YAMAHA XMAX 125 2011 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU38262
TIP
Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated paper element, 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 elements need 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 change 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 the 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.

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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/DPR8EA-9
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TIP
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.
EAUS1711
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. 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
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (wit-
hout screwing it in), and then
remove it again to check the oil
level.
TIP
The engine oil should be between the
minimum and maximum level marks.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
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 filler
hole, 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
3
2
1
ZAUM0685
Tightening torque:
Spark plug:
17.5 Nm (1.75 m•kgf,
12.7 ft•lbf)
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3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
1. Engine oil drain bolt
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.
TIP
Make sure that the washer is properly
seated.
6. Refill with the specified amount
of the recommended engine oil,
and then install and tighten the oil
filler cap.
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 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 oil change indicator.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for 15 to 20 seconds.
1. “OIL CHANGE” button
1
NOTICE
Recommended engine oil:
See page 8-1
Oil change quantity:
1.30 L (1.37 US qt, 1.14 Imp.qt)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m•kgf, 14 ft•lbf)
11
ZAUM0686
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1. “OIL CHANGE” button
3. Release the “OIL CHANGE” but-
ton, and the oil change indicator
will go off.
TIP
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator must
be reset after the oil change for the
next periodic oil change to be indica-
ted at the correct time. To reset the oil
change indicator before the periodic
oil change interval has been reached,
follow the above procedure, but note
that the indicator will come on for 1.4
seconds after releasing the “OILCHANGE” button, otherwise repeat
the procedure.
EAU20065
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 up the
final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the
final transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
1
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1. Final transmission oil filler cap
2. O-ring
6. Install the final transmission oil
drain bolt and its new gasket,
and then tighten the bolt to the
specified torque.
1. Final transmission oil drain bolt
7. Refill with the specified amount
of the recommended final trans-
mission oil. WARNING! Make
sure that no foreign material
enters the final transmission
case. Make sure that no oil
gets on the tire or wheel.
[EWA11311]
8. Install the final transmission oil
filler cap and its new O-ring, and
then tighten the oil filler cap.
9. 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.
EAUS1670
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
TIP
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.
2. Check the coolant level through
the check window.
Recommended final transmission
oil:
See page 8-1
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m•kgf, 16 ft•lbf)
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TIP
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. Coolant level check window
3. If the coolant is at or below the
minimum level mark, lift up the
right floorboard mat as shown.
1. Floorboard mat
4. Open the reservoir cap, and then
add coolant to the maximum
level mark. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA15161]
NOTICE: If coolant is not avai-
lable, 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 coolant
as soon as possible, otherwise
the cooling system will not be
protected against frost andcorrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
[ECA10472]
1. Coolant reservoir cap
5. Close the reservoir cap
6. Place the floorboard mat in the
original position and push it
downward to secure it.
Coolant reservoir capacity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
FULL
LOW
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EAU33031
Changing the coolant
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant. WARNING! Never attempt
to remove the radiator cap when
the engine is hot.
[EWA10381]EAUS1334
Air filter and V-belt case air
filter elements
The air filter element should be repla-
ced and the V-belt case air filter ele-
ment should be cleaned at the inter-
vals specified in the periodic
maintenance and lubrication chart.
Service the air filter elements more
frequently if you are riding in unu-
sually wet or dusty areas.
Replacing 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
3. Air filter element
3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case.
5. 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.
1. V-belt case air filter element cover
2. Screw
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.
1
2 2
ZAUM06623
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1. V-belt case air filter cover
2. V-belt case air filter element
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.
NOTICE: Make sure that each
filter element is properly sea-
ted in its case. The engine
should never be operated wit-
hout the filter elements insta-
lled, otherwise the piston(s)
and/or cylinder(s) may become
excessively worn.
[ECA10531]
5. Install the V-belt case air filter
cover by installing the screws.
EAU48431
Adjusting the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 3.0–5.0 mm (0.12–0.20 in) at
the inner edge of the throttle grip.
Periodically check the throttle cable
free play and, if necessary, adjust it as
follows.
TIP
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Slide the rubber cover back.
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).
1. Rubber protector
2. Locknut
3. Adjusting nut
4. Tighten the locknut and then sli-
de the rubber cover to its original
position.
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