check engine YAMAHA XMAX 400 2020 User Guide

For your safety – pre-operation checks
5-1
5
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank overflow hose for obstructions, cracks
or damage, and check hose connection.4-19,
4-20
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.7-10
Final transmission oil• Check vehicle for oil leakage. 7-12
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified
level.
• Check cooling system for leakage.7-13
Front brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic
system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.7-21,
7-23,
7-23
Rear brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic
system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.7-21,
7-23,
7-23
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing.7-17,
7-26
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Operation and important riding points
6-2
6
EAU78231
Starting the engine
NOTICE
ECA10251
See page 6-5 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up. (See page 4-28.)
1. Turn the main switch on and make
sure that the stop/run/start switch
is set to “ ”.
The following warning lights and
indicator lights should come on for
a few seconds, then go off.
Engine trouble warning light
Traction control system indi-
cator light
Smart key system indicator
light
TIP
The ABS warning light should come on
and stay on until the vehicle reaches a
traveling speed of 10 km/h (6 mi/h) or
higher.
NOTICE
ECA22510
If a warning or indicator light does
not work as described above, see
page 4-1 for the corresponding
warning and indicator light circuit
check.
2. Close the throttle.
3. While applying the front or rear
brake, push the “ ” side of the
stop/run/start switch. Release it
when the engine starts.
TIP
If the engine does not start, release the
start switch after 5 seconds. Before
pressing the start switch again, wait 10
seconds to allow battery voltage to re-
store.
NOTICE
ECA11043
For maximum engine life, never ac-
celerate hard when the engine is
cold!
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Operation and important riding points
6-5
6
EAU16821
Tips for reducing fuel con-
sumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing 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 traf-
fic lights or at railroad crossings).
EAU16842
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 fol-
lowing 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 themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that
might result in engine overheating
must be avoided.
EAU34323
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, final transmission oil
and the oil filter element.
[ECA12932]
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 nor-
mally.
NOTICE
ECA10311
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
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Periodic maintenance and adjustment
7-3
7
EAU71031
TIP
The annual checks must be performed every year, except if a distance-
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.
EAU71071
Periodic maintenance chart for the emission control system
NO. ITEM
1*Fuel line• Check fuel hoses for cracks or
damage.
• Replace if necessary.√√√√√
2*Spark plug• Check condition.
• Adjust gap and clean.√√
• Replace.√√
3*Valve clearance• Check and adjust. Every 40000 km (24000 mi)
4*Fuel injection• Check engine idle speed.√√√√√√
5*Exhaust system• Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary.√√√√√
6*Evaporative emis-
sion control sys-
tem• Check control system for dam-
age.
• Replace if necessary.√√
7*Air induction sys-
tem• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if
necessary.√√√√√X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
7-5
7
14*Steering bearings• Check bearing assemblies for
looseness.√√ √
• Moderately repack with lithium-
soap-based grease.√√
15*Chassis fasteners• Make sure that all nuts, bolts
and screws are properly tight-
ened.√√√√√
16Front and rear
brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
17Sidestand, center-
stand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
18*Sidestand switch• Check operation and replace if
necessary.√√√√√√
19*Front fork• Check operation and for oil
leakage.
• Replace if necessary.√√√√
20*Shock absorber
assemblies• Check operation and for oil
leakage.
• Replace if necessary.√√√√
21 Engine oil• Change (warm engine before
draining).
• Check oil level and vehicle for
oil leakage.At the initial interval and
when the oil change indi-
cator flashes or comes
on.√
22Engine oil filter el-
ement• Replace.√√√
23*Final transmission
oil• Check vehicle for oil leakage.√√√√√
• Change.√√√√√√
24
*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change. Every 3 years
25*V-belt• Replace.When the V-belt replacement
indicator flashes [every 20000
km (12000 mi)]
26*Front and rear
brake switches• Check operation.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
7-6
7
EAU72770
TIP
Engine air filters and V-belt air filter
• This model’s engine air filters are equipped with disposable oil-coated pa-
per elements, which must not be cleaned with compressed air to avoid
damaging them.
• The engine air filter elements need to be replaced and the V-belt air filter
element needs to be serviced more frequently when 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 cyl-
inders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
27*Moving parts and
cables• Lubricate.√√√√√
28*Throttle grip hous-
ing and cable• Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous-
ing and cable.√√√√√
29*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance and adjustment
7-8
7
To install the panel
Place the panel in the original position,
and then install the screws.
EAU19623
Checking the spark plug
The spark plug is an important engine
component, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
it should be removed and checked in
accordance with the periodic mainte-
nance and lubrication chart. In addi-
tion, 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 deal-
er check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
1. Screw
1. Panel B
ZAUM1506
1
1
ZAUM1507
1
ZAUM1508
Specified spark plug:
NGK/CR7E
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Periodic maintenance and adjustment
7-10
7
EAUM3940
Engine oil and oil filter ele-
ment
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart and when the oil change
indicator comes on.
To check the engine oil level
1. Place the vehicle on the center-
stand. 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 set-
tles, 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.
TIP
The engine oil should be between the
tip of the dipstick and the maximum
level mark.
4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
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 replace-
ment)
1. Place the vehicle on the center-
stand.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIP
Skip steps 5…7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts. NOTICE:
When removing the oil filter ele-1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Tip of the engine oil dipstick
ZAUM1028
3
4
1
2
1. Engine oil drain bolt
2. Gasket
12
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Periodic maintenance and adjustment
7-12
710. 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 cause.
11. Reset the oil change indicator.
(See page 4-7.)
TIP
If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time.
EAU20067
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 transmis-
sion 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 center-
stand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the fi-
nal transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
1. Final transmission oil filler cap
2. O-ring
3. Final transmission oil drain bolt
4. Gasket
2
1
3
4
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Periodic maintenance and adjustment
7-13
7 6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the speci-
fied torque.
7. Refill with the specified amount of
the recommended final transmis-
sion oil. WARNING! Make sure
that no foreign material enters
the final transmission case.
Make sure that no oil gets on
the tire or wheel.
[EWA11312]
8. Install the final transmission oil fill-
er cap and its new O-ring, and
then tighten the oil filler cap.
9. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20071
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU78580To check the coolant level
1. Place the vehicle on the center-
stand.
TIP
The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level through
the check window.
TIP
The coolant should be between the
minimum and maximum level marks.
Tightening torque:
Final transmission oil drain bolt:
20 N·m (2.0 kgf·m, 15 lb·ft)
Recommended final transmission
oil:
See page 9-1.
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
1. Coolant level check window
2. Maximum level mark
3. Minimum level mark
1
2
3
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