YAMAHA XMAX 125 2006 Service Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
ODOMETER READING (x 1000 Km)
ANNUAL
CHECKNO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24
22Final gear oil• Check vehicle for oil leakage.√√ √• Change.√√√
23*
V-belt case air filter • Clean. Every 6000 kmelements
• Replace. Every 20000 km
24 *Front and rear brake
• Check operation.√√ √ √√ √
switches
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
26 *
and cable• Adjust the throttle cable free play if necessary.√√√√ √
• Lubricate the throttle grip housing and cable.
27 *Muffler and exhaust pipe• Check the screw clamp for looseness.√√ √ √√
28 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
EAU18660
NOTE:
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 cylinder and caliper, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU18712
Removing and installing
cowlings 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
removed and installed.
EAU18790
Cowling A
T
o remove the cowling
1. Screws x 6
Cowling B
T
o remove the cowling
Screws
Remove the screws, and then take
the cowling off.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAUM1250
Panel A
T
o remove the panel
1. Open the storage compartment.
(See page 3-12.)
Screws
2. Remove the screw, and then take
the panel off.
T
o install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Close the storage compartment.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
EAUS1280
Checking the spark plug
The 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 maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Open the seat. (See page 3-11.)
2. Remove the storage compart-
ment under the seat by removing
the bolts.
1. Storage compartment
2. Screws
3. Remove the spark plug cap.
4. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the motorcy-
cle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
Specified spark plug:
NGK / CPR 9EA-91
2
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To install the spark plug
1. Spark plug gap
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
2. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
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. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
4. Install the spark plug cap.
5. Install the storage compartment
by installing the bolts.
6. Close the seat.
EAUM1550
Engine oil
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed at the intervals
specified 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 centers-
tand.
NOTE:
Make sure that the scooter is positio-
ned straight up when checking the oil
level. 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.
Tightening torque:
Spark plug:
12.5 Nm (1.25m•kgf, 9.05 ft•lbf)
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)
1
ZAUM0037
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1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
3. Wait a few minutes until the oil
settles, 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.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to rai-
se it to the correct level.
5. Insert the dipstick into the oil fillerhole, and then tighten the oil filler
cap.
To change the engine oil
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.
1. Engine oil drain bolt
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the washer for damage
and replace it if necessary.
1. Engine oil drain bolt
2. Washer
5. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
NOTE:
Make sure that the washer is properly
seated.
6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
2
1
1
1
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ECA11670
CAUTION:
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 CONSER-
VING II” or higher.
Be sure no foreign material
enters the crankcase.
7. 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 cau-
se.
8. Reset the service indicator. (See
page 3-7.)
EAU20060
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 trans-
mission oil must be changed as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm it up by
riding the scooter for several
minutes, and then stop the engi-
ne.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
1. Final transmission oil filler cap
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil drain bolt
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
1.4 L (1.48 US qt) (1.23 Imp.qt)
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6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUS1270
To check the coolant level
1. Place the vehicle on a level surface
and hold it in an upright position.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Maximum level mark
2. Minimum level mark
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir cap
1
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.21 L (0.22 US qt) (0.18 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
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3. If the coolant is at or below the
minimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION:
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-ness of the coolant will be
reduced.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Close the reservoir cap.
6. Place the floorboard mat in the
original position and push it
downward to secure it.
EAU33030
Changing the coolantEWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAUM1320
Air filter and V-belt case air
filter elements
The air filter and the V-belt case air fil-
ter elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.
Replace the air filter element
1. Place the scooter on the centers-
tand.
2. Remove the air filter case cover
by removing the screws.
1. Air filter case cover
2. Screw
1
2
Coolant reservoir capacity:
0.26 L (0.28 US qt) (0.23 Imp.qt)
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3. Pull the air filter element out.
4. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air.
5. Check the air filter element for
damage and replace it if neces-
sary.
6. Insert the air filter element into
the air filter case.
7. Install the air filter case cover by
installing the screws.Cleaning the V-belt case air filter
element
1. Remove the V-belt case air filter
cover by removing the screws.
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.3. Check the air filter element for
damage and replace it if neces-
sary.
4. Install the air filter element with
the colored side facing outward.
5. Install the V-belt case air filter
cover by installing the screws.
6
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ECA10530
CAUTION:
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
EAUS1290
Adjusting the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 4 ~ 6 mm (0.16 ~ 0.24) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Remove cowling A (See page
6-6).2. Loosen the locknut.
3. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
4. Tighten the locknut.
5. Install the cowling.
(a)
(b)
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