YAMAHA XMAX 125 2008 Service Manual

EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 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
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUM2280
0 ~ 500 km (0 ~ 300 mi)
Avoid prolonged operation above 1/3
throttle.
500 ~ 1000 km (300 ~ 600 mi)
Avoid prolonged operation above 1/2
throttle.
ECAM1090
CAUTION:
After 1000 km (600 mi) of operation,
the engine oil and final transmis-
sion oil must be changed, and the
engine oil filter element replaced.
1000 km (600 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.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
s s
WARNING
●Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
●Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
OPERATION AND IMPORTANT RIDING POINTS
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EAU17280
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the follo-
wing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EWA10330
s s
WARNING
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
EAU17520
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-14.)
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 pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
PERIODIC MAINTENANCE AND MINOR REPAIR
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NOTE:
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any chan-
ges.
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU17715
Periodic maintenance and lubrication chart
NOTE:
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK,
a mileage-based maintenance, is performed instead.
●From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
1*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
• Check condition.
2Spark plug• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√√√
4Air filter element• Replace.√√
5V-belt case air filter
element• Clean.√√√√
• Check operation, fluid level and vehicle for fluid
6*Front brakeleakage.√√√√√ √
• Replace brake pads. Whenever worn to the limit
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check operation, fluid level and vehicle for fluid 7*Rear brakeleakage.√√√√√ √
• Replace brake pads. Whenever worn to the limit
8*Brake hose• 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 24000 km (14000 mi)
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
assemblies• Check operation and shock absorbers for oil leakage.√√√√
18 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
19 *Fuel injection• Check engine idle speed.√√√√√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
√When the oil change indicator light
20Engine oil• Change. (See pages 6-10)comes on (5000 km (2920 mi) after the initial
1000 km (600 mi) and every
6000 km (3500 mi) thereafter)
• Check oil level and vehicle for oil leakage. Every 3000 km (1800 mi)√
21Engine oil filter
element• Replace.√√√
22Final transmission oil• Check vehicle for oil leakage.√√ √• Change.√√√
23 *V-belt• Replace. Every 18000 km (10500 mi)
24 *Front and rear brake
switches• Check operation.√√√√√ √
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing • Check operation and free play.
26 * • Adjust the throttle cable free play if necessary.√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
27 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√√√√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18670
NOTE:
●The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• 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.
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18731
Removing and installing the
cowlings and panel
1. Cowling A
2. Cowling B
3. Cowling C
4. Panel A
1. Cowling D
The cowlings and panel shown 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.
EAU18900
Cowling A
T
o remove the cowling
1. Remove the cowling bolts.
1. Screw
2. Cowling A
2. Disconnect the turn signal light
lead connectors, and then take
the cowling off.
1. Turn signal light lead coupler
To install the cowling
1. Connect the turn signal light lead
connectors.
2. Place the cowling in the original
position.
3. Install the cowling bolts.
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EAU18790
Cowling B
T
o remove the cowling
Remove the screws, and then take
the cowling off.
1. Screw
2. Cowling B
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAU18790
Cowling C
T
o remove the cowling
Remove the screws, and then take
the cowling off.
1. Screw
2. Cowling C
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAU18790
Cowling D
T
o remove the cowling
Remove the screws, and then take
the cowling off.
1. Cowling D
2. Screw
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
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EAUM1250
Panel A
T
o remove the panel
1. Open the storage compartment.
(See page 3-15.)
1. Screw
2. Panel A
2. Remove the screw, and then take
the panel off.
T
o install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Close the storage compartment.
EAU19631
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. Remove cowling D. (See page
6-7.)
2. Remove the spark plug cap.
1. Spark plug cap
3. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
1. Spark plug wrench
To check the spark plug
1. Spark plug gap
1
1
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