YAMAHA XMAX 125 2010 Repair Manual

EAUM2061
Checking the front and rear
brake lever free play
1. Brake lever free play
1. Brake lever free play
The brake lever free play should mea-
sure 3.0-3.5 mm (0.12-0.20 in) as
shown. Periodically check the brakelever free play and, if necessary, have
a Yamaha dealer check the brake sys-
tem.
EWA10641
An incorrect brake lever free play indi-
cates a hazardous condition in the
brake system. Do not operate the
vehicle until the brake system has
been checked or repaired by a Yama-
ha dealer.
EAU22392
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU22430
Front brake pads
1. Wear indicator groove
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the
wear indicator grooves have almost
WARNING
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disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22510
Rear brake pads
1. Lining thickness
The rear brake is provided with a
check plug, which, if it is removed,
allows you to check the brake pad
wear without disassembling the bra-
ke. If the lining thickness is less than
0.8 mm (0.03 in), have a Yamaha dea-
ler replace the brake pads as a set.
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Recommended brake fluid:
DOT 4
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Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU23112
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated by a Yamaha dealer at the inter-
vals specified in the periodic mainte-
nance chart.
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EAU23172
Lubricating the front and
rear brake levers
Front brake lever
Rear brake lever
The pivoting points of the front and
rear brake levers must be lubricatedat the intervals specified in the perio-
dic maintenance and lubrication
chart.
EAU23213
Checking and lubricating the
centerstand and sidestand
1. Sidestand
1. Centerstand
The operation of the centerstand and
sidestand should be checked before
Recommended lubricant:
Silicone grease
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each ride, and the pivots and metal-
to-metal contact surfaces should be
lubricated if necessary.
EWA10741
If the centerstand or sidestand
does not move up and down smo-
othly, have a Yamaha dealer check
or repair it. Otherwise, the centers-
tand or sidestand could contact the
ground and distract the operator,
resulting in a possible loss of con-
trol.
EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
1. Check the inner tubes for scrat-
ches, damage and excessive oil
leakage.
To check the operation
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
NOTICE
Recommended lubricant:
Lithium-soap-based grease
WARNING
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EAU45511
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place the vehicle on the centers-
tand. WARNING! To avoid
injury, securely support the
vehicle so there is no danger of
it falling over.
[EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
EAU23291
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
check the wheel bearings.
EAU34224
Battery
1. Battery
The battery is located behind cowling
A. (See page 6-8).
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the elec-
trolyte or to add distilled water. Howe-
ver, the battery lead connections
need to be checked and, if necessary,
tightened.
EWA10760
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
WARNING
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tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed spa-
ce.
KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind thatthe battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
ECA16520
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (cons-
tant-voltage) battery charger is
required. Using a conventional bat-
tery charger will damage the bat-
tery. If you do not have access to a
constant-voltage battery charger,
have a Yamaha dealer charge your
battery.
To store the battery
1. If the vehicle will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
NOTICE:When removing the
battery, be sure the key is tur-
ned to “OFF”, then disconnect
the negative lead before dis-
connecting the positive lead.
[ECA16302]
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
ECA16530
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
NOTICE
NOTICE
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EAUS1771
Replacing the fuses
1. Fuse box
2. Hazard fuse
The fuse box, which contains the
fuses for the individual circuits, is
located behind cowling A. (See page
6-8).
TIP
The main fuse, which is in a different
and hard-to-reach location, must be
replaced by a Yamaha dealer.
If a fuse for the individual circuits is
blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specifiedamperage. WARNING! Do not
use a fuse of a higher ampera-
ge rating than recommended
to avoid causing extensive
damage to the electrical sys-
tem and possibly a fire.
[EWA15131]
TIP
Fuse tongs and a bag containing spa-
re fuses are included in the owner’s
tool kit. Use the tongs to remove and
install a fuse.
1. Radiator fan fuse
2. ECU fuse
3. Backup fuse
4. Signaling system fuse
5. Headlight fuse
6. Ignition fuse
7. Spare fuse
8. Spare fuse
9. Spare fuse
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
7.5 A
Hazard fuse:
10.0 A
ECU fuse:
5.0 A
Backup fuse:
5.0 A
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EAU34240
Replacing a headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, have a Yamaha dealer
replace it and, if necessary, adjust the
headlight beam.
EAU43051
Replacing a front turn signal
light bulb
1. Place the scooter on the centers-
tand.
2. Remove the socket (together
with the bulb) by turning it coun-
terclockwise.
1. Turn signal light bulb
2. Turn signal light bulb socket
3. Remove the burnt-out bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with
the bulb) by turning it clockwise.
EAUS1781
Replacing a tail/brake light
bulb or a rear turn signal
light bulb
1. Place the vehicle on the centers-
tand.
2. Remove panel A. (See page 6-8).
3. Remove the tail/brake light unit
by removing the screws.
1. Screw
4. Remove the tail/brake light and
turn signal light bulb holder
together with the dust protector
by pressing the tabs, and then
pulling both outward.
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1. Dust protector
2. Tabs
1. Turn signal light bulb
2. Tail/brake light bulb
5. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.6. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
7. Install the bulb holder together
with the dust protector by pus-
hing both into the original posi-
tion.
TIP
Place the bulb holder and dust cover
correctly in its position to avoid dust
and water entering.
8. Install the screws and the
tail/brake light unit.
9. Install the panel.
EAU47910
Replacing the license plate
light bulb
1. Remove the license plate light
cover by removing the screw.
1. Screw
2. License plate light bulb socket
2. Remove the burnt-out bulb by
pulling it out from the socket.
3. Insert a new bulb into the socket.
4. Install the license plate light
cover by installing the screw.

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