Yamaha X MAX CZD300-A Owner'S Manual Download

Page: 93 / 114

Perio

ic maintenance an

justment

8-29

EAU78242

Replacin

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 8-7.)

TIP

To access the main fuse, remove the
starter relay cover as shown.

If a fuse is blown, replace it as follows.

1. Turn the main switch off and turn

off the electrical circuit in ques-
tion.

2. Remove the blown fuse, and then

install a new fuse of the specified
amperage.

WARNING! Do not

use a fuse of a hi

her ampera

ratin

than recommen

avoi

causin

extensive

am-

e to the electrical system an

possi

ly a fire.

[EWA15132]

3. Turn the main switch on and turn

on the electrical circuit in question
to check if the device operates.

1. Fuse box
2. Main fuse
3. Spare main fuse
4. Starter relay cover

1. Signaling system fuse
2. ABS control unit fuse
3. Main fuse 2
4. Radiator fan motor fuse
5. Backup fuse
6. Spare fuse
7. ABS motor fuse
8. ABS solenoid fuse
9. Turn signal light and hazard fuse
10.Terminal fuse 1
11.Answer back fuse

10
11

Specifie

fuses:

Main fuse:

20.0 A

Main fuse 2:

7.5 A

Terminal fuse 1:

2.0 A

Signaling system fuse:

10.0 A

Radiator fan motor fuse:

7.5 A

Backup 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

UB74EWE0.book Page 29 Monday, September 11, 2017 2:31 PM

Summary of Contents for X MAX CZD300-A

Page 1: ...DIC183 CZD300 A OWNER S MANUAL Read this manual carefully before operating this vehicle B74 F8199 EW English E ...

Page 2: ...EAU46094 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB74EWE0 book Page 1 Monday September 11 2017 2 31 PM ...

Page 3: ...In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact 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 Therefore while this manual contains the most cur rent ...

Page 4: ...tial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates 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 vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NO...

Page 5: ...ndonesia Motor Manufacturing 1st edition July 2017 All rights reserved Any reprinting or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufac turing is expressly prohibited Printed in Indonesia UB74EWE0 book Page 2 Monday September 11 2017 2 31 PM ...

Page 6: ...7 For your safety pre operation checks 6 1 Operation and important riding points 7 1 Starting the engine 7 2 Starting off 7 2 Acceleration and deceleration 7 3 Braking 7 3 Tips for reducing fuel consumption 7 3 Engine break in 7 4 Parking 7 4 Periodic maintenance and adjustment 8 1 Owner s tool kit 8 1 Periodic maintenance chart for the emission control system 8 2 General maintenance and lubricati...

Page 7: ... 30 Brake tail light 8 31 Front turn signal light 8 31 Rear turn signal light bulb 8 31 Replacing the license plate light bulb 8 32 Troubleshooting 8 32 Troubleshooting charts 8 34 Emergency mode 8 36 Scooter care and storage 9 1 Matte color caution 9 1 Care 9 1 Storage 9 3 Specifications 10 1 Consumer information 11 1 Identification numbers 11 1 Vehicle data recording 11 2 Index 12 1 UB74EWE0 boo...

Page 8: ...icle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 UB74EWE0 book Page 1 Monday September 11 2017 2 31 PM ...

Page 9: ...Location of important labels 1 2 1 1WD F1668 01 200 29 200 29 225 33 225 33 100kPa 1bar kPa psi kPa psi 2 1 3 B74 F2259 00 2PL F1568 01 UB74EWE0 book Page 2 Monday September 11 2017 2 31 PM ...

Page 10: ...u Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 6 1 for a list of pre operation checks This motorcycle is designed to carry the operator and a passen ger The failure of motorists to detect and recogniz...

Page 11: ... main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not ...

Page 12: ...le is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo mu...

Page 13: ...ies related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per formance of your motorcycle Carefully 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 st...

Page 14: ...rn signals or parts that could break Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs if possible so that the mo torcycle will not bounce exces sively during transport EAU57610 Further safe riding points Be sure to signal clearly when making turns Braking can be extremely...

Page 15: ...ity of fatalities from motorcycle or scooter accidents are the result of head injuries The use of a safety hel met is the single most critical factor in the prevention or reduction of head in juries Always select an approved motorcy cle helmet Pay attention to the following when choosing a motorcycle helmet The helmet must meet the safety standard TIS The helmet size must match the size of the rid...

Page 16: ...formation 2 7 2 Full type use only for riding at low to mid range speeds Full face type use for riding at mid range to high speeds ZAUU0004 ZAUU0005 ZAUU0006 UB74EWE0 book Page 7 Monday September 11 2017 2 31 PM ...

Page 17: ...sorber assembly spring preload adjusting ring page 5 23 6 Final transmission oil filler cap page 8 11 7 Final transmission oil drain bolt page 8 11 8 V belt case air filter element page 8 14 9 Engine oil drain bolt page 8 9 10 Engine oil filter element page 8 9 11 Sidestand page 5 24 12 Spark plug page 8 8 13 Coolant reservoir page 8 12 UB74EWE0 book Page 1 Monday September 11 2017 2 31 PM ...

Page 18: ... page 5 19 2 Fuel tank cap page 5 15 3 Storage compartment B page 5 19 4 Windshield page 5 21 5 Battery page 8 27 6 Fuses page 8 29 7 Centerstand page 8 25 8 Engine oil level check window page 8 9 9 Engine oil filler cap page 8 9 UB74EWE0 book Page 2 Monday September 11 2017 2 31 PM ...

Page 19: ...brake fluid reservoir page 8 22 4 Speedometer page 5 2 5 Multi function display page 5 3 6 Tachometer page 5 3 7 Front brake fluid reservoir page 8 22 8 Right handlebar switches page 5 11 9 Front brake lever page 5 12 10 Throttle grip page 8 18 11 Main switch page 4 7 12 Auxiliary DC jack page 5 27 UB74EWE0 book Page 3 Monday September 11 2017 2 31 PM ...

Page 20: ...he opera tion of such devices when close by If you have an electric medical device consult a doctor or the device manufacturer 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 The smart key is placed in a lo cation exposed to strong radio waves or other electromagnetic noise There are facilities ne...

Page 21: ... 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 As the smart key system uses weak radio waves the operating range may be affected by the sur rounding environment When the battery of the smart key is discharged the smart key may not work or its operating range may become very small If the smart key is turned off the vehicle ...

Page 22: ...e vehi cle Included with the vehicle is one smart key two mechanical keys and one identification number card The identi fication number can also be found on the inside of the smart key itself If the vehicle battery is discharged the mechanical key can be used to open the seat Carry one mechanical key in addition to the smart key If the smart key is lost or the smart key battery has discharged the ...

Page 23: ...art key away from electric medical equipment Do not allow oils polishing agents fuel or any strong chemicals to come in contact with the smart key The smart key body may become discol ored or cracked TIP The smart key battery life is ap proximately two years but this may vary according to operating conditions Replace the smart key battery when the smart key system indi cator light flashes for 20 s...

Page 24: ... twice This feature is convenient for locating your vehicle in a parking lot and other areas Operating range of the answer back function The approximate operating range of the answer back function using the smart key is shown in the following il lustration As the smart key system uses weak ra dio waves the operating range may be affected by the surrounding environ ment To turn the answer back beep...

Page 25: ...or other heat sources NOTICE ECA15784 Use a cloth when opening the smart key case with a screw driver Direct contact with hard objects may damage or scratch the smart key Take precautions to prevent the waterproof seal from being damaged or contaminated by dirt Do not touch the internal cir cuits and terminals This may cause malfunctions Do not apply excessive force to the smart key when replacing...

Page 26: ...p the smart key case closed EAU76892 Main switch The main switch is used to turn the ve hicle power on and off lock and unlock the steering and open the seat fuel tank cap lid and storage compartment 1 Battery Specified battery CR2032 1 1 Battery 1 1 Main switch 2 Main switch knob 1 Smart key system indicator light 2 1 1 UB74EWE0 book Page 7 Monday September 11 2017 2 31 PM ...

Page 27: ... until the indicator light stops flashing before operating the main switch again The main switch positions are de scribed below EAU76500 ON on All electrical circuits are supplied with the power and the engine can be start ed To turn the vehicle power on 1 Turn the smart key on and bring it within operating range 2 Push the main switch knob and the smart key indicator light will come on for approx...

Page 28: ...be freely operated After 30 seconds the vehicle power will turn off automatically To turn the vehicle power off im mediately push the main switch knob four times within 2 seconds EAU79042 OPEN open Power is supplied to the main switch The seat and storage compartment A can be opened To open the seat and storage compart ment A 1 With the smart key turned on and within operating range push the main ...

Page 29: ...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 smart key on and walk back into range TIP The beeper will turn off after 1 mi nute The seat can also be opened with the mechanical key See page 5 19 EAU76521 lock The steering is locked and all electrical systems are off To l...

Page 30: ... to the desired posi tion EAU79000 fuel tank cap lid To open the fuel tank 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 of...

Page 31: ...n the ABS warning light comes on when 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 does not come on when the main switch is turned to ON comes on or flashes while riding 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 deale...

Page 32: ... the light should come on for a 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 indic...

Page 33: ...er 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 direction a To use the INFO switch move the TRIP INFO switch in direction b The multi fun...

Page 34: ...er disappear from F full towards E empty as the fuel level decreases When the last segment of the fuel meter starts flashing refuel as soon as possible TIP If a problem is detected in the fuel meter the all segments will flash repeatedly If this occurs have a Yamaha dealer check the vehicle When approximately 2 4 L 0 63 US gal 0 53 Imp gal of fuel re mains in the fuel tank the last seg ment of the...

Page 35: ...and V belt replacement tripmeter V Belt Trip in the following order Odo Trip Trip Time Oil Trip V Belt Trip Odo TIP 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 Odometer Odo ...

Page 36: ...der F Trip Oil Trip V Belt Trip Odo Trip Trip Time F Trip To reset the fuel reserve tripmeter se lect it by pushing the TRIP switch and then push the TRIP switch for three seconds The fuel reserve tripmeter will reset au tomatically and disappear after refuel ing and traveling 5 km 3 mi Oil change tripmeter Oil Trip The oil change tripmeter shows the distance traveled since the oil was last change...

Page 37: ...for three seconds While the V belt replacement tripmeter is flashing push the TRIP switch for 15 to 20 seconds Release the TRIP switch and the V belt trip value will re set to zero TIP If the V belt is replaced before the V belt replacement indicator comes on i e before the periodic V belt replace ment interval has been reached the V belt replacement tripmeter must be re set for the V belt replace...

Page 38: ...mperature displayed may vary from the actual ambient temperature TIP The accuracy of the temperature read ing may be affected by engine heat when riding slowly under 20 km 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 If the engine turns over slowly when using the start switch have a Yamaha dealer charge the...

Page 39: ...s shown 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 40: ...l 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 is displayed change...

Page 41: ...ng 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 EAU79500 Hazard switch With the main switch in the ON posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn o...

Page 42: ... brake lever is located on the right side of the handlebar To apply the front brake pull this lever toward the throttle grip EAU12952 Rear brake lever The rear brake lever is located on the left side of the handlebar To apply the rear brake pull this lever toward the handlebar grip 1 TRIP INFO switch 1 b a 1 Front brake lever 1 1 Rear brake lever 1 UB74EWE0 book Page 12 Monday September 11 2017 2 ...

Page 43: ... ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the main switch is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a clicking noise can be heard from the front of the vehicle and if ei ther brake lever is even slightly ap plie...

Page 44: ...p ping As with any vehicle approach surfaces that may be slippery with caution and avoid especially slip pery surfaces Setting the traction control system When the vehicle is turned on traction control is automatically turned on To turn the traction control system off use the INFO switch to change the information display to the traction con trol system display Then push the IN FO switch for three ...

Page 45: ...sables try resetting it as fol lows 1 Stop the vehicle and turn it off completely 2 Wait a few seconds and then turn the vehicle power on 3 The indicator light should turn off and the system be en abled TIP If the indicator light remains on af ter resetting the vehicle may still be ridden however have a Yamaha deal er check the vehicle as soon as possi ble 4 Have a Yamaha dealer check the vehicle ...

Page 46: ...fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when...

Page 47: ...asoline spills on your clothing change your clothes EAUU0045 NOTICE ECA11401 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 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...

Page 48: ...tem is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before doing any maintenance work Do not allow the engine to idle more than a few...

Page 49: ...h to OPEN and then push the LID button To close storage compartment A push the storage compartment lid until it is closed Storage compartment B To open storage compartment B push the storage compartment lid inward to unlock it and then pull to open To close storage compartment B push the storage compartment lid into the original position Seat rear storage compartment To open the seat rear storage ...

Page 50: ...inside it To avoid humidity from spread ing through the storage com partment wrap wet articles in a plastic bag before storing them in the compartment Since the storage compartment may get wet while the vehicle is being washed wrap any articles stored in the compartment in a plastic bag Do not keep anything valuable or breakable in the storage compartment WARNING EWA18950 Do not exceed the load li...

Page 51: ... 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 4 Install the windshield to the high position by installing the bolts and then tighten the bolts to the spec ified torque WARNING A loose windshield could cause an acci 1 Windshield 1 1 Quick fastener 2 Bolt access cover 1 Bolt 2 1 1 1 1 Bolt 1 Bolt 1 1 1 1 UB74...

Page 52: ...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 4 Install the windshield to the low position by installing the bolts and then tighten the bolts to the spec ified torque WARNING A loose windshield could cause an acci 1 Bolt Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 9 lb ft 1 1 1 Bolt access cover 1 1 ...

Page 53: ...handling and loss of stability may re sult Each shock absorber assembly is equipped with a spring preload adjust ing ring NOTICE ECA10102 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 direct...

Page 54: ...the ignition circuit cut off system WARNING EWA10242 The vehicle must not be ridden with the sidestand 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 s...

Page 55: ...he follow ing functions It prevents the engine from start ing when the sidestand is down It prevents the engine from start ing if the brakes are not applied 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 UB74EWE0 book Page 25 Monday September 11 2017 2 31 PM ...

Page 56: ...The system is OK The vehicle can be ridden YES NO YES NO NO YES The sidestand 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 The brake switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha...

Page 57: ...s 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 4 9 2 Turn the main switch off 3 Remove the auxiliary DC jack cap 4 Turn the accessory off 5 Insert ...

Page 58: ...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 5 16 5 18 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 8 9 Final transmission oil Check vehicle for oil leakage 8 11 Coolant Check coolant level in reser...

Page 59: ...ion is smooth Lubricate if necessary 8 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 8 19 8 20 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 8 25 Chassis fasteners Make sure that all nuts bolts...

Page 60: ...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 though the engine will crank when pushing the start switch EAUN0073 NOTICE EC...

Page 61: ...s not work as described above see page 5 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 ...

Page 62: ... approaching such areas and cross them with cau tion Keep in mind that braking on a wet road is much more difficult 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 ...

Page 63: ...ond 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 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 ...

Page 64: ...place where pedestri ans 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 increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire UB74EWE0 book Page 5 Monday September 11 2017 2 31 PM ...

Page 65: ...engine when performing maintenance unless otherwise 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 ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more in formation about carbon monox ide WARNING EWA15461 Brake discs...

Page 66: ... chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition Replace if necessary 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check v...

Page 67: ... element Clean Every 20000 km 12500 mi 4 Sub air filter ele ment Replace Every 20000 km 12500 mi 5 Air filter check hose Clean 6 V belt case air filter element Clean Replace if necessary 7 Battery Check voltage Charge if necessary 8 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 9 Rear brake Check operation fluid level and vehicl...

Page 68: ...roperly tightened 17 Front brake lever pivot shaft Lubricate with silicone grease 18 Rear brake lever pivot shaft Lubricate with silicone grease 19 Sidestand center stand Check operation Lubricate with lithium soap based grease 20 Sidestand switch Check operation 21 Front fork Check operation and for oil leak age 22 Shock absorber as semblies Check operation and shock ab sorbers for oil leakage NO...

Page 69: ...000 km 6000 mi 27 V belt Replace When the V belt replacement indicator flashes every 20000 km 12500 mi 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate 30 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 31 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINT...

Page 70: ...he V belt air filter element needs to be serviced more frequently 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 b...

Page 71: ...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 1 Screw 1 Panel A 1 1 1 UB74EWE0 book Page 7 Monday September 11 2017 2 31 PM ...

Page 72: ... 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 mati...

Page 73: ...evel 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 then check the oil level through the check window locat ed at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4...

Page 74: ...nd replace the oil filter element and O ring 7 Install the oil filter element cover by installing the bolts then tight ening them to the specified torque TIP Make sure that the O ring is properly seated 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque 1 Engine oil filler cap 2 O ring 1 2 1 Engine oil drain bolt 2 Gasket 1 Bolt 2 Oil filter el...

Page 75: ...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 ...

Page 76: ...hould be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU78580 To 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 t...

Page 77: ... has been used instead of coolant replace it with cool ant as soon as possible other wise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10473 6 Install the coolant reservoir cover 7 Place th...

Page 78: ...n chart Service the air filter elements more frequently if you are riding in un usually wet or dusty areas The air filter check hose must be frequently checked and cleaned if necessary Cleaning the air filter check hose 1 Check the hose on the rear side of the air filter case for accumulated dirt or water 2 If dirt or water is visible remove the hose from the clamp clean it and then install it TIP...

Page 79: ...t 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 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 A...

Page 80: ...talled 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 5 Lift up the air filter case slightly re move the rear wheel sensor lead from the holder and then remove the V belt case cover 1 Long scr...

Page 81: ...v er by installing the bolts 11 Install the rear wheel sensor lead into the holder at the white tape on the lead as shown 12 Install the air filter case bolts and then tighten the bolts to the spec ified torque 13 Install the V belt case cover by in stalling the screws 1 Rear wheel sensor lead 2 Lead holder 1 V belt case air filter cover 2 Bolt 1 2 2 1 2 2 1 V belt case air filter element 1 Clean ...

Page 82: ... component and since valve clearance changes with use they must be checked and adjusted at the intervals specified in the periodic maintenance chart Unadjusted valves can result in improper air fuel mixture engine noise and eventually engine damage To prevent this from occurring have your Yamaha dealer check and adjust the valve clearance at regular intervals TIP This service must be performed whe...

Page 83: ...ssure must be adjusted in accordance with the riding speed and with the total weight 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 a tire tread shows crosswise lines minimum tread depth if the tire has a nail or g...

Page 84: ...r use WARNING EWA10462 The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be different which could lead to an accident After extensive tests only the tires list ed below have been approved for this model by Yamaha EAU21963 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following ...

Page 85: ...e 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 EAU22312 Checking the front and rear brake pads Front brake Rear brake 1 No brake lever free play 1 No brake lever free play 1 1 1...

Page 86: ...r re place the brake pads as a set EAU60680 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 braking ability Observe these precautions Insufficient brake fluid...

Page 87: ...mediately 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 EAU22734 Changing the brake fluid Have...

Page 88: ... 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 EAU49921 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In ...

Page 89: ...nd and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10742 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator ...

Page 90: ...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 falling over EWA10752 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothl...

Page 91: ...ng 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 is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU60691 Battery The battery is located behind panel A See page 8 7 This model is equipped with a VRLA Valve Regulated Lead Acid ba...

Page 92: ...es NOTICE ECA16522 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure to turn the main sw...

Page 93: ...possibly a fire EWA15132 3 Turn the main switch on and turn on the electrical circuit in question to check if the device operates 1 Fuse box 2 Main fuse 3 Spare main fuse 4 Starter relay cover 1 2 3 4 1 Signaling system fuse 2 ABS control unit fuse 3 Main fuse 2 4 Radiator fan motor fuse 5 Backup fuse 6 Spare fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Turn signal light and hazard fuse 10 Terminal...

Page 94: ...pe headlights If a headlight does not come 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 UB74EWE0 book Page 30 Monday September 11 2017 2 31 PM ...

Page 95: ...amaha 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 EAUT1331 Rear turn signal light bulb If a rear turn signal light does not come on have a Yamaha dealer check the electrical circuit or replace the bulb UB74EWE0 book Page 31 Monday September 11 2017 2 31 PM ...

Page 96: ...tion systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your vehicle re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the vehicle prop erly Use only genuine Yamaha replace me...

Page 97: ...Is the smart key being used in a lo cation with strong radio waves or other electromagnetic noise See page 4 1 Are you using the smart key that is registered to the vehicle Is the vehicle battery discharged When the vehicle battery is dis charged the smart key system will not operate Please have the vehi cle battery charged or replaced See page 8 27 If the smart key system does not work after chec...

Page 98: ... vehicle Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Dry We...

Page 99: ... 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 cool ant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leak...

Page 100: ...ee 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 to...

Page 101: ...ill flash quickly for 3 seconds In this case start over again from step 2 When there are no knob opera tions for 10 seconds during the identification number input pro cess When the smart key system indi cator light is allowed to flash nine or more times 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 emergen...

Page 102: ...fler 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 plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and ...

Page 103: ... Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain or near the sea Since sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea 1 Clean the scooter with cold water and a mild detergent after t...

Page 104: ...er apply oil or wax to any rubber parts plastic parts or headlight taillight and meter lenses but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of t...

Page 105: ...prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10952 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the scooter so that both of its wheels are off the ground Alterna tively turn the wh...

Page 106: ...il 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 Recomme...

Page 107: ... single disc brake Specified brake fluid YAMAHA GENUINE BRAKE FLUID DOT 4 Rear brake Type Hydraulic single disc brake Specified brake fluid YAMAHA GENUINE 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 3 1 in El...

Page 108: ...ght 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 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 UB74EWE0 book Page 3 Monday September 11 2017 2 31 PM ...

Page 109: ...ENTIFICATION NUMBER ENGINE SERIAL NUMBER EAU26411 Vehicle identification number The 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 1 Vehicle identification number...

Page 110: ... or service procedures are performed Although the sensors and recorded data will vary by model the main data points are Vehicle status and engine perfor mance data Fuel injection and emission relat ed data Yamaha will not disclose this data to a third party except With the consent of the vehicle owner Where obligated by law For use by Yamaha in litigation For general Yamaha conducted research purp...

Page 111: ... hose 5 18 Fuses replacing 8 29 H Handlebar position adjusting 5 23 Handlebar switches 5 11 Hazard switch 5 11 Headlights 8 30 Helmets 2 6 High beam indicator light 5 1 Horn switch 5 11 I Identification numbers 11 1 Ignition circuit cut off system 5 25 Indicator lights and warning lights 5 1 K Key handling of smart and mechanical keys 4 3 L Labels location 1 1 License plate light bulb replacing 8 ...

Page 112: ...raction control system indicator light 5 2 TRIP INFO switch 5 11 Troubleshooting 8 32 Troubleshooting charts 8 34 Turn signal indicator lights 5 1 Turn signal switch 5 11 V Valve clearance 8 18 V belt checking 8 24 Vehicle identification number 11 1 W Wheel bearings checking 8 27 Wheels 8 20 Windshield 5 21 UB74EWE0 book Page 2 Monday September 11 2017 2 31 PM ...

Page 113: ...UB74EWE0 book Page 3 Monday September 11 2017 2 31 PM ...

Page 114: ...DIC183 PRINTED IN INDONESIA 2017 07 E ...

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Yamaha X MAX CZD300-A, Owner'S Manual

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