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Yamaha XMAX 300, Owner'S Manual

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Yamaha XMAX 300 Owner'S Manual Download Page 68

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Engine air filter and V-belt air filter

• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned

with compressed air to avoid damaging it.

• The engine air filter element and sub air filter element need to be replaced and the V-belt air filter element needs to

be serviced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

• 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 brake

fluid.

• Replace the brake hoses every four years and if cracked or damaged.

UB5X20E0.book  Page 7  Tuesday, March 24, 2020  3:36 PM

Summary of Contents for XMAX 300

Page 1: ... MOTORCYCLE OWNER S MANUAL Consumer information Index Specifications Scooter care and storage Operation and important riding points For your safety pre operation checks Instrument and control functions Smart key system Description Safety information Location of important labels Periodic maintenance and adjustment English E ...

Page 2: ...EAU46094 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB5X20E0 book Page 1 Tuesday March 24 2020 3 36 PM ...

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 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 re...

Page 4: ...ntial 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 N...

Page 5: ... Indonesia Motor Manufacturing 1st edition April 2021 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 UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

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

Page 7: ...t turn signal light 8 31 Rear turn signal light bulb 8 32 Replacing the license plate light bulb 8 32 Troubleshooting 8 33 Troubleshooting chart 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 Diagnostic connector 11 2 Vehicle data recording 11 2 Motorcycle noise regulation ...

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 4 5 UB5X20E0 book Page 1 Tuesday March 24 2020 3 36 PM ...

Page 9: ...13 39R 00 9740 41R 04 9625 53R 01 0742 78R 03 5117 WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing B74 F118K 00 100kPa 1bar kPa psi kPa psi 200 29 225 33 200 29 225 33 1WD F1668 00 B74 F2259 00 1 5 3 2 4 UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

Page 10: ...st you 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 scooter is designed to carry the operator and a passenger The failure of motorists to detect and recogni...

Page 11: ... main tain control of the scooter 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 scooter is designed for on road use only It is not suitab...

Page 12: ...ity of an accident use extreme caution when adding cargo or acces sories to your scooter Use extra care when riding a scooter that has added cargo or accessories 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 Oper...

Page 13: ...delines 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 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 refle...

Page 14: ...eak Choose the lo cation 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 scooter will not bounce exces sively during transport EAU57600 Further safe riding points Be sure to signal clearly when making turns Braking can be extremely difficult on a wet road Avoid hard ...

Page 15: ...ly colored jacket Do not carry too much luggage on the scooter An overloaded scoot er is unstable Use a strong cord to secure any luggage to the carri er if equipped A loose load will affect the stability of the scooter and could divert your attention from the road See page 2 3 UB5X20E0 book Page 6 Tuesday March 24 2020 3 36 PM ...

Page 16: ...er assembly spring preload adjusting ring page 5 23 6 Final transmission oil filler cap page 8 13 7 Final transmission oil drain bolt page 8 13 8 V belt case air filter element page 8 15 9 Engine oil drain bolt page 8 10 10 Engine oil filter element page 8 10 11 Sidestand page 5 24 12 Spark plug page 8 9 13 Coolant reservoir page 8 14 UB5X20E0 book Page 1 Tuesday March 24 2020 3 36 PM ...

Page 17: ...t page 5 18 2 Fuel tank cap page 5 15 3 Storage compartment B page 5 18 4 Windshield page 5 20 5 Battery page 8 28 6 Fuses page 8 30 7 Centerstand page 8 26 8 Engine oil level check window page 8 10 9 Engine oil filler cap page 8 10 UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

Page 18: ... brake fluid reservoir page 8 23 4 Speedometer page 5 2 5 Multi function display page 5 3 6 Tachometer page 5 2 7 Front brake fluid reservoir page 8 23 8 Right handlebar switches page 5 10 9 Front brake lever page 5 12 10 Throttle grip page 8 19 11 Main switch page 4 7 12 Auxiliary DC jack page 5 23 UB5X20E0 book Page 3 Tuesday March 24 2020 3 36 PM ...

Page 19: ...the 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 n...

Page 20: ...ately 9 days after the vehicle was last used the answer back function is dis abled In this situation simply push the main switch knob to turn the smart key system back on EAU76452 Operating range of the smart key system The approximate operating range of the smart key system is shown below If the smart key is turned off the vehi cle will not recognize the smart key even if it is within operating r...

Page 21: ...emergen cy If the smart key is lost and the smart key system identification number is un known the entire smart key system will need to be replaced at considerable cost Keep the identification number card in a safe place NOTICE ECA21573 The smart key has precision elec tronic components Observe the fol lowing precautions to prevent possible malfunction or damage Do not place or store the smart key...

Page 22: ...art key battery if the smart key system still does not operate check the vehicle battery and then have a Yamaha dealer check the vehicle If the smart key continually re ceives radio waves the smart key battery will discharge quickly For example when placed in the vicin ity of electrical products such as televisions radios or computers You can register up to six smart keys for the same vehicle See ...

Page 23: ...all of the turn signal lights will flash 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 is as shown 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 beeper on or...

Page 24: ...ts may cause injury if swallowed Keep the battery and other removable parts away from children Do not expose the battery to di rect sunlight or other heat sources 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 ...

Page 25: ...ushing the main switch knob and confirmation with the smart key has taken place the main switch can be turned while the smart key system indicator light is on approximately 4 seconds WARNING EWA18720 Never turn the main switch to OFF or OPEN while the ve hicle is moving Otherwise the elec trical systems will be switched off which may result in loss of control or an accident TIP Do not push the mai...

Page 26: ... electrical systems are off To turn the vehicle power off 1 With the smart key turned on and within operating range 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 ...

Page 27: ...or light is on turn the main switch to OPEN 3 To open the seat push the SEAT button and then lift the rear of the seat 4 To open storage compartment A push the LID button TIP Make sure that the seat and storage compartment are securely closed be fore starting off 1 Push 2 Turn 1 2 1 SEAT button 1 1 LID button 1 Storage compartment A 1 1 UB5X20E0 book Page 9 Tuesday March 24 2020 3 36 PM ...

Page 28: ...and walk back into range TIP The beeper will turn off after 1 minute The seat can also be opened with the mechanical key See page 5 18 EAU76521 lock The steering is locked and all electrical systems are off To lock the steering 1 Turn the handlebar all the way to the left 2 With the smart key turned on and within operating range push the main switch knob 3 While the smart key system indi cator lig...

Page 29: ...ange 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 UB5X20E0 book Page 11 Tuesday March 24 2020 3 36 PM ...

Page 30: ...ystem may not work correctly WARNING EWA16043 If the ABS warning light does not turn off after reaching 10 km h 6 mi h or if the warning light comes on while riding Use extra caution to avoid pos sible wheel lock during emer gency braking Have a Yamaha dealer check the vehicle as soon as possible TIP If the engine is revved while the brakes are applied or the vehicle is on its cen terstand if equi...

Page 31: ...d when cer tain smart key system operations are carried out EAU63544 Speedometer The speedometer shows the vehicle s traveling speed When the vehicle power is turned on the speedometer needle will sweep once across the speed range and then return to zero in order to test the elec trical circuit EAU63551 Tachometer The electric tachometer allows the rid er to monitor the engine speed and keep it wi...

Page 32: ...ay is equipped with the following clock fuel meter coolant temperature meter tripmeter display information display Clock The clock uses a 24 hour time system To set the clock 1 Turn the main switch to OFF 2 Push and hold the TRIP switch 3 Turn the main switch to ON while pushing the TRIP switch and then continue to push the TRIP switch for eight seconds The hour digits will start flashing 4 Use th...

Page 33: ...el meter will start flashing The display will automat ically change to the fuel reserve tripmeter F Trip and start count ing the distance traveled from that point Coolant temperature meter The coolant temperature meter indi cates the temperature of the coolant If the top segment flashes stop the ve hicle then stop the engine and let the engine cool See page 8 35 NOTICE ECA10022 Do not continue to ...

Page 34: ...tripmeter Trip The odometer shows the total distance traveled by the vehicle The tripmeter shows the distance trav eled since it was last reset To reset the tripmeter select it by pushing the TRIP switch and then push the TRIP switch for three sec onds TIP The odometer will lock at 999999 The tripmeter will reset and con tinue counting after 9999 9 is reached Time tripmeter Time The time tripmeter...

Page 35: ...then at 4000 km 2400 mi and every 5000 km 3000 mi thereafter to indicate that the engine oil should be changed After changing the engine oil reset the oil change indicator and the oil change tripmeter To reset them both select the oil change tripmeter and then push the TRIP switch for three seconds While the oil change tripmeter is flash ing push the TRIP switch for 15 to 20 seconds Release the TR...

Page 36: ...on at the correct time Information display The information display is equipped with the following air temperature display battery voltage display traction control system display average fuel consumption display instantaneous fuel consumption display average speed display warning message function Navigating the information display Push the INFO switch to change the display between the air temperatu...

Page 37: ...rge the bat tery 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 the traction control system See page 5 13 TCS ON the system is on TCSOFF the system is off TIP If only TCS is displayed there is a communication error within the vehi cle Have a Yamaha dealer check the vehicle as soon as possib...

Page 38: ...onsumption_ _ _L 100 km Consumption_ _ _km L The distance that can be traveled on 1 0 L of fuel under the current rid ing conditions is shown Consumption_ _ _L 100 km The amount of fuel necessary to travel 100 km under the current riding conditions is shown TIP If traveling at speeds under 10 km h 6 mi h _ _ _ is displayed Average speed display The average speed Average_ _ _kmh is displayed The av...

Page 39: ...IL SERV Appears when the oil change indicator OIL starts flashing If OIL SERV is displayed change the engine oil and then reset the oil change indicator and oil change trip meter V BELT SERV Appears when the V belt replacement indicator V Belt starts flashing If V BELT SERV is displayed replace the V belt and then reset the V belt replacement indicator and V belt replacement tripmeter When there a...

Page 40: ...ng 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 warn other drivers when your vehicle...

Page 41: ...h ABS as you would conventional brakes If the ABS is activated a pulsating sensation may be felt at the brake levers In this situa tion continue to apply the brakes and let the ABS work do not pump the brakes as this will reduce braking ef fectiveness WARNING EWA16051 Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS The ABS performs best with long br...

Page 42: ...ystem The traction control system TCS helps maintain traction when acceler ating on slippery surfaces such as un paved or wet roads If sensors detect that the rear wheel is starting to slip uncontrolled spinning the traction control system assists by regulating engine power until traction is restored When traction control has engaged the indicator light will flash You may notice changes in engine ...

Page 43: ...trol system from controlling tire rotation accurately Resetting the traction control sys tem The traction control system will auto matically disable under certain condi tions such as when a sensor fault is detected or 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 ...

Page 44: ...heck the vehicle as soon as possi ble 4 Have a Yamaha dealer check the vehicle and turn off the warning light EAU78502 Fuel tank cap To remove the fuel tank cap 1 Turn the main switch to to open the fuel tank cap lid 2 Turn the fuel tank cap counter clockwise until the release mark aligns with and then pull the cap off To install the fuel tank cap 1 Insert the fuel tank cap onto the tank opening a...

Page 45: ...ter heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or p...

Page 46: ... reduce maintenance costs 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 ...

Page 47: ...nts This model is equipped with 3 storage compartments The front storage com partments and rear storage compart ment are located as shown TIP Storage compartment A must be opened using the smart key sys tem See page 4 8 The seat rear storage compart ment can be opened using the smart key system or the mechani cal key Some helmets cannot be stored in the rear storage compartment be cause of their s...

Page 48: ... all stor age compartments before starting off NOTICE ECA24020 Make sure that the keyhole cover is installed when the mechanical key is not being used NOTICE ECA21150 Keep the following points in mind when using the storage compart ment Since the storage compartment accumulates heat when ex posed to the sun and or the en gine heat do not store anything susceptible to heat consum ables or flammable...

Page 49: ...B Do not exceed the load limit of 5 0 kg 11 lb for the rear storage compartment Do not exceed the maximum load of 161 kg 355 lb for the ve hicle 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 position 1 Remove the bolt access covers by removing the quick fasteners 2 Remove the windshield b...

Page 50: ...15511 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 1 1 1 1 Bolt Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 9 lb ft 1 1 ...

Page 51: ...screws to the specified torque EWA15511 5 Place the bolt access covers and then install the quick fasteners EAU46833 Handlebar position The handlebar can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handlebar 1 Bolt 1 Bolt 1 1 1 1 1 Bolt Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 9 lb ft 1 1 1 Handlebar 1 UB5X20E0 book...

Page 52: ... tool kit to make this adjustment EAU78213 Auxiliary DC jack WARNING EWA14361 To prevent electrical shock or short circuiting make sure that the cap is installed when the auxiliary DC jack is not being used NOTICE ECA15432 The accessory connected to the auxiliary DC jack should not be used with the engine turned off and the load must never exceed 12 W 1 A otherwise the fuse may blow or the battery...

Page 53: ...ircuit cut off system which cuts the ignition in certain situa tions See the following section for an explanation of 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...

Page 54: ... regularly and have a Yamaha dealer repair it if it does not function properly EAUT1098 Ignition circuit cut off system Check the operation of the sidestand switch according to the following pro cedure UB5X20E0 book Page 25 Tuesday March 24 2020 3 36 PM ...

Page 55: ...the brake levers The engine will start Put the sidestand down If the engine stalls The sidestand switch is OK Place vehicle on centerstand WARNING The vehicle must be placed on the centerstand during this inspection If a malfunction is found have the vehicle inspected before riding UB5X20E0 book Page 26 Tuesday March 24 2020 3 36 PM ...

Page 56: ... 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 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 8 10 Final transmission oil Check vehicle for oil leakage 8 13 Coolant Check coolant level in res...

Page 57: ...tion is smooth Lubricate if necessary 8 25 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 8 20 8 22 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 26 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 8 26 Chassis fasteners Make sure that all nuts bolt...

Page 58: ... 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU34323 0 1000 km 0 600 mi Avoid prolonged operation above 4500 r min NOTICE After 1000 km 600 mi of operation be sure to replace the engine oil final transmiss...

Page 59: ...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 to re store...

Page 60: ...tle grip in di rection a To reduce the speed turn the throttle grip in direction b EAU60650 Braking WARNING EWA17790 Avoid braking hard or suddenly especially when leaning over to one side otherwise the vehicle may skid or overturn Railroad crossings streetcar rails iron plates on road con struction sites and manhole covers become extremely slip pery when wet Therefore slow down when approaching s...

Page 61: ... the engine and operate the vehicle Please turn the smart key off when leaving the ve hicle See page 4 4 If the sidestand is lowered when the engine is running the engine will stop and the beeper will sound for approxi mately 1 minute To stop the beeper turn the vehicle power off or raise the sidestand TIP Before leaving the vehicle be sure to turn the main switch to OFF or Otherwise the battery m...

Page 62: ...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 calipers dr...

Page 63: ...t are intended to assist you in the perfor mance of preventive maintenance and minor repairs However a torque wrench and other tools are necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have your Yamaha dealer perform it for you 1 Tool kit 1 UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

Page 64: ...ce chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 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...

Page 65: ... Replace 3 Pre air filter element Clean 4 Sub air filter ele ment Replace 5 Air filter case check hose Clean 6 V belt case air filter element Clean Replace if necessary 7 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 8 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 9 Brake hoses Check for cracks or damage...

Page 66: ... tightened 16 Front and rear brake lever pivot shaft Lubricate with silicone grease 17 Sidestand center stand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation and replace if necessary 19 Front fork Check operation and for oil leak age Replace if necessary 20 Shock absorber as semblies Check operation and for oil leak age Replace if necessary NO ITEM CHEC...

Page 67: ...ery 3 years 25 V belt Replace When the V belt replacement indicator flashes every 20000 km 12000 mi 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 29 Lights signals and switches Check operation Adjust...

Page 68: ... the 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...

Page 69: ...s 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 UB5X20E0 book Page 8 Tuesday March 24 2020 3 36 PM ...

Page 70: ...t 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 mat...

Page 71: ... 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 for the oil level to settle for an accurate reading 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 maxim...

Page 72: ...and 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 e...

Page 73: ... passion and belief that engine oil is an impor tant liquid engine component We form teams of specialists in the fields of me chanical engineering chemistry elec tronics and track testing and have them develop the engine together with the oil it will use Yamalube oils take full advantage of the base oil s qualities and blend in the ideal balance of addi tives to make sure the final oil clears our ...

Page 74: ...ission 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 tire ...

Page 75: ...If the coolant is at or below the minimum 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 NOTICE If coolant is not available...

Page 76: ...emove the radiator cap when the engine is hot EWA10382 EAU78574 Air filter and V belt case air fil ter elements The air filter element and the sub air fil ter element should be replaced and the pre air filter element and the V belt case air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Service the air filter elements more frequently i...

Page 77: ...ent and cleaning 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 elemen...

Page 78: ...age and replace it if neces sary 9 Insert the pre air filter element into the air filter case cover 10 Install the air filter case cover by installing 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 be...

Page 79: ...ilter cover by removing the bolts 7 Remove the air filter element and then blow out the dirt with com pressed air from the clean side as shown 8 Check the V belt case air filter ele ment for damage and replace it if necessary 1 Screw 1 Bolt 1 1 1 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 side 1 1 UB5X20E0 book ...

Page 80: ...ll the V belt case cover by in stalling the screws 14 Install the air filter case cover by installing 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 4 lb ft...

Page 81: ... speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressur...

Page 82: ...he 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 tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked ...

Page 83: ...anced wheel can result in poor performance adverse han dling characteristics and a short ened tire life EAU50861 Checking the front and rear brake lever free play Front Rear There should be no free play at the brake lever ends If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydr...

Page 84: ...icator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer re place the brake pads as a set EAU22584 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark TIP Make sure the reservoir is parallel to the ground when checking NOTICE ECA17641 Brake fluid may damage pai...

Page 85: ...ing Use only DOT 4 brake fluid from a sealed container Use only the specified brake flu id otherwise the rubber seals may deteriorate causing leak age Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point ...

Page 86: ...es 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 I...

Page 87: ...and 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 88: ... Place the vehicle on a level sur face 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 smooth...

Page 89: ...king 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 8 This model is equipped with a VRLA Valve Regulated Lead Acid ...

Page 90: ...ies 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 s...

Page 91: ...e electrical system and possibly a fire EWA15132 1 Fuse box 2 Main fuse 3 Spare main fuse 4 Starter relay cover 1 2 3 4 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...

Page 92: ...for headlights auxiliary lights and brake tail light If a light does not come on check the fuse and then have a Yamaha dealer check the vehicle NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens 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 1 Headlight low beam...

Page 93: ... 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 socket...

Page 94: ... no open 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 EAU76551 Smart key system troubleshooting Please check the following items when the smart key system does not work Is the smart key turned on See page 4 4 Is the smart key battery dis charged See page 4 6 Is the sm...

Page 95: ...e 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 s 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 Wet Try star...

Page 96: ...topped 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 fo...

Page 97: ... come on for 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 lig...

Page 98: ...will 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 emerge...

Page 99: ...ay be sprayed with salt as a de icing method This salt can stay on the roads well into spring so be sure to wash the underside and chassis parts after riding in such areas Genuine Yamaha care and main tenance products are sold under the YAMALUBE brand in many markets worldwide See your Yamaha dealer for addi tional cleaning tips NOTICE ECA26280 Improper cleaning can cause cos metic and mechanical ...

Page 100: ...h for hard to reach places NOTICE Use cold water if the vehicle has been exposed to salt Warm wa ter will increase salt s corrosive properties ECA26301 3 For windshield equipped vehicles Clean the windshield with a soft towel or sponge dampened with water and a pH neutral detergent If necessary use a high quality windshield cleaner or polish for motorcycles NOTICE Never use any strong chemicals to...

Page 101: ...ants left on the brakes or tires can cause loss of control Make sure there is no lubricant or wax on the brakes or tires If necessary wash the tires with warm water and a mild deter gent If necessary clean the brake discs and pads with brake cleaner or acetone Before riding at higher speeds test the vehicle s braking per formance and cornering behav ior EAU83472 Storage Always store the vehicle in...

Page 102: ...is 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 WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 7 Lubricate all cont...

Page 103: ...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 Fuel Recommended fuel Gasohol E25 acceptable Octane number RON 90 Fuel tank capacity ...

Page 104: ...ectrical system System voltage 12 V Battery Model GTZ8V Voltage capacity 12 V 7 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light 10 0 W Rear turn signal light 10 0 W Auxiliary light LED License plate light 5 0 W UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

Page 105: ...CLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION 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 E...

Page 106: ...lopment purpos es 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 This data will be uploaded only when a special Yamaha diagnostic tool is at tached to the vehicle such as when maintenance checks or service proce dures are performed Yamaha will not disclose this data to a third ...

Page 107: ...OISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicl...

Page 108: ...rflow hose 5 17 Fuses replacing 8 30 H Handlebar position adjusting 5 22 Handlebar switches 5 10 Hazard switch 5 11 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 32 M Main switch 4 7 Ma...

Page 109: ...control system indicator light 5 1 TRIP INFO switch 5 11 Troubleshooting 8 33 Troubleshooting chart 8 34 Turn signal indicator lights 5 1 Turn signal switch 5 11 V Valve clearance 8 20 V belt checking 8 25 Vehicle identification number 11 1 Vehicle lights 8 31 W Wheel bearings checking 8 28 Wheels 8 22 Windshield 5 20 Y Yamalube 8 12 UB5X20E0 book Page 2 Tuesday March 24 2020 3 36 PM ...

Page 110: ...DIC183 PRINTED IN INDONESIA 2021 04 ...

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