Yamaha XMAX 125 Manuals

Manuals and User Guides for Yamaha XMAX 125. We have 2 Yamaha XMAX 125 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XMAX 125 Service Manual (498 pages)

MBK Skycruiser

Brand: Yamaha | Category: Scooter | Size: 22.76 MB

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Oil Change Indicator
    14
  - Instrument Functions
    16
  - Important Information
    17
    
    Preparation for Removal and Disassembly
    17
    
    Replacement Parts
    17
    
    Gaskets, Oil Seals and O-Rings
    17
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    18
    
    Circlips
    18
  - Checking the Connections
    19
  - Special Tools
    20
Specifications

29
- General Specifications (Yp125R)
  32
- Engine Specifications (Yp125R)
  33
- Chassis Specifications (Yp125R)
  40
- Electrical Specifications (Yp125R)
  43
- Tightening Torques (Yp125R)
  46
- Lubrication Points and Lubricant Types (Yp125R)
  52
  - Engine
    52
  - Chassis
    54
- Lubrication System Diagrams (Yp125R)
  56
- Cooling System Diagrams (Yp125R)
  58
- Cable Routing (Yp125R)
  60
- General Specifications (Yp250R)
  78
- Engine Specifications (Yp250R)
  79
- Chassis Specifications (Yp250R)
  87
- Electrical Specifications (Yp250R)
  90
- Tightening Torques (Yp250R)
  93
- Lubrication Points and Lubricant Types (Yp250R)
  100
  - Engine
    100
  - Chassis
    102
Periodic Checks and Adjustments

125
- Periodic Maintenance
  
  128
- Engine (Yp125R)
  
  133
  - Adjusting the Valve Clearance
    133
  - Adjusting the Exhaust Gas Volume
    135
  - Adjusting the Throttle Cable Free Play
    136
  - Checking the Spark Plug
    136
  - Checking the Ignition Timing
    137
  - Measuring the Compression Pressure
    138
  - Checking the Engine Oil Level
    139
  - Changing the Engine Oil
    139
  - Changing the Final Transmission Oil
    141
  - Replacing the Air Filter Element
    142
  - Cleaning the V-Belt Case Air Filter Element
    142
  - Checking the Throttle Body Joint
    143
  - Checking the Fuel Hose
    143
  - Checking the Breather Hoses
    143
  - Checking the Exhaust System
    144
  - Checking the Coolant Level
    144
  - Checking the Cooling System
    145
  - Changing the Coolant
    145
- Engine (Yp250R)
  
  148
  - Adjusting the Valve Clearance
    148
  - Adjusting the Exhaust Gas Volume
    150
  - Adjusting the Throttle Cable Free Play
    150
  - Checking the Spark Plug
    151
  - Checking the Ignition Timing
    152
  - Measuring the Compression Pressure
    152
  - Checking the Engine Oil Level
    153
  - Changing the Engine Oil
    154
  - Changing the Final Transmission Oil
    155
  - Replacing the Air Filter Element
    156
  - Cleaning the V-Belt Case Air Filter Element
    157
  - Checking the Throttle Body Joint
    157
  - Checking the Fuel Hose
    157
  - Checking the Breather Hoses
    157
  - Checking the Exhaust System
    158
  - Checking the Coolant Level
    158
  - Checking the Cooling System
    159
  - Changing the Coolant
    159
- Chassis
  
  162
  - Checking the Brake Fluid Level
    162
    
    Checking the Front Brake Pads
    162
    
    Checking the Rear Brake Pads (Yp125R)
    162
    
    Checking the Rear Brake Pads (Yp250R)
    163
    
    Checking the Front Brake Hose
    163
    
    Checking the Rear Brake Hose
    163
    
    Bleeding the Hydraulic Brake System
    163
    
    Checking and Adjusting the Steering Head
    164
    
    Checking the Front Fork
    166
    
    Adjusting the Rear Shock Absorber Assemblies
    166
    
    Checking the Tires
    166
    
    Checking the Wheels
    168
    
    Checking and Lubricating the Cables
    168
    
    Lubricating the Levers
    168
    
    Lubricating the Sidestand
    168
    
    Lubricating the Centerstand
    169
- Electrical System
  
  170
  - Checking and Charging the Battery
    170
  - Checking the Fuses
    170
  - Replacing a Headlight Bulb
    170
  - Adjusting the Headlight Beam
    171
Chassis

173
- General Chassis
  
  176
  - Removing the Storage Box
    177
  - Installing the Seat
    177
- Front Wheel
  
  184
  - Removing the Front Wheel
    186
  - Disassembling the Front Wheel
    186
  - Checking the Front Wheel
    186
  - Assembling the Front Wheel
    187
  - Adjusting the Front Wheel Static Balance
    187
  - Installing the Front Wheel (Front Brake Disc)
    188
- Rear Wheel
  
  190
- Front Brake
  
  192
- Rear Brake
  
  204
- Handlebar
  
  221
  - Removing the Handlebar
    223
  - Checking the Handlebar
    223
  - Installing the Handlebar
    223
- Front Fork
  
  225
  - Removing the Front Fork Legs
    227
  - Disassembling the Front Fork Legs
    227
  - Checking the Front Fork Legs
    228
  - Assembling the Front Fork Legs
    228
  - Installing the Front Fork Legs
    230
- Steering Head
  
  232
  - Removing the Lower Bracket
    234
  - Checking the Steering Head
    234
  - Installing the Steering Head
    234
- Rear Shock Absorber Assemblies and Swingarm
  
  236
  - Removing the Rear Shock Absorber Assemblies
    238
  - Removing the Swingarm
    238
  - Checking the Rear Shock Absorber Assembly
    238
  - Checking the Swingarm
    238
  - Installing the Swingarm
    238
Engine

241
- Engine Removal (Yp125R)
  
  246
  - Installing the Engine
    250
  - Engine
    252
- Cylinder Head (Yp125R)
  
  252
  - Checking the Cylinder Head
    254
  - Removing the Cylinder Head
    254
  - Checking the Camshaft Sprocket
    255
  - Checking the Timing Chain Tensioner
    255
  - Installing the Cylinder Head
    256
- Camshaft (Yp125R)
  
  259
- Valves and Valve Springs (Yp125R)
  
  263
  - Removing the Valves
    264
  - Checking the Valves and Valve Guides
    264
  - Checking the Valve Seats
    266
  - Checking the Valve Springs
    267
  - Installing the Valves
    268
- Cylinder and Piston (Yp125R)
  
  270
  - Removing the Piston
    271
  - Checking the Cylinder and Piston
    271
  - Checking the Piston Rings
    272
  - Checking the Piston Pin
    273
  - Checking the Timing Chain Guide
    273
  - Installing the Piston and Cylinder
    273
- V-Belt Automatic Transmission (Yp125R)
  
  275
  - Removing the Primary Sheave
    278
  - Removing the Secondary Sheave
    278
  - Disassembling the Secondary Sheave
    279
  - Checking the Clutch Housing
    279
  - Checking the Clutch Shoes
    279
  - Checking the V-Belt
    279
  - Checking the Primary Sheave
    280
  - Checking the Primary Sheave Weights
    280
  - Checking the Primary Sheave Sliders
    280
  - Checking the Secondary Sheave
    280
  - Assembling the Primary Sheave
    280
  - Assembling the Secondary Sheave
    281
  - Installing the V-Belt
    282
- Starter Clutch and Generator (Yp125R)
  
  284
  - Removing the Generator
    286
  - Removing the Starter Clutch
    286
  - Checking the Starter Clutch
    286
  - Installing the Starter Clutch
    287
  - Installing the Generator
    287
- Electric Starter (Yp125R)
  
  289
  - Checking the Starter Motor
    291
- Oil Pump (Yp125R)
  
  294
  - Checking the Oil Pump
    294
  - Assembling the Oil Pump
    294
  - Installing the Oil Pump
    295
- Transmission (Yp125R)
  
  297
  - Removing the Transmission
    298
  - Checking the Transmission
    298
  - Installing the Transmission
    298
- Crankshaft (Yp125R)
  
  299
  - Disassembling the Crankcase
    301
  - Removing the Crankshaft Assembly
    301
  - Checking the Timing Chain and Timing Chain Guide
    301
  - Checking the Crankshaft and Connecting Rod
    301
  - Checking the Crankcase
    302
  - Checking the Bearing and Oil Seal
    302
  - Checking the Oil Pump Drive Gear
    302
  - Checking the Oil Strainers
    303
  - Installing the Crankshaft
    303
  - Assembling the Crankcase
    304
- Engine Removal (Yp250R)
  
  306
  - Installing the Engine
    310
- Cylinder Head (Yp250R)
  
  312
  - Removing the Cylinder Head
    314
  - Checking the Cylinder Head
    314
  - Checking the Camshaft Sprocket
    315
  - Checking the Timing Chain Tensioner
    315
  - Installing the Cylinder Head
    316
- Camshaft (Yp250R)
  
  318
- Valves and Valve Springs (Yp250R)
  
  322
  - Removing the Valves
    323
  - Checking the Valves and Valve Guides
    323
  - Checking the Valve Seats
    325
  - Checking the Valve Springs
    326
  - Installing the Valves
    327
- Cylinder and Piston (Yp250R)
  
  329
  - Removing the Piston
    330
  - Checking the Cylinder and Piston
    330
  - Checking the Piston Rings
    331
  - Checking the Piston Pin
    332
  - Checking the Timing Chain Guide
    332
  - Installing the Piston and Cylinder
    332
- V-Belt Automatic Transmission (Yp250R)
  
  334
  - Removing the Primary Sheave
    338
  - Removing the Secondary Sheave
    338
  - Disassembling the Secondary Sheave
    339
  - Checking the Clutch Housing
    339
  - Checking the Clutch Shoes
    339
  - Checking the V-Belt
    339
  - Checking the Primary Sheave
    340
  - Checking the Primary Sheave Weights
    340
  - Checking the Primary Sheave Sliders
    340
  - Checking the Secondary Sheave
    340
  - Assembling the Primary Sheave
    340
  - Assembling the Secondary Sheave
    341
  - Installing the V-Belt
    342
- Starter Clutch and Generator (Yp250R)
  
  344
  - Removing the Generator
    346
  - Removing the Starter Clutch
    346
  - Checking the Starter Clutch
    346
  - Installing the Starter Clutch
    347
  - Installing the Generator
    347
- Electric Starter (Yp250R)
  
  349
  - Checking the Starter Motor
    351
  - Assembling the Starter Motor
    352
- Oil Pump (Yp250R)
  
  353
  - Checking the Oil Pump
    355
  - Assembling the Oil Pump
    355
  - Installing the Oil Pump
    356
- Transmission (Yp250R)
  
  357
  - Removing the Transmission
    359
  - Checking the Transmission
    359
  - Installing the Transmission
    359
- Crankshaft (Yp250R)
  
  360
  - Disassembling the Crankcase
    362
  - Removing the Crankshaft Assembly
    362
  - Checking the Timing Chain and Timing Chain Guide
    363
  - Checking the Crankshaft and Connecting Rod
    363
  - Checking the Crankcase
    364
  - Checking the Bearing and Oil Seal
    364
  - Checking the Oil Strainers
    364
  - Installing the Crankshaft
    364
  - Assembling the Crankcase
    365
Cooling System

367
- Cooling System
  
  369
- Radiator (Yp125R)
  
  369
  - Checking the Radiator
    369
  - Installing the Radiator
    369
- Thermostat (Yp125R)
  
  370
  - Checking the Thermostat
    371
  - Installing the Thermostat
    371
- Water Pump (Yp125R)
  
  373
  - Disassembling the Water Pump
    373
  - Checking the Water Pump
    373
  - Assembling the Water Pump
    373
  - Installing the Water Pump
    374
- Radiator (Yp250R)
  
  375
  - Checking the Radiator
    376
  - Installing the Radiator
    376
- Thermostat (Yp250R)
  
  377
  - Checking the Thermostat
    378
  - Installing the Thermostat
    378
- Water Pump (Yp250R)
  
  379
  - Disassembling the Water Pump
    381
  - Checking the Water Pump
    381
  - Assembling the Water Pump
    381
  - Installing the Water Pump
    382
Fuel System

383
- Fuel Tank
  
  384
  - Removing the Fuel Tank
    386
  - Checking the Fuel Pressure
    386
  - Installing the Fuel Tank
    387
- Throttle Body
  
  388
  - Removing the Fuel Hose
    392
  - Checking the Fuel Injector
    392
  - Checking the Throttle Body
    392
  - Installing the Intake Manifold (Yp125R)
    392
  - Installing the Intake Manifold (Yp250R)
    392
  - Installing the Fuel Hose
    393
  - Installing the Throttle Body
    393
  - Checking the Throttle Position Sensor
    393
  - Checking the Isc (Idle Speed Control) Unit
    393
Electrical System

395
- Ignition System
  
  398
  - Circuit Diagram
    398
  - Troubleshooting
    400
- Electric Starting System
  
  402
  - Circuit Diagram
    402
  - Starting Circuit Cut-Off System Operation
    404
  - Troubleshooting
    406
- Charging System
  
  408
  - Circuit Diagram
    408
  - Troubleshooting
    410
- Lighting System
  
  412
  - Circuit Diagram
    412
  - Troubleshooting
    414
- Signaling System
  
  416
  - Circuit Diagram
    416
  - Troubleshooting
    418
- Cooling System
  
  424
  - Circuit Diagram
    424
  - Troubleshooting
    426
- Fuel Injection System
  
  428
  - Circuit Diagram
    428
  - Ecu Self-Diagnostic Function
    430
  - Troubleshooting Method
    431
  - Diagnostic Mode
    431
  - Troubleshooting Details
    433
  - Diagnostic Code Table
    451
- Fuel Pump System
  
  454
  - Circuit Diagram
    454
  - Troubleshooting
    456
- Immobilizer System
  
  458
  - Circuit Diagram
    458
  - General Information
    460
  - Part Replacement and Key Code Registration Requirements
    460
  - Troubleshooting
    464
  - Self-Diagnosis Fault Code Indication
    464
- Electrical Components
  
  468
  - Checking the Switches
    470
  - Checking the Bulbs and Bulb Sockets
    473
  - Checking the Fuses
    474
  - Checking and Charging the Battery
    475
  - Checking the Relays
    477
  - Checking the Turn Signal/Hazard Relay
    478
  - Checking the Spark Plug Cap
    479
  - Checking the Ignition Coil
    479
  - Checking the Ignition Spark Gap
    480
  - Checking the Crankshaft Position Sensor
    480
  - Checking the Lean Angle Sensor
    481
  - Checking the Starter Motor Operation
    481
  - Checking the Stator Coil
    482
  - Checking the Rectifier/Regulator
    482
  - Checking the Horn
    482
  - Checking the Fuel Sender
    483
  - Checking the Fuel Level Warning Light
    483
  - Checking the Speed Sensor
    484
  - Checking the Radiator Fan Motor
    484
  - Checking the Coolant Temperature Sensor
    484
  - Checking the Throttle Position Sensor
    485
  - Checking the Intake Air Pressure Sensor
    485
  - Checking the Intake Air Temperature Sensor
    486
  - Checking the Air Temperature Sensor
    486
  - Checking the Isc (Idle Speed Control) Unit
    487
  - Checking the V-Belt Replacement Indicator Reset Coupler
    487
  - Electrical System
    490
    
    Troubleshooting
    490
    
    General Information
    490
    
    Starting Failure/Hard Starting
    490
    
    Incorrect Engine Idling Speed
    490
  - Fuel System
    490
  - Troubleshooting
    491
    
    Poor Medium-And-High-Speed Performance
    491
    
    Faulty Clutch
    491
    
    Overheating
    491
    
    Overcooling
    492
    
    Poor Braking Performance
    492
    
    Faulty Front Fork Legs
    492
    
    Unstable Handling
    492
    
    Faulty Lighting or Signaling System
    492
    
    Wiring Diagram
    494

Yamaha XMAX 125 Owner's Manual (94 pages)

Brand: Yamaha | Category: Motorcycle | Size: 3.67 MB

R&TTE Directive(1999/5/EC EN300 330-2 V1.3.1(2006-01), EN300 330-2 V1.5.1(2010
2
Important Manual Information
4
Table of Contents
6
Safety Information

8
- Further Safe-Riding Points
  12
Description

14
- Left View
  14
- Right View
  15
- Controls and Instruments
  16
Instrument and Control Functions

17
- Immobilizer System
  17
- Main Switch/Steering Lock
  18
- Indicator Lights and Warning Lights
  19
- Multi-Function Meter Unit
  21
- Anti-Theft Alarm (Optional)
  29
- Handlebar Switches
  30
- Front Brake Lever
  31
- Rear Brake Lever
  31
- ABS (for ABS Models)
  32
- Fuel Tank Cap
  33
- Fuel
  33
- Catalytic Converters
  35
- Seat
  35
- Storage Compartments
  36
- Adjusting the Shock Absorber Assemblies
  37
- Sidestand
  38
- Ignition Circuit Cut-Off System
  39
For Your Safety - Pre-Operation Checks

41
Operation and Important Riding Points

43
- Starting the Engine
  43
- Starting off
  44
- Acceleration and Deceleration
  45
- Braking
  45
- Tips for Reducing Fuel Consumption
  46
- Engine Break-In
  46
- Parking
  47
Periodic Maintenance and Adjustment

48
- Owner's Tool Kit
  49
- Periodic Maintenance Chart for the Emission Control System
  50
- General Maintenance and Lubrication Chart
  51
- Removing and Installing Panels
  55
- Checking the Spark Plug
  57
- To Install Spark Plug
  58
- Engine Oil
  59
- Final Transmission Oil
  61
- Coolant
  62
- Air Filter and V-Belt Case Air Filter Elements and Check Hoses
  63
- Checking the Throttle Grip Free Play
  65
- Valve Clearance
  65
- Tires
  65
- Cast Wheels
  67
- Checking the Front and Rear Brake Lever Free Play
  68
- Pads
  68
- Checking the Brake Fluid Level
  69
- Changing the Brake Fluid
  71
- Checking and Lubricating the Cables
  71
- Checking and Lubricating the Throttle Grip and Cable
  71
- Lubricating the Front and Rear Brake Levers
  72
- Checking and Lubricating the Centerstand and Sidestand
  72
- Checking the Front Fork
  73
- Checking the Steering
  74
- Checking the Wheel Bearings
  74
- Battery
  74
- Replacing the Fuses
  76
- Replacing a Headlight Bulb
  77
- Tail/Brake Light
  78
- Front Turn Signal Light
  78
- Replacing a Rear Turn Signal Light Bulb
  78
- Replacing the License Plate Light Bulb
  79
- Auxiliary Light
  80
- Troubleshooting
  80
- Troubleshooting Charts
  81
Scooter Care and Storage

83
- Matte Color Caution
  83
- Care
  83
- Cleaning
  83
- Storage
  86
Specifications

87
Consumer Information

90
- Identification Numbers
  90
Index

91

Yamaha Categories

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More Yamaha Manuals

Yamaha XMAX 125 Manuals

Yamaha XMAX 125 Service Manual (498 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine (Yp125R)

Engine (Yp250R)

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assemblies and Swingarm

Engine

Engine Removal (Yp125R)

Cylinder Head (Yp125R)

Camshaft (Yp125R)

Valves and Valve Springs (Yp125R)

Cylinder and Piston (Yp125R)

V-Belt Automatic Transmission (Yp125R)

Starter Clutch and Generator (Yp125R)

Electric Starter (Yp125R)

Oil Pump (Yp125R)

Transmission (Yp125R)

Crankshaft (Yp125R)

Engine Removal (Yp250R)

Cylinder Head (Yp250R)

Camshaft (Yp250R)

Valves and Valve Springs (Yp250R)

Cylinder and Piston (Yp250R)

V-Belt Automatic Transmission (Yp250R)

Starter Clutch and Generator (Yp250R)

Electric Starter (Yp250R)

Oil Pump (Yp250R)

Transmission (Yp250R)

Crankshaft (Yp250R)

Cooling System

Cooling System

Radiator (Yp125R)

Thermostat (Yp125R)

Water Pump (Yp125R)

Radiator (Yp250R)

Thermostat (Yp250R)

Water Pump (Yp250R)

Fuel System

Fuel Tank

Throttle Body

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

Immobilizer System

Electrical Components

Yamaha XMAX 125 Owner's Manual (94 pages)

Table of Contents

Safety Information

Description

Instrument and Control Functions

For Your Safety - Pre-Operation Checks

Operation and Important Riding Points

Periodic Maintenance and Adjustment

Scooter Care and Storage

Specifications

Consumer Information

Index

Related Products

Yamaha Categories