engine YAMAHA XMAX 125 2007 Owner's Manual

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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-9
2
1
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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
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1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
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 (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
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 fillerhole, 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. Engine oil drain bolt
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
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.
NOTE:
Make sure that the washer is properly
seated.
6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
2
1
1
1
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ECA11670
CAUTION:
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 service indicator. (See
page 3-7.)
EAU20060
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 it up by
riding the scooter for several
minutes, and then stop the engi-
ne.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
1. Final transmission oil filler cap
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil drain bolt
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
1.4 L (1.48 US qt) (1.23 Imp.qt)
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6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. 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.
EAUS1270
To check the coolant level
1. Place the vehicle on a level surface
and hold it in an upright position.
NOTE:
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.
1. Maximum level mark
2. Minimum level mark
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir cap
1
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.21 L (0.22 US qt) (0.18 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
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3. If the coolant is at or below the
minimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION:
If coolant is not available, 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 coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-ness of the coolant will be
reduced.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Close the reservoir cap.
6. Place the floorboard mat in the
original position and push it
downward to secure it.
EAU33030
Changing the coolantEWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAUM1320
Air filter and V-belt case air
filter elements
The air filter and the V-belt case air fil-
ter elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.
Replace 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
1
2
Coolant reservoir capacity:
0.26 L (0.28 US qt) (0.23 Imp.qt)
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ECA10530
CAUTION:
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
EAUS1290
Adjusting the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 4 ~ 6 mm (0.16 ~ 0.24) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Remove cowling A (See page
6-6).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).
4. Tighten the locknut.
5. Install the cowling.
(a)
(b)
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EAU21401
Valve clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clearan-
ce must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU21870
Tires
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressureThe tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
EWA10500
s s
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperatu-
re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories appro-
ved for this model.
EWA10450
s s
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characte-
ristics of your vehicle, you should
keep the following precautions in
mind.
Tire air pressure (measured on
cold tires):
Up to 90 kg (198 lb):
Front:
190 kPa (27 psi) (1.9 kgf/cm
2)
Rear:
220 kPa (31 psi) (2.2 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front:
210 kPa (30 psi) (2.1 kgf/cm
2)
Rear:
250 kPa (36 psi) (2.5 kgf/cm
2)
Maximum load*:
189 kg (417 lb)
* Total weight of rider, passenger,
cargo and accessories
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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
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23280
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 a stand under the engine to
raise the front wheel off the
ground.
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any freeplay can be felt, have a Yamaha
dealer check or repair the stee-
ring.
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EAU25921
Troubleshooting charts
Starting problems or poor engine performanceEWA10840
s s
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
We tOpen the throttle halfway and operate
the electric starter.
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