YAMAHA XMAX 400 2014 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
EAUM3051
Air filter elements and check
hoses and V-belt case air filter
elementThe air filter elements and the V-belt
case air filter element should be ser-
viced at the intervals specified in the
periodic maintenance and lubrication
chart. Service all air filter elements
more frequently if you are riding in un-
usually wet or dusty areas.
Replacing the air filter elements
1. Place the scooter on the center-
stand.TIPContinue as follows for each air filter el-
ement.2. Remove the air filter case cover by
removing the rubber caps and
screws.Left
Right
3. Pull the air filter element out.Left
Right
4. Insert a new air filter element into
the air filter case.
5. Install the air filter case cover by
installing the screws. NOTICE:
Make sure that each filter ele-
ment is properly seated in its
1. Screw
2. Air filter case cover
3. Rubber cap
1. Screw
2. Air filter case cover
3. Rubber cap
1
21
13
3
1
1
23
1. Air filter element
1. Air filter element
1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6case. Always replace both air fil-
ter elements at the same time,
otherwise poor engine perfor-
mance or damage to the engine
may result. The engine should
never be operated without the
filter elements installed, other-
wise the piston(s) and/or cylin-
der(s) may become excessively
worn.
[ECA12924]
6. Install the rubber caps.
To clean the air filter check hoses
1. Check the hose at the bottom of
both air filter cases for accumulat-
ed dirt or water.
LeftRight
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
Cleaning the V-belt case air filter el-
ement
1. Remove panel A. (See page 6-8.)
2. Remove the left air filter case cov-
er.
3. Remove the V-belt air filter case
cover by removing the screws.4. Remove the V-belt case air filter
element by removing the screws.1. Air filter check hose
1
1. Air filter check hose
1
1. Screw
2. V-belt air filter case cover
1. Screw
2. V-belt case air filter elementZAUM10312
11
2
1 1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6 5. Lightly tap the V-belt case air filter
element to remove most of the
dust and dirt, and then blow out
the dirt with compressed air as
shown.
6. Check the V-belt case air filter ele-
ment for damage and replace it if
necessary.
7. Install the V-belt case air filter ele-
ment by installing the screws.
NOTICE: Make sure that the V-
belt filter element is properly
seated in its case.
[ECA12942]
8. Install the V-belt air filter case cov-
er by installing the screws.
9. Install the left air filter case cover.
10. Install the panel.
EAU21385
Checking the throttle grip free
playThe throttle grip free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er adjust it.
EAU21402
Valve clearanceThe valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle grip free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
EAU21877
TiresTires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
EWA10504
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be
adjusted in accordance with the
riding speed and with the totalweight of rider, passenger, car-
go, and accessories approved
for this model.
WARNING
EWA10512
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.TIPThe tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
220 kPa (2.20 kgf/cm², 32 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
YP400R 90–185 kg (198–408 lb)
YP400RA 90–181 kg (198–399 lb):
Front:
220 kPa (2.20 kgf/cm², 32 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Maximum load*:
YP400R 185 kg (408 lb)
YP400RA 181 kg (399 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6 Tire information
This model is equipped with tubeless
tires.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA10472
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience to do so.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
EAU21995
Cast wheelsTo maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
The wheel rims should be
checked for cracks, bends, warp-
age or other damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
After repairing or replacing the
rear tire, tighten the valve stem nut
and locknut to the specified
torques.
Front tire:
Size:
120/70-15 M/C 56S
Manufacturer/model:
MICHELIN/CITY GRIP
SAVA/DIAMONDS MC28
Rear tire:
Size:
150/70-13 M/C 64S
Manufacturer/model:
MICHELIN/CITY GRIP
SAVA/DIAMONDS MC28
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU50861
Checking the front and rear
brake lever free playFront
RearThere should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.
1. Valve stem nut
2. Valve stem locknutTightening torques:
Valve stem nut:
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Valve stem locknut:
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
1
2
1. No brake lever free play
1. No brake lever free playZAUM1049ZAUM1050
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
EAU22393
Checking the front and rear
brake padsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22431
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU34211
Rear brake pads
Have a Yamaha dealer check each rear
brake pad for damage and measure
the lining thickness and if necessary,
replace them as a set.
EAU40262
Checking the brake fluid levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Wear indicator groove
1. Minimum level mark
1
ZAUM1057
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6Rear brake
WARNING
EWA16011
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-
sult in vapor lock, an
d dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17641
Brake fluid may damage painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brakefluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level markSpecified brake fluid:
DOT 4ZAUM1032
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
EAU22733
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the master cylinders and calipers as
well as the brake hoses replaced at the
intervals listed below or whenever they
are damaged or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU23098
Checking and lubricating the
cablesThe operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Damage to the
outer housing of cables may result
in internal rusting and cause inter-
ference with cable movement. Re-
place damaged cables as soon as
possible to prevent unsafe condi-
tions.
[EWA10712]EAU23115
Checking and lubricating the
throttle grip and cableThe operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from wa-
ter entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
Recommended lubricant:
Yamaha cable lubricant or other
suitable cable lubricant
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
6
EAU23173
Lubricating the front and rear
brake leversFront brake lever
Rear brake lever
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU23215
Checking and lubricating the
centerstand and sidestand
Recommended lubricant:
Silicone grease
1. Sidestand
1. Centerstand
ZAUM1033
1
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