Yamaha XMAX CZD300-A Manual Download

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DIC183

CZD300-A

B5X-F8199-EY

Read this manual carefully

before operating this vehicle.

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)]

Summary of Contents for XMAX CZD300-A

Page 1: ...RCYCLE 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 UB5XEYE0 book Page 1 Monday November 16 2020 8 46 AM ...

Page 3: ...ury 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 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: ...donesia Motor Manufacturing 1st edition February 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 UB5XEYE0 book Page 2 Monday November 16 2020 8 46 AM ...

Page 6: ... system 5 25 For your 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 4 Tips for reducing fuel consumption 7 4 Parking 7 4 Periodic maintenance and adjustment 8 1 Tool kit 8 1 Periodic maintenance chart for the emission control system 8 2 General maintenance and lubric...

Page 7: ...fuses 8 30 Vehicle lights 8 31 Front turn signal light 8 32 Rear turn signal light bulb 8 32 Replacing the license plate light bulb 8 32 Troubleshooting 8 33 Troubleshooting chart 8 35 Emergency mode 8 37 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 UB5XEYE0...

Page 8: ...hicle 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 UB5XEYE0 book Page 1 Monday November 16 2020 8 46 AM ...

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 UB5XEYE0 book Page 2 Monday November 16 2020 8 46 AM ...

Page 10: ...t 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 recogniz...

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 suitabl...

Page 12: ...ty 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 Opera...

Page 13: ...elines 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 reflec...

Page 14: ...ak 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 b...

Page 15: ... 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 rider ...

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 UB5XEYE0 book Page 7 Monday November 16 2020 8 46 AM ...

Page 17: ...r assembly spring preload adjusting ring page 5 22 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 UB5XEYE0 book Page 1 Monday November 16 2020 8 46 AM ...

Page 18: ... 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 29 6 Fuses page 8 30 7 Centerstand page 8 27 8 Engine oil level check window page 8 10 9 Engine oil filler cap page 8 10 UB5XEYE0 book Page 2 Monday November 16 2020 8 46 AM ...

Page 19: ...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 UB5XEYE0 book Page 3 Monday November 16 2020 8 46 AM ...

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: ...tely 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 EAU76453 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 ra...

Page 22: ...mergen 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 23: ...rt 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 a...

Page 24: ...ice and 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 beep...

Page 25: ...s 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 s...

Page 26: ...shing 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 main...

Page 27: ...ectrical 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 and...

Page 28: ...r 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 UB5XEYE0 book Page 9 Monday November 16 2020 8 46 AM ...

Page 29: ...nd 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 ligh...

Page 30: ...nge 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 UB5XEYE0 book Page 11 Monday November 16 2020 8 46 AM ...

Page 31: ...em 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 equippe...

Page 32: ... 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 wit...

Page 33: ...y 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 the...

Page 34: ...l 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 36 NOTICE ECA10022 Do not continue to o...

Page 35: ...ripmeter 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 36: ...hen 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 TRI...

Page 37: ...n 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 temperatur...

Page 38: ...ge 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 possibl...

Page 39: ...nsumption_ _ _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 ave...

Page 40: ...L 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 ar...

Page 41: ...g 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 42: ... 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 bra...

Page 43: ...stem 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 r...

Page 44: ...rol 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 o...

Page 45: ...eck 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 an...

Page 46: ...er 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 pl...

Page 47: ...ked and clean it if necessary EAU13435 Catalytic converter The exhaust system contains catalytic converter s to reduce harmful exhaust emissions WARNING EWA10863 The exhaust system 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 ar...

Page 48: ...ch 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 49: ...side 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 limi...

Page 50: ...g 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 UB5...

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 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 52: ...lity 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 Turn the adjusting ring in direction a to increase the spring preload Turn the adjusting ring in direction b to decrease the spring preload Align the appropr...

Page 53: ...artment 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 8 2 Turn the main switch off 3 Remove the auxiliary DC jack cap 4 Turn the accessory off 5 Insert the accessory plug into the auxiliary DC jack 6 Turn the main swi...

Page 54: ...tion 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 sibility ...

Page 55: ...the sidestand is up Also it will stop the running engine should the sidestand be lowered Periodically check the system via the following procedure TIP This check is most reliable if per formed with a warmed up engine See pages 4 7 and 5 10 for switch operation information UB5XEYE0 book Page 25 Monday November 16 2020 8 46 AM ...

Page 56: ...estand down Does the engine stall The system is OK The vehicle can be ridden YES NO YES NO NO YES The sidestand switch may not be working The vehicle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working The vehicle should not be ridden until checked by a Yamaha dealer The brake switch may not be working The vehicle should not be ridden until checked by a Ya...

Page 57: ...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 rese...

Page 58: ...ion 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 27 Chassis fasteners Make sure that all nuts bolts...

Page 59: ...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 transmissi...

Page 60: ...s 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 61: ... the center stand 2 Sit astride the seat and then ad just the rear view mirrors 3 Switch the turn signals on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signals off EAU16782 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in di rection...

Page 62: ...ring acceleration Avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAUN1421 Parking When parking turn the vehicle power off and then turn the smart key off TIP Even when the vehicle is parked in a lo cation partitioned by a fence or the glass window of a...

Page 63: ... 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 UB5XEYE0 book Page 5 Monday November 16 2020 8 46 AM ...

Page 64: ...ervice WARNING EWA15123 Turn off the 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 m...

Page 65: ...n 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 Every 12000 km 7500 mi 3 Spark plug Check condition Clean and regap Replace Every 8000 km 50...

Page 66: ...lace if necessary At 19000 km 12000 mi and thereafter every 12000 km 8000 mi 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 UB5XEYE0 book Page 3 Monday November 16 2020 8 46 AM ...

Page 67: ...r element Clean Every 12000 km 7500 mi 4 Sub air filter ele ment Replace Every 12000 km 7500 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 vehicle...

Page 68: ... nuts bolts and screws are properly tightened 17 Front and rear brake lever pivot shaft Lubricate with silicone grease 18 Sidestand center stand Check operation Lubricate with lithium soap based grease 19 Sidestand switch Check operation 20 Front fork Check operation and for oil leak age 21 Shock absorber as semblies Check operation and shock ab sorbers for oil leakage NO ITEM CHECK OR MAINTENANCE...

Page 69: ...0000 km 6000 mi 26 V belt Replace When the V belt replacement indicator flashes every 20000 km 12500 mi 27 Front and rear brake switches Check operation 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 30 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAIN...

Page 70: ...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 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 UB5XEYE0 book Page 8 Monday November 16 2020 8 46 AM ...

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: ...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 maximu...

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: ...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 p...

Page 76: ...ssion 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 o...

Page 77: ...f 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 78: ...move 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 if...

Page 79: ...nt 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 element...

Page 80: ...ge 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 bel...

Page 81: ...lter 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 UB5XEYE0 book P...

Page 82: ...l 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 83: ...speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure...

Page 84: ...timal characteristics Tire information This model is equipped with tubeless tires and 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 by tire specialists to ascertain their suitability for further use WARN...

Page 85: ...nced 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 hydra...

Page 86: ...e brake To check the brake pad wear check the position of the wear in dicator 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 EAU60681 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...

Page 87: ...areful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cat...

Page 88: ...he periodic maintenance and lubrication chart EAU23098 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubri cated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or re place it WARNING Damage to the outer housing of cables may ...

Page 89: ...t ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU23173 Lubricating the front and rear brake levers Front brake lever Rear brake lever The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Recommended lubricant Silicone grease UB5XEYE0 book Page 26 Monday November...

Page 90: ...ntrol EAU23273 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid inj...

Page 91: ...enter stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing EAU23292 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in...

Page 92: ... space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltag...

Page 93: ...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 higher amperage 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...

Page 94: ... 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 Specified 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...

Page 95: ...me on have a Yamaha dealer check the electrical circuit or replace the bulb EAU78560 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the 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 1 License plate light unit 2 Bolt 3 License plate light bulb socket...

Page 96: ...s but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWA15142 When checking the fuel system do not smoke and make sure there are 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 troubles...

Page 97: ...t key system does not work after checking the above items have a Yamaha dealer check the smart key system TIP See Emergency mode on page 8 37 for information on starting the engine without the smart key UB5XEYE0 book Page 34 Monday November 16 2020 8 46 AM ...

Page 98: ... 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 start...

Page 99: ...opped 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...

Page 100: ...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 ligh...

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: ...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 damage Do not use high pressure washers or steam jet cleaners Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes trans mission seals and electrical de vices Av...

Page 103: ...ld 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 clean the windshield Additionally some cleaning compounds for plastic may scratch the wind shield so be sure to test all cleaning products before gen eral application ECA26310 4 Rinse off thoroughly with ...

Page 104: ...es 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 a cool dry place If necessary protect it against dust with a porous cover Be sure the engine and the exhaust...

Page 105: ...s 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 contr...

Page 106: ...moval 1 60 L 1 69 US qt 1 41 Imp qt Final transmission oil Type Motor oil SAE 10W 40 type SG or higher 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 Unleaded gasoline E10 to E20 only Octane number RON 90 Fuel tank capacity 13 L 3 4...

Page 107: ...ctrical 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 UB5XEYE0 book Page 2 Monday November 16 2020 8 46 AM ...

Page 108: ...DENTIFICATION 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 numbe...

Page 109: ...ached to the vehicle such as when maintenance checks or service proce dures are performed Yamaha will not disclose this data to a third party except in the following cas es In addition Yamaha may provide vehicle data to a contractor in order to outsource services related to the han dling of vehicle data Even in this case Yamaha will require the contractor to properly handle the vehicle data we pro...

Page 110: ...r position adjusting 5 22 Handlebar switches 5 10 Hazard switch 5 11 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 32 M Main switch 4 7 Maintenance and lubrication periodic ...

Page 111: ...1 Troubleshooting 8 33 Troubleshooting chart 8 35 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 UB5XEYE0 book Page 2 Monday November 16 2020 8 46 AM ...

Page 112: ...DIC183 PRINTED IN INDONESIA 2021 02 ...

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