Lubricate.√√√√√
15*Sidestand switchCheck operation.√√√√√√
16*Front forkCheck operation and for oil leak-
age.√√√√
17*Shock absorber as-
sembliesCheck operation and shock ab-
sorbers for oil leakage.√√√√
18*Fuel injectionCheck engine idle speed.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
U16PE1E0.book Page 3 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
19 Engine oilChange. (See page 3-3.)√When the oil change indicator light comes on [5000 km (3000 mi)
after the initial 1000 km (600 mi) and every 6000 km (3500 mi)
thereafter]
Check oil level and vehicle for oil
leakage.Every 3000 km (1800 mi)√
20Engine oil filter ele-
mentReplace.√√√
21*Cooling systemCheck coolant level and vehicle
for coolant leakage.√√√√√
Change. Every 3 years
22Final transmission
oilCheck vehicle for oil leakage.√√ √
Change.√√√
23*V- b e l tReplace. Every 18000 km (10500 mi)
24*Front and rear brake
switchesCheck operation.√√√√√√
25Moving parts and
cablesLubricate.√√√√√
26*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.√√√√√
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
U16PE1E0.book Page 4 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
EAU18670
TIP

The air filter needs more frequent service if you are 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 cylinders and calipers, and change the brake
fluid.Replace the brake hoses every four years and if cracked or damaged.
U16PE1E0.book Page 5 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
EAU18712
Removing and installing cowl-
ings and panels The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAUM2221
Cowling A
To remove the cowling1. Remove the cowling screws.2. Disconnect the headlight coupler
and the turn signal couplers.
3. Pull the cowling off.
1. Cowling AZAUM0652
1
1. Panel A
1. Panel BZAUM0653
1
ZAUM0654
1
1. Cowling A
2. Screw
1. Turn signal light lead coupler
2. Headlight couplerZAUM0655
2
1
12
ZAUM0428
U16PE1E0.book Page 6 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6To install the cowling
1. Connect the headlight coupler and
the turn signal couplers.
2. Place the cowling in the original
position, and then install the
screws.
EAU19481
Panel A
To remove the panel1. Open the seat. (See page 3-12.)
2. Remove the screws, and then pull
the panel off as shown.
To install the panelPlace the panel in the original position,
and then install the screws.
EAU19210
Panel B
To remove the panelRemove the screws, and then take the
panel off.
To install the panelPlace the panel in the original position,
and then install the screws.
EAU19622
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 ac-
cordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter 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 differ-
ent color, the engine could be operating
improperly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced.
1. Screw
2. Panel AZAUM0656
1
2
1. ScrewZAUM0657
1
Specified spark plug:
NGK/CPR9EA-9
U16PE1E0.book Page 7 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
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 speci-fied torque as soon as possible.
EAUM2271
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec-
ified in the periodic maintenance and
lubrication chart and when the service
indicator light comes on.
To check the engine oil level
1. Place the scooter 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 theminimum and maximum level marks.
1. Spark plug gapSpark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
1
ZAUM0037
U16PE1E0.book Page 8 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
64. If the engine oil is below the mini-
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. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the drain bolt washer for
damage and replace it if neces-
sary.
TIPSkip steps 5–9 if the oil filter element isnot being replaced.
5. Remove the oil filter element cover
by removing the bolts.
6. Remove the oil filter element and
O-ring.
1. Engine oil filler capZAUM0701
1
1. Engine oil drain bolt
1. Engine oil drain bolt
2. WasherZAUM0702
112
ZAUM0129
1. Oil filter element coverZAUM0711
1
U16PE1E0.book Page 9 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 7. Check the O-ring for damage and
replace it if necessary.
8. Install the new oil filter element and
an O-ring.
9. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
TIPMake sure that the O-ring is properlyseated.10. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
TIPMake sure that the washer is properlyseated.
11. 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
ECA11670


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.
12. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
13. Turn the engine off, and then
check the oil level and correct it if
necessary.
14. Reset the oil change indicator.
(See page 3-8.)
1. Oil filter element
2. O-ring
3. Oil filter element coverTightening torque:
Oil filter cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)1
2
3
ZAUM0712
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil change quantity:
Without oil filter element replace-
ment:
1.40 L (1.48 US qt, 1.23 Imp.qt)
With oil filter element replacement:
1.50 L (1.59 US qt, 1.32 Imp.qt)
U16PE1E0.book Page 10 Monday, July 28, 2008 9:57 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
EAU20064
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 final transmission
drain bolt to drain the oil from the fi-
nal transmission case.5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.6. Refill with the specified amount of
the recommended final transmis-
sion oil, and then install and tighten
the oil filler cap. WARNING! Make
sure that no foreign material en-
ters the final transmission case.
Make sure that no oil gets on the
tire or wheel.
[EWA11311]
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
1. Final transmission oil filler cap
1. Final transmission oil drain boltTightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1
ZAUM0658ZAUM0703
1
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.21 L (0.22 US qt, 0.18 Imp.qt)
U16PE1E0.book Page 11 Monday, July 28, 2008 9:57 AM