YAMAHA XMAX 300 2017 Repair Manual

Operation and important ri din g points
6-4
6
EAU16794
Brakin g
WARNING
EWA10301
zAvoi d b rakin g har d or su ddenly
(especially when leanin g over to
one si de), otherwise the scooter
may ski d or overturn.
z Railroa d crossin gs, streetcar
rails, iron plates on roa d con-
struction sites, an d manhole
covers become extremely slip-
pery when wet. Therefore, slow
d own when approachin g such
areas an d cross them with cau-
tion.
z Keep in min d that b raking on a
wet roa d is much more difficult.
z Ride slowly d own a hill, as brak-
in g d ownhill can be very d iffi-
cult.
1. Close the throttle completely.
2. Apply both front and rear brakes simultaneously while gradually in-
creasing the pressure.
EAU16821
Tips for re ducin g fuel con-
sumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
z Avoid high engine speeds during
acceleration.
z Avoid high engine speeds with no
load on the engine.
z Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
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Operation and important rid ing points
6-5
6
EAU16842
En gine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that
might result in engine overheating
must be avoided.
EAU34323
0–1000 km (0–600 mi)
Avoid prolonged operation above 4500
r/min. NOTICE: After 1000 km (600
mi) of operation, be sure to replace
the en gine oil, final transmission oil
an d the oil filter element.
[ECA12932]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 5400
r/min.
1600 km (1000 mi) an d b eyon d
The vehicle can now be operated nor-
mally.
NOTICE
ECA10311
z Keep the en gine spee d out of
the tachometer red zone.
z If any en gine trou ble shoul d oc-
cur during the en gine break-in
period , imme diately have a
Yamaha dealer check the vehi-
cle.
EAUN1421
Parkin g
When parking, turn the vehicle power
off, and then turn the smart key off.
TIP
Even when the vehicle is parked in a lo-
cation partitioned by a fence or the
glass window of a shop, if the smart
key is within operating range, other
people will be able to start the engine
and operate the vehicle. Please turn
the smart key off when leaving the ve-
hicle. (See page 3-5.)
If the sidestand is lowered when the
engine is running, the engine will stop
and the beeper will sound for approxi-
mately 1 minute. To stop the beeper,
turn the vehicle power off or raise the
sidestand.
TIP
zBefore leaving the vehicle, be sure
to turn the main switch to “OFF”
or “ ”. Otherwise, the battery may
discharge.
z The sidestand alarm beeper can
be set to not activate. Please con-
tact your Yamaha dealer.
WARNING
EWA10312
zSince the en gine an d exhaust
system can become very hot,
park in a place where ped estri-
ans or chil dren are not likely to
touch them and b e burne d.
z Do not park on a slope or on soft
groun d, otherwise the vehicle
may overturn, increasin g the
risk of a fuel leak an d fire.
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Operation and important ri din g points
6-6
6
z
Do not park near g rass or other
flammab le materials which
mi ght catch fire.
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Periodic maintenance an d a djustment
7-1
7
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or d eath durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
z A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
z Runnin g the en gine while ser-
vicing can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 1-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot during
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
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Periodic maintenance an d a djustment
7-2
7
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
EAU79250
Owner’s tool kit
The owner’s tool kit is located on the
bottom of the seat. (See page 3-9.)
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 preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Owner’s tool kit
1
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Periodic maintenance an d a djustment
7-3
7
EAU71030
TIP
z The annual checks must be performe d every year, except if a kilometer-
b ased maintenance, or for the UK, a mileag e-based maintenance, is
performed instead.
z From 50000 km (30000 mi), repeat the maintenance intervals starting from
10000 km (6000 mi).
z Items marked with an asterisk should be performed by a Yamaha dealer as
they require special tools, data and technical skills.
EAU71071
Perio dic maintenance chart for the emission control system
NO. ITEM
1 *Fuel line • Check fuel hoses for cracks or
damage.
• Replace if necessary. √√√√√
2 *Spark plu g • Check condition.
• Adjust gap and clean.
√√
• Replace. √√
3 *Valve clearance • Check and adjust. Every 20000 km (12000 mi)
4 *Fuel injection • Check engine idle speed. √√√√√√
5 *Exhaust system • Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary. √√√√√
6 *Evaporative emis-
sion control sys-
tem • Check control system for dam-
age.
• Replace if necessary. √√X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGS
ANNUAL CHECK
1 10203040
0.6 6 12 18 24
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Periodic maintenance an d a djustment
7-4
7
EAU71372
General maintenance an d lu brication chart
NO. ITEM
1 *Dia
gnostic system
check • Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes. √√√√√√
2 *Air filter element • Replace. √√
3 *Pre air filter ele-
ment • Clean.
√√
4 *Su
b air filter ele-
ment • Replace.
√√
5 Air filter case
check hose
• Clean.
√√√√√
6 *V-
belt case air fil-
ter element • Clean.
• Replace if necessary.
√√√√√
7 *Front brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
8 *Rear brake • Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces- sary. √√√√√√
9 *Brake hoses • Check for cracks or damage.
√√√√√
• Replace. Every 4 years
10 *Brake flui d • Change. Every 2 years
11 *Wheels • Check runout and for damage.
• Replace if necessary.
√√√√
12 *Tires • Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
13 *Wheel bearin gs • Check bearing for looseness or
damage. √√√√X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance an d a djustment
7-5
7
14 *Steerin g b earin gs • Check bearing assemblies for
looseness. √√ √
• Moderately repack with lithium- soap-based grease. √√
15 *Chassis fasteners • Make sure that all nuts, bolts
and screws are properly tight-
ened. √√√√√
16 Front an
d rear
b rake lever pivot
shaft • Lubricate with silicone grease.
√√√√√
17 Si
destan d, center-
stan d • Check operation.
• Lubricate with lithium-soap-
based grease. √√√√√
18 *Sidestan d switch • Check operation and replace if
necessary. √√√√√√
19 *Front fork • Check operation and for oil
leakage.
• Replace if necessary. √√√√
20 *Shock ab
sorber
assem blies • Check operation and for oil
leakage.
• Replace if necessary. √√√√
21 En gine oil • Change (warm engine before
draining).
• Check oil level and vehicle for oil leakage. At the initial interval and
when the oil change indi-
cator flashes or comes on [every 5000km (3000 mi)]. √
22 En
gine oil filter el-
ement • Replace.
√√√
23 *Final transmission
oil • Check vehicle for oil leakage.
√√√√√
• Change. √√√
24 *Co
olin g syst
em• Check coolant level and vehicle
for coolant leakage. √√√√√
• Change. Every 3 years
25 *V-belt • Replace. When the V-belt replacement
indicator flashes [every 20000 km (12000 mi)]
26 *Front an
d rear
b rake switches • Check operation.
√√√√√√
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi ODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance an d a djustment
7-6
7
EAU79370
TIP
z Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated pa- per element, which must not be cleaned with compressed air to avoid
damaging it.
• The engine air filter element and sub air filter element need to be replaced and the V-belt air filter element needs to be serviced more frequently when
riding in unusually wet or dusty areas.
z 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 cyl- inders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
27 *Movin
g parts an d
cab les • Lubricate.
√√√√√
28 *Throttle
grip hous-
in g an d cab le • Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous- ing and cable. √√√√√
29 *Li
ghts, si gnals an d
switches • Check operation.
• Adjust headlight beam.
√√√√√√
NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance an d a djustment
7-7
7
EAU18752
Removin g an d installin g the
panel
The panel shown needs to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time the panel needs
to be removed and installed.
EAU78530
Panel A
To remove the panel
Remove the screws, and then pull the
panel outward and slide it forward as
shown. To install the panel
Place the panel in the original position,
and then install the screws.
1. Panel A
1. Screw
1
1
1
1. Panel A
1
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