engine YAMAHA XMAX 125 2011 Owner's Manual

ECA15022
If a warning light, indicator light or
indicator does not go off, see
pages 3-4 or 3-6 for the correspon-
ding warning light, indicator light or
indicator circuit check.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake. NOTICE: For
maximum engine life, never
accelerate hard when the engi-
ne is cold!
[ECA11041]
1. Rear brake lever
2. Front brake lever
3. Start switch
3. If the engine does not start, rele-
ase the start switch, wait a few
seconds, and then try again.
Each starting attempt should be
as short as possible to preserve
the battery. Do not crank the
engine more than 10 seconds on
any one attempt.EAU45091
Starting off
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 centers-
tand.
1. Grab bar
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signals 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 signals off.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-2
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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, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUS1810
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min. NOTICE: After 1000
km (600 mi) of operation, be
sure to replace the engine oil
and final transmission oil.
[ECA11661]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.1600 km (1000 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
NOTICE
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
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.
WARNING
OPERATION AND IMPORTANT RIDING POINTS
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAUS1820
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
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
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
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.
WARNING
WARNING
WARNING
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46861
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 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
EAU46910
Periodic maintenance chart for the emission control system
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 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.√√
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
6-5
6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check bearing play and steering
9*Steering bearingsfor roughness.√√ √ √ √
• Lubricate with lithium-soap-
based grease.Every 20000 km (12000 mi)
10 *Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√ √√
11Front brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
12Rear brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
Sidestand, • Check operation.
13 • Lubricate with lithium-soap-√√√ √√
centerstand
based grease.
14 *Sidestand switch• Check operation.√√ √ √ √ √
15 *Front fork• Check operation and for oil
leakage.√√√ √
16 *Shock absorber • Check operation and shock
assembliesabsorbers for oil leakage.√√√ √
• Change. (See pages 3-6
√When the oil change indicator flashes [At 4000 km
17Engine oiland 6-10.) (2500 mi) and every 3000 km (1800 mi) thereafter]
• Check oil level and vehicle for oil
leakage.Every 3000 km (1800 mi)√
18 *Engine oil strainer• Clean.√
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU38262
TIP
Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned
with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter elements need to be serviced more fre-
quently when riding in unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change 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 cylinders and calipers, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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1. Screw
To install the panel
Place the panel in the original posi-
tion, and then install the screws.
EAU19622
Checking the spark plug
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be operating improperly. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
1. Spark plug gap
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1
ZAUM0037
Specified spark plug:
NGK/DPR8EA-9
PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
EAUS1711
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.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
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
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
3
2
1
ZAUM0685
Tightening torque:
Spark plug:
17.5 Nm (1.75 m•kgf,
12.7 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
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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 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.
TIP
Make sure that the washer is properly
seated.
6. Refill with the specified amount
of the recommended engine oil,
and then install and tighten the oil
filler cap.
ECA11670
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 oil change indicator.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for 15 to 20 seconds.
1. “OIL CHANGE” button
1
NOTICE
Recommended engine oil:
See page 8-1
Oil change quantity:
1.30 L (1.37 US qt, 1.14 Imp.qt)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m•kgf, 14 ft•lbf)
11
ZAUM0686
PERIODIC MAINTENANCE AND ADJUSTMENT
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