warning YAMAHA XMAX 300 2017 Service Manual

Periodic maintenance an d a djustment
7-23
7
EAU22312
Checkin g the front an d rear
b rake pa ds
Front brake
Rear brake
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad
wear without having to disassemble
the brake. To check the brake pad
wear, check the position of the wear in-
dicator while applying the brake. If a
brake pad has worn to the point that
the wear indicator almost touches the
brake disc, have a Yamaha dealer re-
place the brake pads as a set.
EAU22582
Checkin g the brake flui d level
Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA15991
Improper maintenance can result in
loss of brakin g a bility. O bserve
these precautions: z Insufficient brake flui d may al-
low air to enter the brake sys-
tem, re ducing brakin g
performance.
1. Brake pad wear indicator
1. Brake pad wear indicator
1
1
1. Minimum level mark
1. Minimum level mark
Specified b rake flui d:
DOT 4
1
1
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Periodic maintenance an d a djustment
7-25
7
EAUU0311
Checkin g the V- belt
The V-belt must be checked and re-
placed by a Yamaha dealer at the inter-
vals specified in the periodic
maintenance and lubrication chart.
EAU23098
Checkin g an d lu bricatin g the
ca bles
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with cab le movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712]
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
UB74E0E0.book Page 25 Tuesday, May 2, 2017 1:04 PM

Periodic maintenance an d a djustment
7-27
7
EAU23215
Checkin g an d lu bricatin g the
centerstan d an d si destan d
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
WARNING
EWA10742
If the centerstan d or si destan d d oes
not move up an d d own smoothly,
have a Yamaha dealer check or re-
pair it. Otherwise, the centerstan d or
si destan d coul d contact the groun d
an d d istract the operator, resultin g
in a possi ble loss of control.
EAU23273
Checkin g the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
Check the inner tubes for scratches,
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 avoi d injury,
securely support the vehicle so
there is no d anger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any damag e is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
Recommen ded lu bricant:
Lithium-soap-based grease
UB74E0E0.book Page 27 Tuesday, May 2, 2017 1:04 PM

Periodic maintenance an d a djustment
7-28
7
EAU45512
Checkin g the steerin g
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place the vehicle on the center- stand. WARNING! To avoi d inju-
ry, securely support the vehicle
so there is no dan ger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU23292
Checkin g the wheel bearin gs
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion 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.
UB74E0E0.book Page 28 Tuesday, May 2, 2017 1:04 PM

Periodic maintenance an d a djustment
7-29
7
EAU60691
Battery
The battery is located behind panel A.
(See page 7-7.)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery lead connections need to
be checked and, if necessary, tight-
ened.
WARNING
EWA10761
z Electrolyte is poisonous an d
d an gerous since it contains sul-
furic aci d, which causes severe
b urns. Avoi d any contact with
skin, eyes or clothin g an d al-
ways shiel d your eyes when
workin g near b atteries. In case
of contact, ad minister the fol-
lowin g FIRST AID.
EXTERNAL: Flush with plenty of water.
INTERNAL: Drink lar ge quan-
tities of water or milk an d im-
me diately call a physician.
EYES: Flush with water for 15 minutes and seek prompt
me dical attention. z
Batteries prod uce explosive hy-
d ro gen gas. Therefore, keep
sparks, flames, ci garettes, etc.,
away from the battery an d pro-
vi de sufficient ventilation when
char gin g it in an enclose d
space.
z KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To char ge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quick-
ly if the vehicle is equipped with op-
tional electrical accessories.
NOTICE
ECA16522
To char ge a VRLA (Valve Re gulate d
Lea d Aci d) battery, a special (con-
stant-voltag e) battery char ger is re-
quired . Using a conventional battery
char ger will d amage the b attery.
To store the b attery
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 removin g the
b attery, be sure to turn the main
switch off, then d isconnect the
ne gative lea d before discon-
nectin g the positive lea d.
[ECA16304]
2. If the battery will be stored for
more than two months, check it at
least once a month and fully char-
ge it if necessary.
1. Negative battery lead (black)
2. Positive battery lead (red)
3. Battery
1
3
2
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Periodic maintenance an d a djustment
7-31
7
If a fuse is blown, replace it as follows.
1. Turn the main switch off and turn off the electrical circuit in ques-
tion.
2. Remove the blown fuse, and then install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a hi gher ampera ge
ratin g than recommen ded to
avoi d causin g extensive d am-
a g e to the electrical system an d
possi bly a fire.
[EWA15132]
3. Turn the main switch 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.
1. Signaling system fuse 2
2. Signaling system fuse
3. ABS control unit fuse
4. Main fuse 2
5. Radiator fan motor fuse
6. Backup fuse
7. Spare fuse
8. ABS motor fuse
9. ABS solenoid fuse
10.Turn signal light and hazard fuse
11.Terminal fuse 1
12.Answer back fuse
123456 7
8910
11
12
7
Specified
fuses:
Main fuse: 20.0 A
Main fuse 2:
7.5 A
Terminal fuse 1: 2.0 A
Signaling system fuse: 10.0 A
Signaling system fuse 2:
7.5 A
Radiator fan motor fuse: 7.5 A
Backup fuse: 7.5 A
Turn signal light and hazard fuse:
7.5 A
ABS control unit fuse: 7.5 A
ABS motor fuse: 30.0 A
ABS solenoid fuse:
15.0 A
Answer back fuse: 2.0 A
UB74E0E0.book Page 31 Tuesday, May 2, 2017 1:04 PM

Periodic maintenance an d a djustment
7-35
7
EAU60701
Trou bleshootin g
Although Yamaha vehicles receive a
thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your vehicle re-
quire any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the vehicle prop-
erly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checkin g the fuel system, do
not smoke, an d make sure there are
no open flames or sparks in the ar-
ea, inclu din g pilot lig hts from water
heaters or furnaces. Gasoline or
g asoline vapors can i gnite or ex-
plod e, causin g severe injury or prop-
erty damag e.
EAU76550Smart key system trou bleshootin g
Please check the following items when
the smart key system does not work. z Is the smart key turned on? (See
page 3-5.)
z Is the smart key battery dis-
charged? (See page 3-6.) z
Is the smart key battery installed
correctly? (See page 3-6.)
z Is the smart key being used in a lo-
cation with strong radio waves or
other electromagnetic noise? (See
page 3-1.)
z Are you using the smart key that is
registered to the vehicle?
z Is the vehicle battery discharged?
When the vehicle battery is dis-
charged, the smart key system will
not operate. Please have the vehi-
cle battery charged or replaced.
(See page 7-29.)
If the smart key system does not work
after checking the above items, have a
Yamaha dealer check the smart key system.
TIP
See “Emergency mode” on page 7-38
for information on starting the engine
without the smart key.
UB74E0E0.book Page 35 Tuesday, May 2, 2017 1:04 PM

Periodic maintenance an d a djustment
7-37
7 En
gine overheatin g
WARNING
EWAT1041
zDo not remove the ra diator cap when the en gine an d ra diator are hot.
Scal din g hot flui d an d steam may b e blown out un der pressure, which
coul d cause serious injury. Be sure to wait until the eng ine has cooled.
z Place a thick ra g, like a towel, over the ra diator cap, an d then slowly ro-
tate the cap counterclockwise to the detent to allow any resi dual pres-
sure to escape. When the hissin g soun d has stopped , press down on the
cap while turnin g it counterclockwise, an d then remove the cap.
TIP
If coolant is not available, tap water can be temporarily used instead, provided
that it is changed to the recommended coolant as soon as possible.
Wait until the engine
has cooled.
Check the coolant
level in the reservoir
and radiator.Add coolant.
(See TIP.)
The coolant level is
OK.
There is no leakage.
There is leakage.
The coolant level is
low.
Check the cooling
system for leakage.
Have a Yamaha
dealer check and
repair the cooling
system.
Start the engine. If the engine overheats again,
have a Yamaha dealer check and repair the cooling
system.
UB74E0E0.book Page 37 Tuesday, May 2, 2017 1:04 PM

Scooter care and stora ge
8-3
8
Cleaning the windshield
Avoid using any alkaline or strong acid
cleaner, gasoline, brake fluid, or any
other solvent. Clean the windshield
with a cloth or sponge dampened with
a neutral detergent, and after cleaning,
thoroughly wash it off with water. For
additional cleaning, use Yamaha Wind-
shield Cleaner or other quality cleaner.
Some cleaning compounds for plastics
may leave scratches on surfaces of the
windshield. Before using them, make a
test by polishing an area which does
not affect your visibility.
After cleaning
1. Dry the scooter with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt.
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be- fore storing or covering it.
WARNING
EWA10943
Contaminants on the brakes or tires
can cause loss of control. z
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
d iscs an d b rake linin gs with a
re gular brake disc cleaner or
acetone, an d wash the tires with
warm water an d a mil d d eter-
g ent.
z Before operatin g the scooter
test its brakin g performance
an d cornerin g b ehavior.
NOTICE
ECAU0022
z Apply spray oil an d wax spar-
in gly an d make sure to wipe off
any excess.
z Never apply oil or wax to any
rubber parts, plastic parts or
hea dlig ht, tailli ght an d meter
lenses, but treat them with a
suita ble care pro duct.
z Avoi d using abrasive polishin g
compoun ds as they will wear
away the paint.
TIP
z Consult a Yamaha dealer for ad-
vice on what products to use.
z Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
UB74E0E0.book Page 3 Tuesday, May 2, 2017 1:04 PM

Scooter care and stora ge
8-4
8
EAU36564
Stora ge
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the
scooter.
NOTICE
ECA10821
z Storin g the scooter in a poorly
ventilate d room or coverin g it
with a tarp, while it is still wet,
will allow water an d humi dity to
seep in an d cause rust.
z To prevent corrosion, avoi d
d amp cellars, sta bles ( because
of the presence of ammonia)
an d areas where stron g chemi-
cals are stored .
Long-term
Before storing your scooter for several
months: 1. Follow all the instructions in the “Care” section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to protect the cylinder, piston rings,
etc. from corrosion.a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place
the spark plug on the cylinder head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damag e or injury
from sparkin g, make sure to
g roun d the spark plu g elec-
tro des while turning the en-
g ine over.
[EWA10952]
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully char- ge it. Store it in a cool, dry place
and charge it once a month. Do
not store the battery in an exces-
sively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
7-29.
UB74E0E0.book Page 4 Tuesday, May 2, 2017 1:04 PM