engine YAMAHA XMAX 125 2009 Owner's Manual

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).
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.
EAUM2281
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. NOTICE: After 1000
km (600 mi) of operation, the
engine oil and final transmis-
sion oil must be changed, andthe engine oil filter element
replaced.
[ECAM1091]
1000 km (600 mi) and beyond
●The vehicle can now be operated
normally.
ECA10270
NOTICE
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS
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EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
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 and be burned.
●Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
●Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
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EAU17281
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following 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, geographical
location, and individual use, the main-
tenance intervals may need to be
shortened.
EWA10321
s s
WARNING
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15121
s s
WARNING
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
●A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
●Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
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.
EAU17521
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.
TIP
If you do not have the tools or expe-
rience required for a particular job, have
a Yamaha dealer perform it for you.
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46870
TIP
●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.
EAU46920
Periodic maintenance chart for the emission control system
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM 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.√√√ √√
2Spark plug• Check condition.
• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√√ √
4*Fuel injection• Check engine idle speed.√√ √√ √ √
5*Muffler and exhaust • Check the screw clamp(s) for
pipelooseness.√√ √√ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
10 * Chassis fasteners • Make sure that all nuts, bolts and
screws are properly tightened. √√√ √√
11 Front brake lever
pivot shaft • Lubricate with silicone grease.
√√√ √√
12 Rear brake lever
pivot shaft • Lubricate with silicone grease.
√√√ √√
13 Sidestand,
• Check operation.
centerstand• Lubricate. √√√ √√
14 *
Sidestand switch • Check operation. √√ √√ √ √
15 * Front fork • Check operation and for
oil leakage. √√√ √
16 * Shock absorber
• Check operation and shock
assemblies absorbers for oil leakage. √√√ √
When the oil change indicator light comes on
• Change. (See page 6-9 ). √[5000 km (3000 mi) after the initial 1000 km (600 mi)
17Engine oil and every 6000 km (3500 mi) thereafter]
• Check oil level and vehicle for
oil leakage. Every 3000 km (1800 mi)
√
18 Engine oil filter
element • Replace.
√√ √
• Check coolant level and vehicle
19 * Cooling system for coolant leakage. √√√ √√
• Change. Every 3 years
20
Final transmission
• Check vehicle for oil leakage.
√√ √
oil • Change. √√ √
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EAUM1250
Panel A
T
o remove the panel
1. Open the storage compartment.
(See page 3-16).
2. Remove the screw, and then take
the panel off.
1. Screw
To install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Close the storage compartment.
EAU19632
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
6-6).
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. 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
vehicle is ridden normally).
TIP
If the spark plug shows a distinctly
different color, the engine could be
operating improperly. Do not attempt
to diagnose such problems yourself.
PERIODIC MAINTENANCE AND ADJUSTMENT
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Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
1. Spark plug gap
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.
TIP
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 cowling.
EAUM2271
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. 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.
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 (wit-
hout screwing it in), and then
remove it again to check the oil
level.
TIP
The engine oil should be between the
minimum and maximum level marks.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1
ZAUM0037
Specified spark plug:
NGK/ CPR 9EA-9
PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Engine oil filler cap
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 filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element
replacement)
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.3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.1. Engine oil drain bolt
4. Check the drain bolt washer for
damage and replace it if neces-
sary.
1. Engine oil drain bolt
2. Washer
TIP
Skip steps 5–9 if the oil filter element
is not being replaced.
5. Remove the oil filter element
cover by removing the bolts.
1. Oil filter element cover
6. Remove the oil filter element and
O-ring.
ZAUM07111
ZAUM07021
ZAUM07011
PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Oil filter element
2. O-ring
3. Oil filter element cover
7. Check the O-ring for damage and
replace it if necessary.
8. Install the new oil filter element
and an O-ring.
9. Install the oil filter element cover
by installing the bolts, then tigh-
tening them to the specified tor-
que.
TIP
Make sure that the O-ring is properly
seated.
10. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
TIP
Make sure that the washer is properly
seated.
11. Refill with the specified amount
of the recommended engine oil,
and then install and tighten the oil
filler cap.
TIP
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
ECA11670
NOTICE
●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.
12. 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.
13. Turn the engine off, and then
check the oil level and correct it if
necessary.
14. Reset the oil change indicator.
(See page 3-6).
Recommended engine oil:
See page 8-1
Oil change quantity:
Without oil filter element
replacement:
1.40 L (1.48 US qt, 1.23 Imp.qt)
With oil filter element
replacement:
1.50 L (1.59 US qt, 1.32 Imp.qt)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Tightening torque:
Oil filter cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
2
3
ZAUM0712
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU20064
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 up the
final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and final transmission
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil filler cap
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1. Final transmission oil drain bolt
6. Refill with the specified amount
of the recommended final trans-
mission oil, and then install and
tighten the oil filler cap. WAR-
NING! Make sure that no
foreign material enters the final
transmission case. Make sure
that no oil gets on the tire or
wheel.
[EWA11311]
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
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 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
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