check engine YAMAHA XMAX 125 2006 Owners Manual

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicators, indicator lights and
warning light ..................................3-3
Speedometer ....................................3-4
Fuel gauge ........................................3-4
Coolant temperature gauge..............3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) .................3-7
Handlebar switches ..........................3-8
Front brake lever...............................3-9
Rear brake lever................................3-9
Fuel tank cap ..................................3-10
Fuel .................................................3-10
Catalytic converter..........................3-11
Seat.................................................3-11
Front storage compartment............3-12
Storage compartment.....................3-12
Adjusting the shock absorber
assemblies...................................3-13
Sidestand ........................................3-13PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT
RIDING POINTS..................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-3
Removing and installing cowlings
and panels .....................................6-6
Checking the spark plug ..................6-7
Engine oil ..........................................6-8
Final transmission oil ......................6-10
Coolant ...........................................6-11
Air filter and V-belt case air filter
elements ......................................6-12
Adjusting the throttle cable
free play .......................................6-14
Valve clearance ...............................6-15
Tires ................................................6-15
Cast wheels ....................................6-17Front and rear brake lever free
play ..............................................6-17
Checking the front and rear brake
pads.............................................6-17
Checking the brake fluid level ........6-18
Changing the brake fluid ................6-19
Checking and lubricating the
throttle grip and cable .................6-19
Lubricating the front and rear
brake levers .................................6-20
Checking and lubricating the
centerstand and sidestand .........6-20
Checking the front fork ...................6-20
Checking the steering.....................6-21
Checking the wheel bearings .........6-22
Battery ............................................6-22
Replacing the fuses ........................6-23
Replacing a headlight bulb .............6-24
Replacing a front turn signal
light bulb......................................6-25
Replacing the tail/brake light bulb
or a rear turn signal light bulb .....6-25
Replacing the license plate light
bulb .............................................6-26
Replacing the auxiliary light bulb ...6-27
Troubleshooting ..............................6-27
Troubleshooting charts ...................6-28
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage .............................................7-3
TABLE OF CONTENTS
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an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
scooter in an area that has ade-
quate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the
main switch. When parking the
scooter, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,
park the scooter in a placewhere pedestrians or children
are not likely to touch these hot
areas.
• Do not park the scooter on a
slope or soft ground, otherwise
it may fall over.
• Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
EAU10371
Further safe-riding points
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard bra-
king, because the scooter could
slide. Apply the brakes slowlywhen stopping on a wet surface.
Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Slow down and
cross them with caution. Keep
the scooter upright, otherwise it
could slide out from under you.
The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
Always wear a helmet, gloves,
trousers (tapered around the cuff
and ankle so they do not flap),
and a bright colored jacket.
Do not carry too much luggage
on the scooter. An overloaded
scooter is unstable.
1
SAFETY INFORMATION t
1-4
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EAU33461
Indicators, indicator lights
and warning light
1. Fuel level gauge circuit
2. High beam indicator light
3. Left turning signal light
4. Immobilizer system indicator light
5. Right turning signal light
6. Engine trouble warning light
7. Coolant temperature gauge
EAU11030
Turn signal indicator lights “c” and
“
d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11350
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
2 L (0.44 US gal) (1.76 Imp.gal). When
this occurs, refuel as soon as possi-
ble.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
EAU11480
Engine trouble warning light “ ”
This warning light comes on when an
electrical circuit monitoring the engine
is defective. When this occurs, have a
Yamaha dealer check the self-diagno-
sis system.
The electrical circuit of the warning
light can be checked by turning thekey to “ON”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
EAUS1310
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the
key to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
When the key is turned to “OFF”, the
indicator light will start flashing indi-
cating the immobilizer system is ena-
bled. After 24 hours have passed, the
indicator light will stop flashing,
however the immobilizer system is
still enabled.
123 5 764
3
INSTRUMENT AND CONTROL FUNCTIONS
3-3
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3
INSTRUMENT AND CONTROL FUNCTIONS
3-15
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
The system is OK. The scooter can be ridden.
This check is most reliable if performed with
a warmed-up engine.
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO NO YESNOTE:
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4
PRE-OPERATION CHECKS
4-2
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-4, 3-10
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-8
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-10
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 3-4, 6-11
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake• Check brake pads for wear.
3-9, 5-2, 6-17
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake• Check brake pads for wear.
3-9, 5-2, 6-17
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
5-2, 6-14, 6-19
• If necessary, have Yamaha dealer adjust cable free play and lubricate
cable and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-15 ~ 6-17
• Check air pressure.
• Correct if necessary.
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EAU16760
Starting off
NOTE:
Before starting off, allow the engine to
warm up.
1. Grab bar
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and
deceleration
The speed can be adjusted by ope-
ning and closing the throttle. To incre-
ase the speed, turn the throttle grip in
direction (a). To reduce the speed,
turn the throttle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
EWA10300
s s
WARNING
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the sco-
oter may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Therefore, slow
down when approaching such
areas and cross them with cau-
tion.
1
5
OPERATION AND IMPORTANT RIDING POINTS
5-2
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Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as bra-
king downhill can be very diffi-
cult.
EAU16820
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Avoid high engine speeds during
acceleration.
Avoid high engine speeds with no
load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cros-
sings).
EAU16841
Engine 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 following 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 them-
selves to the correct operating clea-
rances. During this period, prolongedfull-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUM2010
0~1000 km (0~600 mi)
Avoid prolonged operation above 1/3
throttle.
1000~1600 km (600~1000 mi)
Avoid prolonged operation above 1/2
throttle.
ECA11660
CAUTION:
After 1000 km (600 mi) of operation,
be sure to replace the engine oil
and final transmission oil.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10270
CAUTION:
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
5
OPERATION AND IMPORTANT RIDING POINTS
5-3
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
ODOMETER READING (x 1000 Km)
ANNUAL
CHECKNO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24
8*Brake hoses• Check for cracks or damage.√√√√ √• Replace. Every 4 years
9*Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
10 *Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
11 *Wheel bearings• Check bearing for looseness or damage.√√√√
12 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 20000 km
13 *Chassis fasteners• Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
15 *Sidestand switch• Check operation.√√ √ √√ √
16 *Front fork• Check operation and for oil leakage.√√√√
17 *Shock absorber
• Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 *Fuel injection• Check engine idle speed.√√ √ √√ √
• Change. (See page 6-8)√When the oil change
19Engine oilindicator light comes on (every 6000 km)• Check oil level/top up.√Every 3000 km
20Engine oil filter element• Replace.√√√
21 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
EAUS1280
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug 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.
To remove the spark plug
1. Open the seat. (See page 3-11.)
2. Remove the storage compart-
ment under the seat by removing
the bolts.
1. Storage compartment
2. Screws
3. Remove the spark plug cap.
4. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the motorcy-
cle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
Specified spark plug:
NGK / CPR 9EA-91
2
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To install the spark plug
1. Spark plug gap
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
2. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
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.
4. Install the spark plug cap.
5. Install the storage compartment
by installing the bolts.
6. Close the seat.
EAUM1550
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.
NOTE:
Make sure that the scooter is positio-
ned straight up when checking the oil
level. 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.
Tightening torque:
Spark plug:
12.5 Nm (1.25m•kgf, 9.05 ft•lbf)
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)
1
ZAUM0037
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
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