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Yamaha X-MAX 300, Owner'S Manual

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Yamaha X-MAX 300 Owner'S Manual Download Page 78

Perio

d

ic maintenance an

d

 a

d

justment

7-15

7

Replacin

g

 the air filter element an

d

su

b

 air filter element an

d

 cleanin

g

the pre air filter element

1. Place the vehicle on the center-

stand.

2. Remove the rubber plugs.

3. Remove the air filter case cover by

removing the screws.

4. Pull the air filter element and sub

air filter element out.

5. Insert a new sub air filter element

into the air filter case cover.

6. Insert a new air filter element into

the air filter case. 

NOTICE:

 Make

sure that the air filter element is
properly seate

d

 in the air filter

case. The en

g

ine shoul

d

 never

b

e operate

d

 without the air filter

element installe

d

, otherwise the

piston(s) an

d

/or cylin

d

er(s) may

b

ecome excessively worn.

[ECA10482]

7. Pull the pre air filter element out,

and then blow out the dirt with
compressed air as shown.

1. Rubber plug

1. Air filter case cover
2. Screw

1

1

2

2

2

2

1. Air filter element

1. Sub air filter element
2. Air filter case cover

1

1

2

UB74E0E0.book  Page 15  Tuesday, May 2, 2017  1:04 PM

Summary of Contents for X-MAX 300

Page 1: ...DIC183 CZD300 A X MAX 300 OWNER S MANUAL B74 F8199 E0 MOTORCYCLE English E Read this manual carefully before oper ating this vehicle ...

Page 2: ...eclaration of conformity is available at the following inter net address http www mitsubishielectric com bu automotive doc re html REMOTE CONT UNIT Smart Unit Frequency band 125 kHz The maximum radio frequency power 117 dBuV m at 10 meters XTMR COMP Hand Unit Frequency band 433 92 MHz The maximum radio frequency power 10 mW Manufacturer MITSUBISHI ELECTRIC CORPORATION HIMEJI WORKS 840 Chiyoda mach...

Page 3: ...njury In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any further questions do not hesitate to con tact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality There fore while this manual contains the most curr...

Page 4: ...tes a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehi cle or other property A TIP provides key information to make proce dures easier or clearer CZD300 A OWNER S MANUAL 2016 PT Yamaha Indonesia Motor Manufacturing 1st edition October 2016 All rights reserved Any reprinting or unau...

Page 5: ...k 4 29 For your safety pre operation checks 5 1 Operation and important riding points 6 1 Starting the engine 6 2 Starting off 6 3 Acceleration and deceleration 6 3 Braking 6 4 Tips for reducing fuel consumption 6 4 Engine break in 6 5 Parking 6 5 Periodic maintenance and adjustment 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubr...

Page 6: ...iliary lights 7 32 Brake tail light 7 33 Front turn signal light 7 33 Rear turn signal light bulb 7 34 Replacing the license plate light bulb 7 34 Troubleshooting 7 35 Troubleshooting charts 7 36 Emergency mode 7 38 Scooter care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Diagnostic connector 10 2 Vehicle dat...

Page 7: ...dition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks z This scooter is designed to carry the operator and a passenger z The failure of motorists to detect and recognize scooters in traffic is the predominating cause of auto mobile scooter accidents Many accidents have been caused by ...

Page 8: ...ever ride under the influence of alcohol or other drugs z This scooter is designed for on road use only It is not suitable for off road use Protective Apparel The majority of fatalities from scooter accidents are the result of head inju ries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries z Always wear an approved helmet z Wear a face ...

Page 9: ...ccessories Here along with the information about accessories be low are some general guidelines to fol low if loading cargo to your scooter The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Operation of an overloaded vehicle could cause an accident When loading within this weight limit keep the following in mind z Cargo and accessory weight sh...

Page 10: ...elines in mind as well as those provided under Load ing when mounting accessories z Never install accessories or carry cargo that would impair the per formance of your scooter Careful ly inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or refl...

Page 11: ...so that the scooter will not bounce exces sively during transport EAU57600 Further safe riding points z Be sure to signal clearly when making turns z Braking can be extremely difficult on a wet road Avoid hard braking because the scooter could slide Apply the brakes slowly when stopping on a wet surface z Slow down as you approach a corner or turn Once you have completed a turn accelerate slowly z...

Page 12: ... absorber assembly spring preload adjusting ring page 4 25 6 Final transmission oil filler cap page 7 12 7 Final transmission oil drain bolt page 7 12 8 V belt case air filter element page 7 14 9 Engine oil drain bolt page 7 9 10 Engine oil filter element page 7 9 11 Sidestand page 4 26 12 Spark plug page 7 8 13 Coolant reservoir page 7 13 UB74E0E0 book Page 1 Tuesday May 2 2017 1 04 PM ...

Page 13: ...ent page 4 20 2 Fuel tank cap page 4 17 3 Storage compartment B page 4 20 4 Windshield page 4 22 5 Battery page 7 29 6 Fuses page 7 30 7 Centerstand page 7 27 8 Engine oil level check window page 7 9 9 Engine oil filler cap page 7 9 UB74E0E0 book Page 2 Tuesday May 2 2017 1 04 PM ...

Page 14: ...ar brake fluid reservoir page 7 23 4 Speedometer page 4 2 5 Multi function display page 4 3 6 Tachometer page 4 3 7 Front brake fluid reservoir page 7 23 8 Right handlebar switches page 4 12 9 Front brake lever page 4 13 10 Throttle grip page 7 18 11 Main switch page 3 8 12 Auxiliary DC jack page 4 29 UB74E0E0 book Page 3 Tuesday May 2 2017 1 04 PM ...

Page 15: ...turer before us ing this vehicle NOTICE ECA24080 The smart key system uses weak ra dio waves The smart key system may not work in the following situa tions z The smart key is placed in a lo cation exposed to strong radio waves or other electromagnetic noise z There are facilities nearby that are emitting strong radio waves TV or radio towers power plants broadcasting stations airports etc z You ar...

Page 16: ...EAU76450 Operating range of the smart key system The operating range of the smart key system is about 80 cm 31 5 in from the main switch TIP z As the smart key system uses weak radio waves the operating range may be affected by the sur rounding environment z When the battery of the smart key is discharged the smart key may not work or its operating range may become very small z If the smart key is...

Page 17: ...ng and take the smart key with you It is recommended that you turn the smart key off EAU78623 Handling of the smart key and mechanical keys WARNING EWA17952 z The smart key should be carried with you Do not store it on the vehicle z When the smart key is within operating range exercise due care because other people not carrying the smart key can start the engine and operate the vehi cle 1 Smart ke...

Page 18: ...smart key in water or other liquids z Do not place heavy items or ex cessive stress on the smart key z Do not leave the smart key in a place exposed to direct sun light high temperature or high humidity z Do not grind or attempt to mod ify the smart key z Keep the smart key away from strong magnetic fields and magnetic objects such as key holders TVs and computers z Keep the smart key away from el...

Page 19: ...is within operating range To operate the vehicle turn the smart key on and bring it within operat ing range To check whether the smart key is turned on or off Push the smart key button to confirm the current operating status of the smart key If the smart key indicator light z Short flash 0 1 seconds The smart key is turned on z Long flash 0 5 seconds The smart key is turned off Remote answer back ...

Page 20: ...urned off z Sounds once The beeper is turned on EAU76481 Replacing the smart key bat tery Replace the battery in the following sit uations z The smart key system indicator light flashes for about 20 seconds when the power of the vehicle is turned on z The answer back function does not operate when the smart key button is pushed WARNING EWA14724 z The battery and other remov able parts may cause in...

Page 21: ... z Make sure the battery is in stalled correctly Confirm the di rection of the positive side of the battery To replace the smart key battery 1 Open the smart key case as shown 2 Remove the battery TIP Dispose of the removed battery in ac cordance with local regulations 3 Install a new battery as shown Note the polarity of the battery 4 Gently snap the smart key case closed 1 Battery 1 Specified ba...

Page 22: ...s of control or an accident TIP Do not push the main switch knob re peatedly or turn the main switch back and forth beyond normal use Other wise to protect the main switch from damage the smart key system will temporarily disable and the smart key system indicator light will flash If this occurs wait until the indicator light stops flashing before operating the main switch again The main switch po...

Page 23: ...ange turn the main switch to OFF 2 The turn signal lights flash once and the vehicle power turns off TIP When the main switch is turned to OFF but the smart key cannot be confirmed the smart key is either out side operation range or has been turned off the beeper will sound for 3 seconds and the smart key system in dicator light will flash for 30 seconds z During this 30 seconds the main switch ca...

Page 24: ... z When the main switch has been in the open position for 3 minutes z If the smart key is turned off while the main switch is in the open po sition z If you walk out of range of the smart key system with the main switch in the open position If the beeper sounds after 3 minutes turn the main switch to OFF or If the beeper sounds because the smart key was turned off or moved out of range turn the sm...

Page 25: ...ck the steering 1 With the smart key turned on and within operating range push the main switch knob 2 While the smart key system indi cator light is on push and turn the main switch to the desired posi tion EAU76903 parking The hazard lights and turn signal lights can be turned on but all other electri cal systems are off To use the position 1 With the main switch in the position and the smart key...

Page 26: ... cap lid 1 With the smart key turned on and within operating range push the main switch knob 2 While the smart key system indi cator light is on turn the main switch to To close the fuel tank cap lid Push the fuel tank cap lid down until it is closed TIP Make sure that fuel tank cap lid is se curely closed before starting off 1 Push 2 Turn 1 2 UB74E0E0 book Page 12 Tuesday May 2 2017 1 04 PM ...

Page 27: ...hen the main switch is turned to ON and goes off after trav eling at a speed of 10 km h 6 mi h or higher If the ABS warning light z does not come on when the main switch is turned to ON z comes on or flashes while riding z does not go off after traveling at a speed of 10 km h 6 mi h or high er The ABS may not work correctly If any of the above occurs have a Yamaha dealer check the system as soon a...

Page 28: ... few seconds and then go off If the light does not come on or if the light remains on have a Yamaha dealer check vehicle EAU78600 Smart key system indicator light This indicator light communicates the status of the smart key system When the smart key system is operating nor mally this indicator light will be off If there is an error in the smart key sys tem the indicator light will flash The indic...

Page 29: ... sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident The TRIP INFO switch is located on the right side of the handlebar This switch allows you to control or change the settings of the multi function meter unit To use the TRIP switch move the TRIP INFO switch in dire...

Page 30: ... eight seconds The hour digits will start flashing 4 Use the TRIP switch to set the hours 5 Push the TRIP switch for three seconds and then release it The minute digits will start flashing 6 Use the TRIP switch to set the minutes 7 Push the TRIP switch for three seconds and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The segments of th...

Page 31: ...check the vehicle as soon as pos sible z The coolant temperature varies with changes in the weather and engine load Tripmeter display The tripmeter display is equipped with the following z odometer z tripmeter z time tripmeter z fuel reserve tripmeter z oil change tripmeter z V belt replacement tripmeter Push the TRIP switch to change the display between the odometer Odo tripmeter Trip time tripme...

Page 32: ...elect it by pushing the TRIP switch and then push the TRIP switch for three sec onds Fuel reserve tripmeter F Trip When approximately 2 4 L 0 63 US gal 0 53 Imp gal of fuel remains in the fuel tank the last segment of the fuel meter will start flashing The display will automatically change to the fuel re serve tripmeter F Trip and start counting the distance traveled from that point In this case p...

Page 33: ...t the correct time V belt replacement tripmeter V Belt Trip The V belt replacement tripmeter shows the distance traveled since the V belt was last replaced The V belt replacement indicator V Belt will flash every 20000 km 12000 mi to indicate that the V belt should be replaced After replacing the V belt reset the V belt replacement indicator and the V belt replacement tripmeter To reset them both ...

Page 34: ...Consumption_ _ _ km L Consumption_ _ _ L 100 km Av erage Air temp For the UK Push the TRIP switch to change the display between the air temperature display Air temp battery voltage dis play Battery traction control system display TCS ON or TCSOFF aver age fuel consumption display Con sumption Average_ _ _ km L Consumption Average_ _ _ L 100 km or Consumption Average_ _ _ _MPG instantaneous fuel co...

Page 35: ...m h 12 mi h or when stopped at traffic sig nals etc Battery voltage display This display shows the current charge state of the battery TIP z If the engine turns over slowly when using the start switch have a Yamaha dealer charge the bat tery z If appears in the battery volt age display have a Yamaha deal er check the battery Traction control system display This display shows the current status of ...

Page 36: ...hown To reset the average fuel consumption push the INFO switch for at least three seconds TIP After resetting the average fuel con sumption _ _ _ will be shown until the vehicle has traveled 1 km 0 6 mi Instantaneous fuel consumption display This function calculates the fuel con sumption under current riding condi tions The instantaneous fuel consumption can be displayed as either Consumption_ _ ...

Page 37: ...is displayed refuel as soon as possible H TEMP Appears when the top seg ment of the coolant temperature meter starts flashing If H TEMP is dis played stop the vehicle then stop the engine and let the engine cool ICE Appears when the icy road warning indicator starts flashing If ICE is displayed be careful of icy roads OIL SERV Appears when the oil change indicator OIL starts flashing If OIL SERV i...

Page 38: ...rting instructions prior to starting the engine Set this switch to to stop the en gine in case of an emergency such as when the vehicle overturns or when the throttle cable is stuck EAU78190 Hazard switch With the main switch in the ON or position use this switch to turn on the hazard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to wa...

Page 39: ...the INFO switch move the TRIP INFO switch in direction b EAU12902 Front brake lever The front brake lever is located on the right side of the handlebar To apply the front brake pull this lever toward the throttle grip 1 TRIP INFO switch 1 b a 1 Front brake lever 1 UB74E0E0 book Page 13 Tuesday May 2 2017 1 04 PM ...

Page 40: ...Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS z The ABS performs best with long braking distances z On certain surfaces such as rough or gravel roads the brak ing distance may be longer with the ABS than without The ABS is monitored by an ECU which will revert the system to conven tional braking if a malfunction occurs TIP z The ABS performs a sel...

Page 41: ...ulating engine power until traction is restored When traction control has engaged the indicator light will flash You may notice changes in engine re sponse or exhaust sound WARNING EWA18860 The traction control system is not a substitute for riding appropriately for the conditions Traction control cannot prevent loss of traction due to excessive speed when entering turns when accelerating hard at ...

Page 42: ...r when only one wheel is al lowed to rotate for more than a few seconds Should this happen the indicator light will come on and possi bly the warning light too TIP When the vehicle is on the centerstand do not rev the engine for an extended period of time Otherwise the traction control system will automatically dis able and need to be reset If the traction control system automat ically disables tr...

Page 43: ...d then pull the cap off To install the fuel tank cap 1 Insert the fuel tank cap onto the tank opening and turn it clockwise until the install mark aligns with 2 Close the fuel tank cap lid WARNING EWA11092 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Fuel tank cap lid 1 Fuel tank cap 2 Release mark 1 1 2 1 Install mark 1 UB74E0E0 book Page ...

Page 44: ...mmedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cau se injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get...

Page 45: ...sts Gasohol There are two types of gasohol gaso hol containing ethanol and that con taining methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU58301 Fuel tank overflow hose Before operating the vehicle z Check the fu...

Page 46: ... more than a few minutes Long idling can cause a build up of heat NOTICE ECA10702 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU78512 Storage compartments This model is equipped with 3 storage compartments The front storage com partments and rear storage compart ment are located as shown TIP z Storage compartment A must be opene...

Page 47: ...To open the seat rear storage com partment via the main switch Turn the main switch to OPEN and then push the SEAT button To open the seat rear storage com partment with the mechanical key 1 Open the keyhole cover 2 Insert the mechanical key into the seat lock and then turn it clock wise TIP Be sure to close the seat and all stor age compartments before starting off NOTICE ECA24020 Make sure that ...

Page 48: ... vehicle is being washed wrap any articles stored in the compartment in a plastic bag z Do not keep anything valuable or breakable in the storage compartment WARNING EWA15401 Do not exceed the maximum load of 161 kg 355 lb for the vehicle EAU78521 Windshield To suit the rider s preference the wind shield height can be changed to one of two positions To change the windshield height to the high posi...

Page 49: ...ews to the specified torque EWA15511 5 Place the bolt access covers and then install the quick fasteners To change the windshield height to the low position 1 Remove the bolt access covers by removing the quick fasteners 2 Remove the windshield by remov ing the bolts 3 Remove the bolts and then install the bolts in the desired position 1 Bolt 1 Bolt 1 Bolt 1 1 1 1 1 1 1 Bolt Tightening torque Wind...

Page 50: ... spec ified torque WARNING A loose windshield could cause an acci dent Be sure to tighten the screws to the specified torque EWA15511 5 Place the bolt access covers and then install the quick fasteners 1 Bolt 1 Bolt 1 Bolt 1 1 1 1 1 1 Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 8 lb ft UB74E0E0 book Page 24 Tuesday May 2 2017 1 04 PM ...

Page 51: ...CA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly ...

Page 52: ...destand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and...

Page 53: ...he follow ing functions z It prevents the engine from start ing when the sidestand is down z It prevents the engine from start ing if the brakes are not applied z It will stop the running engine if the sidestand is moved down Periodically check the operation of the ignition circuit cut off system accord ing to the following procedure UB74E0E0 book Page 27 Tuesday May 2 2017 1 04 PM ...

Page 54: ...all The system is OK The vehicle can be ridden The sidestand switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer The brake switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer WARNING T...

Page 55: ...e is equipped with an auxil iary DC jack located within storage compartment A A 12 V accessory connected to the auxiliary DC jack can be used when the main switch is in the ON position and should only be used when the engine is running To use the auxiliary DC jack 1 Open storage compartment A See page 3 9 2 Turn the main switch off 3 Remove the auxiliary DC jack cap 4 Turn the accessory off 5 Inse...

Page 56: ...sary add recommended oil to specified level Check vehicle for oil leakage 7 9 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 nece...

Page 57: ...voting points if necessary 7 26 Centerstand side stand Make sure that operation is smooth Lubricate pivots if necessary 7 27 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working co...

Page 58: ...could cause an accident or injury EAU78221 TIP This model is equipped with a lean an gle sensor to stop the engine in case of a turnover In this case the engine trouble warning light will come on but this is not a malfunction Before re starting the engine turn the main switch off and then back on to reset the engine trouble warning light Failing to do so will prevent the engine from starting even ...

Page 59: ...rt 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...

Page 60: ...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 EAU16782 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in di rection a To reduce the speed turn the throttle grip in direction b 1 Grab bar ...

Page 61: ...more difficult z Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply both front and rear brakes simultaneously while gradually in creasing the pressure EAU16821 Tips for reducing fuel con sumption Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fuel consumption z Avoid high engine speeds during acc...

Page 62: ...ld oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAUN1421 Parking When parking turn the vehicle power off and then turn the smart key off TIP Even when the vehicle is parked in a lo cation partitioned by a fence or the glass window of a shop if the smart key is within operating range other people will be able to start the engine and operate the vehicl...

Page 63: ...Operation and important riding points 6 6 6 z Do not park near grass or other flammable materials which might catch fire UB74E0E0 book Page 6 Tuesday May 2 2017 1 04 PM ...

Page 64: ...aintain the vehi cle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified z A running engine has moving parts that can catch on body parts or cl...

Page 65: ...l that is certified if applicable Yamaha dealers are trained and equipped to perform these particular services EAU79250 Owner s tool kit The owner s tool kit is located on the bottom of the seat See page 3 9 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 preventive maintenance and minor repairs How eve...

Page 66: ...071 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 20000 km 12000 mi 4 Fuel injection Check engine idle speed 5 Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary 6 Evaporative em...

Page 67: ...uid level and for fluid leakage Replace brake pads if neces sary 8 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if neces sary 9 Brake hoses Check for cracks or damage Replace Every 4 years 10 Brake fluid Change Every 2 years 11 Wheels Check runout and for damage Replace if necessary 12 Tires Check tread depth and for damage Replace if necessary Check air pressure...

Page 68: ...emblies 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 every 5000km 3000 mi 22 Engine oil filter el ement Replace 23 Final transmission oil Check vehicle for oil leakage Change 24 Cooling system Check coolant level and...

Page 69: ...alipers always chan ge 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 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 Adj...

Page 70: ...is chapter Refer to this section each time the panel needs to be removed and installed EAU78530 Panel A To remove the panel Remove the screws and then pull the panel outward and slide it forward as shown To install the panel Place the panel in the original position and then install the screws 1 Panel A 1 Screw 1 1 1 1 Panel A 1 UB74E0E0 book Page 7 Tuesday May 2 2017 1 04 PM ...

Page 71: ...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 Clean the surface of the spark plug gasket and its m...

Page 72: ...d and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion 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 and th...

Page 73: ...ect the used oil 3 Remove the engine oil filler cap and its O ring and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase 4 Check the O ring for damage and replace it if necessary 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 6 Remove and replace the oil filter element and O ring ...

Page 74: ...oreign material enters the crankcase 10 Install and tighten the oil filler cap and its O ring 11 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 12 Turn the engine off and then check the oil level and correct it if necessary 1 Oil filter element 2 O ring Tightening torque Oil filte...

Page 75: ...smission oil drain bolt and its gasket to drain the oil from the final transmission case 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 tir...

Page 76: ... nimum and maximum level marks 3 If the coolant is at or below the mi nimum level mark remove the left floorboard mat by pulling it up 4 Remove the coolant reservoir cov er 5 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15162 ...

Page 77: ... sub air fil ter element should be replaced every 20000 km 12000 mi The pre air filter element and the V belt case air filter el ement should be cleaned at the inter vals specified in the periodic maintenance and lubrication chart Service the air filter elements more fre quently if you are riding in unusually wet or dusty areas The air filter check hose must be frequently checked and cleaned if ne...

Page 78: ...case cover 6 Insert a new air filter element into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10482 7 Pull the pre air filter element out and then blow out the dirt with compressed air as ...

Page 79: ...g the screws TIP The long screw should be installed as shown 11 Install the rubber plugs Cleaning the V belt case air filter el ement 1 Place the vehicle on the center stand 2 Remove the air filter case cover See the previous section 3 Remove the V belt case cover screws 4 Remove the air filter case bolts 1 Pre air filter element 2 Air filter case cover 1 2 1 Long screw 1 Screw 1 1 1 UB74E0E0 book...

Page 80: ...r from the clean side as shown 8 Check the V belt case air filter ele ment for damage and replace it if necessary 9 Insert the element into the V belt case 10 Install the V belt case air filter cov er by installing the bolts 11 Install the rear wheel sensor lead into the holder at the white tape on the lead as shown 1 Bolt 1 Rear wheel sensor lead 2 Lead holder 1 V belt case air filter cover 2 Bol...

Page 81: ... the screws EAU21386 Checking the throttle grip free play Measure the throttle grip free play as shown Periodically check the throttle grip free play and if necessary have a Yamaha dealer adjust it 1 Rear wheel sensor lead 2 White tape 3 Lead holder Tightening torque Bolt 10 N m 1 0 kgf m 7 2 lb ft 1 3 3 2 2 3 2 2 3 1 Throttle grip free play Throttle grip free play 3 0 5 0 mm 0 12 0 20 in 1 UB74E0...

Page 82: ...sential 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 z The tire air pressure must be checked and ...

Page 83: ...ealer who has the necessary professional knowl edge and experience to do so z Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This model is equipped with tubeless tires and rubber tire air valves Tires age even if they have not been used or have only been used occasion ally Cracking of the t...

Page 84: ...ified wheels z 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 z The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor...

Page 85: ...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 No brake lever free play 1 No brake lever free play 1 1 UB74...

Page 86: ...he wear indicator almost touches the brake disc have a Yamaha dealer re place the brake pads as a set EAU22582 Checking the brake fluid level Before 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 Rear brake WARNING EWA15991 Improper maintenance can result in loss of...

Page 87: ... 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 brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EAU22733 Changing the brake f...

Page 88: ... 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 Reco...

Page 89: ...cat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU23173 Lubricating the front and rear brake levers Front 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 Recommended lubricant Silicone grease UB74E0E0 book Page 26 Tuesday May 2...

Page 90: ...ration of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it...

Page 91: ...ehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing EAU23292 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there i...

Page 92: ...and pro vide sufficient ventilation when charging it in an enclosed space z KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 To charg...

Page 93: ...properly con nected to the battery terminals NOTICE ECA16531 Always keep the battery charged Storing a discharged battery can cause permanent battery damage EAU78242 Replacing the fuses The main fuse and the fuse boxes which contain the fuses for the individ ual circuits are located under panel A See page 7 7 TIP To access the main fuse remove the starter relay cover as shown 1 Fuse box 2 Main fus...

Page 94: ...mediately blows again have a Yamaha dealer check the electrical system 1 Signaling system fuse 2 2 Signaling system fuse 3 ABS control unit fuse 4 Main fuse 2 5 Radiator fan motor fuse 6 Backup fuse 7 Spare fuse 8 ABS motor fuse 9 ABS solenoid fuse 10 Turn signal light and hazard fuse 11 Terminal fuse 1 12 Answer back fuse 1 2 3 4 5 6 7 8 9 10 11 12 7 Specified fuses Main fuse 20 0 A Main fuse 2 7...

Page 95: ...e on have a Yamaha dealer check its electrical circuit NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens EAU54502 Auxiliary lights This model is equipped with LED type auxiliary lights If an auxiliary light does not come on have a Yamaha dealer check it UB74E0E0 book Page 32 Tuesday May 2 2017 1 04 PM ...

Page 96: ... an LED type brake tail light If the brake tail light does not come on have a Yamaha dealer check it EAU39881 Front turn signal light If a front turn signal light does not come on have a Yamaha dealer check its electrical circuit or replace the bulb UB74E0E0 book Page 33 Tuesday May 2 2017 1 04 PM ...

Page 97: ...he bolts and plate and then remove the license plate light bulb socket together with the bulb by pulling it out 2 Remove the burnt out bulb by pulling it out 3 Insert a new bulb into the socket 4 Install the socket together with the bulb by pushing it in and then install the license plate light unit by installing the plate and bolts 1 License plate light unit 2 Bolt 3 License plate light bulb sock...

Page 98: ...pen flames or sparks in the ar ea including pilot lights from water heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage EAU76550 Smart key system troubleshooting Please check the following items when the smart key system does not work z Is the smart key turned on See page 3 5 z Is the smart key battery dis charged See page 3 6 z Is the s...

Page 99: ...e battery lead connections and have a Yamaha dealer charge the battery if necessary 2 Battery The battery is good The engine does not start Check the ignition 3 Ignition Wet Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a Yamaha dealer chec...

Page 100: ...stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator Add coolant See TIP The coolant level is OK There is no leakage There is lea...

Page 101: ...three seconds to indicate the transition to emergency mode 3 After the smart key system indica tor light goes off input the identifi cation number as follows 4 Inputting the identification number is done by counting the number of flashes of the smart key system in dicator light For example if the identification number is 123456 Push and hold the knob The smart key system indicator light will start...

Page 102: ...ill flash quickly for 3 seconds In this case start over again from step 2 z When there are no knob opera tions for 10 seconds during the identification number input pro cess z When the smart key system indi cator light is allowed to flash nine or more times z The identification number is not entered correctly 5 While the smart key system indi cator light is on push the knob once more to complete e...

Page 103: ... appearance of a scooter Fre quent and proper care does not only comply with the terms of the warranty but it will also keep your scooter look ing good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark...

Page 104: ...windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quality plastic polishing compound af ter washing After normal use Remove dirt with war...

Page 105: ...s a universal clean er to remove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the scooter dry completely be fore storing or covering it WARNING EWA10943 Contaminants on the brakes or tires can cause loss of control z Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regu...

Page 106: ...k plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure ...

Page 107: ...Scooter care and storage 8 5 8 TIP Make any necessary repairs before storing the scooter UB74E0E0 book Page 5 Tuesday May 2 2017 1 04 PM ...

Page 108: ...oil filter removal 1 60 L 1 69 US qt 1 41 Imp qt Final transmission oil Type Motor oil SAE 10W 30 type SE or higher or Gear oil SAE 85W GL 3 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 18 L 0 19 US qt 0 16 Imp qt Radiator including all routes 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Oil coated paper element Fuel Recomm...

Page 109: ...e Cast wheel Rim size J14M C x MT4 0 Front brake Type Hydraulic single disc brake Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brake Specified brake fluid DOT 4 Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 110 mm 4 3 in Rear suspension Type Unit swing Spring Coil spring Shock absorber Hydraulic damper Wheel travel 79 mm ...

Page 110: ... system indicator warning light LED Fuse s Main fuse 20 0 A Main fuse 2 7 5 A Terminal fuse 1 2 0 A Signaling system fuse 10 0 A Signaling system fuse 2 7 5 A Radiator fan motor fuse 7 5 A Turn signal light and hazard fuse 7 5 A ABS control unit fuse 7 5 A ABS motor fuse 30 0 A ABS solenoid fuse 15 0 A Answer back fuse 2 0 A Backup fuse 7 5 A UB74E0E0 book Page 3 Tuesday May 2 2017 1 04 PM ...

Page 111: ...e vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the crankcase EAU26501 Model label The model label is affixed to the inside of the rear storage compartment See page 4 20 Recor...

Page 112: ...hen maintenance checks or service procedures are performed Although the sensors and recorded data will vary by model the main data points are z Vehicle status and engine perfor mance data z Fuel injection and emission relat ed data Yamaha will not disclose this data to a third party except z With the consent of the vehicle owner z Where obligated by law z For use by Yamaha in litigation z For gene...

Page 113: ... 4 17 Fuel tank overflow hose 4 19 Fuses replacing 7 30 H Handlebar position adjusting 4 25 Handlebar switches 4 12 Hazard switch 4 12 Headlights 7 32 High beam indicator light 4 1 Horn switch 4 12 I Identification numbers 10 1 Ignition circuit cut off system 4 27 Indicator lights and warning lights 4 1 K Key handling of smart and mechanical keys 3 3 L License plate light bulb replacing 7 34 M Mai...

Page 114: ...5 Traction control system indicator light 4 2 TRIP INFO switch 4 12 Troubleshooting 7 35 Troubleshooting charts 7 36 Turn signal indicator lights 4 1 Turn signal switch 4 12 V Valve clearance 7 19 V belt checking 7 25 Vehicle identification number 10 1 W Wheel bearings checking 7 28 Wheels 7 21 Windshield 4 22 UB74E0E0 book Page 2 Tuesday May 2 2017 1 04 PM ...

Page 115: ...UB74E0E0 book Page 3 Tuesday May 2 2017 1 04 PM ...

Page 116: ...DIC183 Original instructions PRINTED IN INDONESIA 2016 11 ...

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