YAMAHA XMAX 125 2010 Service Manual

EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUS1840
0–500 km (0–300 mi)
Avoid prolonged operation above
4000 r/min.
500–1000 km (300–600 mi)
Avoid prolonged operation above
6000 r/min. NOTICE: After 1000
km (600 mi) of operation, be
sure to replace the engine oil,
final transmission oil and the
oil filter element.
[ECA12931]
1000 km (600 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
Do not park near grass or other
flammable materials which
might catch fire.
WARNING
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
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EAUS1820
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, depending on
the weather, terrain, geographical
location, and individual use, the main-
tenance intervals may need to be
shortened.
EWA10321
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15121
Turn off the engine when perfor-
ming maintenance unless otherwi-
se 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 servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA10330
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.Consult a Yamaha dealer for proper
maintenance intervals.
WARNING
WARNING
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAUS1830
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-15).
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 pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
TIP
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
TIP
Fuse tongs and a bag containing spa-
re fuses are included in the owner’s
tool kit. Be careful not to lose these
items when opening the tool kit.
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46871
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
technical skills.
EAU46920
Periodic maintenance chart for the emission control system
PERIODIC MAINTENANCE AND ADJUSTMENT
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ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
1*Fuel line• Check fuel hoses for cracks or
damage.√√√ √√
• Check condition.
2Spark plug• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√√ √
4*Fuel injection• Check engine idle speed.√√ √ √ √ √
5*Muffler and exhaust • Check the screw clamp(s)
√√ √ √ √
pipefor looseness.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU17717
General maintenance and lubrication chart
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
1Air filter element• Replace.√√
2V-belt case air filter
element• Clean.√√√ √
• Check operation, fluid level and
3*Front brakevehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √
√
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.√√√ √√• Replace. Every 4 years
6*Wheels• Check runout and for damage.√√√ √
• Check tread depth and for
damage.
7*Tires• Replace if necessary.√√√ √√
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for looseness or
damage.√√√ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
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ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check bearing play and steering
9*Steering bearingsfor roughness.√√ √ √ √
• Lubricate with lithium-soap-
based grease.Every 24000 km (14000 mi)
10 *Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√ √√
11Front brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
12Rear brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
13Sidestand, • Check operation.
centerstand• Lubricate.√√√ √√
14 *Sidestand switch• Check operation.√√ √ √ √ √
15 *Front fork• Check operation and for oil
leakage.√√√ √
16 *Shock absorber • Check operation and shock
assembliesabsorbers for oil leakage.√√√ √
When the oil change indicator flashes [5000 km (3000 mi)
• Change. (See pages 3-6
√after the initial 1000 km (600 mi) and every
17Engine oiland 6-10.)
6000 km (3500 mi) thereafter]
• Check oil level and vehicle for
oil leakage.Every 3000 km (1800 mi)√
18Engine oil filter
element• Replace.√√ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
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ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check coolant level and vehicle
19 *Cooling systemfor coolant leakage.√√√ √√
• Change. Every 3 years
20Final transmission • Check vehicle for oil leakage.√√ √oil
• Change.√√ √
21 *V-belt• Replace.When the V-belt replacement indicator flashes
[every 18000 km (10500 mi)]
22 *Front and rear brake
switches• Check operation.√√ √ √ √ √
23Moving parts and
cables• Lubricate.√√√ √√
• Check operation and free play.
Throttle grip • Adjust the throttle cable free play
24 *housingif necessary.√√√ √√
and cable• Lubricate the throttle grip housing
and cable.
25 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √ √ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU38262
TIP
Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated paper eleme\
nt, which must not be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter element needs to be serviced more fre- quently when riding in unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always chan\
ge the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change th\
e bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU18740
Removing and installing the
cowling and panel
1. Cowling A
2. Panel
1. Panel A
The cowling and panel shown above
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.
EAUS1790
Cowling A
T
o remove the cowling
1. Remove the panel by pushing it
out from the back side of the
cowling as shown.
1. Panel
2. Push
2. Remove the screws, and then
pull the cowling off as shown.
1. Cowling A
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the panel by pushing it in.
EAU47890
Panel A
T
o remove the panel
Remove the screws, and then pull the
panel outward.

PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Screw
To install the panel
Place the panel in the original posi-
tion, and then install the screws.
EAU19622
Checking the spark plug
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
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
dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
1. Spark plug gap
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1
ZAUM0037
Specified spark plug:
NGK/CPR9EA-9
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