Contents

Yamaha XC155J SMAX 2018 Owner's Manual PDF

Pages 96
Year 2018
Language(s)
English en
1 of 96
1 of 96

Summary of Content for Yamaha XC155J SMAX 2018 Owner's Manual PDF

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ngratulations on your purchase of the Yamaha XC155J... This model is the result of Y ction of fine sporting, touring, and pacesetting racing machines... It represents the hig ility that have made Yamaha a leader in these fields... is manual will give you an understanding of the operation, inspection, and basic mai y questions concerning the operation or maintenance of your scooter, please consul e design and manufacture of this Yamaha scooter fully comply with the emissions sta te of manufacture... Yamaha has met these standards without reducing the performa ooter... To maintain these high standards, it is important that you and your Yamaha d mended maintenance schedules and operating instructions contained within this ma maha continually seeks advancements in product design and quality... Therefore, whi

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This is the safety alert symbol... It is used to alert you hazards... Obey all safety messages that follow this s or death...

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t the written permission of a Motor Corporation, U... S... A... expressly prohibited... Printed in Taiwan...

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ndicator lights and warning lights ... 3-2 achometer ... 3-3 uel gauge... 3-4 ulti-function display ... 3-4 andlebar switches ... 3-6 ront brake lever ... 3-7 ear brake lever ... 3-8 uel tank cap ... 3-8 uel... 3-9 uel tank breather hose and overflow hose ... 3-10 atalytic converter... 3-10 eat ... 3-11 assenger footrest ... 3-12 elmet holder ... 3-12 torage compartments ... 3-13 hock absorber assembly ... 3-14 uggage hook... 3-14

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onsumer information ... 9-1 Identification numbers ... 9-1 Reporting safety defects... 9-3 Motorcycle noise regulation... 9-4 Maintenance record... 9-5 YAMAHA MOTOR CORPORATION,

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ad and understand all of the labels on your vehicle... They contain important informat r vehicle... Never remove any labels from your vehicle... If a label becomes difficult to re vailable from your Yamaha dealer...

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VEHICL EMISSION CONTROL INFORMATION YAMAHA MOTOR TAIWAN CO... ,LTD... ENG : FYMXC... 155GCA PERM : FYMXPMETALF6 , FYMXPP402BF6 EVAP : FYMXU0008YDB TUNE-UP SPECIFICATIONS AND ADJUSTMENTS (REFER TO YOUR OWNERS MANUAL) DISPLACEMENT : 155cm EXHAUST EMISSION CONTROL SYSTEM : TWC ; SFI ; H02S SPARK PLUG GAP : 0... 8-0... 9mm VALVE LASH : IN 0... 08-0... 12mm, EX 0... 22-0... 26mm IDLE SPEED : 1700 r/min IN NEUTRAL AT NORMAL OPERTING TEMPERATURE FUEL : UNLEADED GASOLINE 91 RON MIN ENGINE OIL : SAE 10W-40 NO OTHER ADJUSTMENTS NEEDED... THIS VEHICE CONFORMS TO US EPA AND CALIFOTNIA REGULATIONS APPLICABLE TO 2015 MODEL YEAR NEW MCS... AND IS CERTIFIED TO HC 1... 0 AND CO 12... 0 (g/km) ENGINE EXHAUST EMISSION STANDARDS... THIS MC MEETS1986 AND LATER EPA NOISE EMISSION REQUIREMENTS OF THE FED... THE FED... TEST PROCEDURES... MODIFICATIONS WHICH CAUSE THIS MC TO EXCEED FED... NOISE STD ARE PROHIBITED BY FED... LAW... SEE OWNERS MANUAL... LIMIT/CLOSING : 80 dBA/ 7125 r/min MODEL CODE: YAM2SW0155

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Obtain thorough instructions from a competent source on all aspects of scooter operation... Observe the warnings and mainte- nance requirements in this Own- ers Manual... Obtain qualified training in safe and proper riding techniques... Obtain professional technical ser- vice as indicated in this Owners Manual and/or when made neces- sary by mechanical conditions... Never operate a scooter without proper training or instruction... Take

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oid Carbon Monoxide Poisoning engine exhaust contains carbon noxide, a deadly gas... Breathing car- n monoxide can cause headaches, ziness, drowsiness, nausea, confu- n, and eventually death... rbon Monoxide is a colorless, odor- s, tasteless gas which may be pres- t even if you do not see or smell any gine exhaust... Deadly levels of car- n monoxide can collect rapidly and u can quickly be overcome and un- le to save yourself... Also, deadly lev- of carbon monoxide can linger for urs or days in enclosed or poorly ntilated areas... If you experience any

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ENT... Do not run engine indoors... Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rap- idly reach dangerous levels... Do not run engine in poorly venti- lated or partially enclosed areas such as barns, garages, or car- ports... Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors...

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cargo that would impair the perfor- mance of your scooter... Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit sus- pension travel, steering travel or control operation, or obscure lights or reflectors...

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to solid parts of the scooter, such as the frame or upper front fork tri- ple clamp (and not, for example, to rubber-mounted handlebars or turn signals, or parts that could break)... Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport... The suspension should be com- pressed somewhat by the tie-downs, if possible, so that the scooter will not bounce excessive- ly during transport...

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Never turn the key to OFF or LOCK while the vehicle is moving... Otherwise the electrical systems will be switched off, which may result in loss of control or an accident...

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To open the keyhole cover Insert the key bow into the keyhole cov- er receptacle as shown, and then turn the key to the right to open the cover...

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Engine trouble warning light This warning light flashes or stays on if an electrical circuit monitoring the en- gine is not working correctly... If this oc- curs, have a Yamaha dealer check the self-diagnosis system... The electrical circuit of the warning light can be checked by turning the key to ON... The warning light should come on for a few seconds, and then go off... If the warning light does not come on initially when the key is turned to ON, or if the warning light remains on, have a Yamaha dealer check the electrical circuit...

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he fuel gauge indicates the amount of el in the fuel tank... The needle moves wards E (Empty) as the fuel level ecreases... When the needle reaches e red zone, refuel as soon as possi- le... hen the key is turned to ON, the fuel

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Oil change tripmeter mode The oil change tripmeter shows the dis- tance traveled since the engine oil was last changed and this tripmeter was re- set... To reset the oil change tripmeter (and the oil change indicator), push the RESET button for 1 second... Then, while the oil change indicator is flash- ing, push the RESET button for 3 sec- onds... The oil change tripmeter will reset and the oil change indicator will stop flashing... Push the SELECT but- ton to start the oil change tripmeter and change the display to odometer mode...

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TIP If you do not push the SELECT or the RESET button within 30 seconds, the setting of the clock will not be complet- ed and the display will change to ODO mode...

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Engine stop switch / Set this switch to before starting the engine... Set this switch to to stop the engine in case of an emergen- cy, such as when the vehicle overturns or when the throttle cable is stuck...

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To open the fuel tank cap Open the fuel tank cap lock cover, in- sert the key into the lock, and then turn it 1/4 turn clockwise... The lock will be re- leased and the fuel tank cap can be opened...

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2... Do not overfill the fuel tank... When refueling, be sure to insert the pump nozzle into the fuel tank filler hole... 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...

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Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn... Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system... Make sure that the exhaust sys- tem has cooled down before do- ing any maintenance work... Do not allow the engine to idle more than a few minutes... Long idling can cause a build-up of heat...

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and then turn it counterclockwise to the first OPEN position... If the main switch is in the LOCK posi- tion, turn the key counterclockwise to the second OPEN position...

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holder, and then securely close the seat... WARNING! Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident... [EWA10162]

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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 items inside it... To avoid humidity from spread- ing through the storage com- partment, wrap wet articles in a plastic bag before storing them in the compartment... Since the storage compartment may get wet while the vehicle is being washed, wrap any articles stored in the compartment in a plastic bag... Do not keep anything valuable or breakable in the storage com- partment...

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his shock absorber assembly con- ins highly pressurized nitrogen as... Read and understand the fol- wing information before handling e shock absorber assembly... Do not tamper with or attempt to

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the sidestand down, or if the sides- tand 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... Yamahas ignition circuit cut-off system has been designed to assist the operator in fulfilling the respon- sibility of raising the sidestand be- fore starting off... Therefore, check this system regularly and have a Yamaha dealer repair it if it does not function properly...

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With the engine turned off: 1... Move the sidestand down... 2... Make sure that the engine stop switch is turned on... 3... Turn the key on... 4... Keep the front or rear brake applied... 5... Push the start switch... Does the engine start?

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Check operation... If soft or spongy, have Yamaha dealer bleed hydraulic system... Check brake pads for wear... Replace if necessary... Check fluid level in reservoir... If necessary, add specified brake fluid to specified level... Check hydraulic system for leakage...

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Check operation... If soft or spongy, have Yamaha dealer bleed hydraulic system... Check brake pads for wear... Replace if necessary... Check fluid level in reservoir... If necessary, add specified brake fluid to specified level... Check hydraulic system for leakage...

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TIP This model is equipped with a lean an- gle sensor to stop the engine in case of a turnover... To start the engine after a turnover, be sure to turn the main switch to OFF and then to ON... Fail- ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch...

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e speed can be adjusted by opening d closing the throttle... To increase the eed, turn the throttle grip in direction ... To reduce the speed, turn the throt- grip in direction (b)...

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Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter 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 such areas and cross them with cau- tion... Keep in mind that braking on a wet road is much more difficult... Ride slowly down a hill, as brak- ing downhill can be very diffi- cult...

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Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned...

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riodic inspection, adjustment, and lu- ation will keep your vehicle in the est and most efficient condition pos- le... Safety is an obligation of the vehi- owner/operator... The most important nts of vehicle inspection, adjust- nt, and lubrication are explained on following pages... e intervals given in the periodic intenance charts should be simply sidered as a general guide under mal riding conditions... However, de- ding on the weather, terrain, geo- phical location, and individual use, maintenance intervals may need to shortened...

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The owners tool kit is located inside the storage compartment under the seat... (See page 3-11... ) The service information included in this manual and the tools provided in the owners tool kit are intended to assist you in the performance of preventive maintenance and minor repairs... How- ever, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly...

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P From 12000 mi (19000 km) or 36 months, repeat the maintenance intervals star months... Items marked with an asterisk require special tools, data and technical skills, have a

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* Exhaust system Check for leakage... Tighten if necessary... Replace gasket(s) if necessary...

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Air filter element Replace... Every 1250 Air filter check hose Clean... V-belt case air filter element

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indicator flashes (after the initial 600 mi every 1800 mi (3000 km) thereafter)

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P Engine air filter and V-belt air filter This models engine air filter is equipped with a disposable oil-coated paper elem

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levels and fill the reservoirs as required... Every two years replace the internal components of the brake master cylinders

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To install the panel Place the panel in the original position, and then install the quick fasteners by pushing them in place and tightening their screws...

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Checking the spark plug The spark plug is an important engine component, which is easy to check... Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte- nance and lubrication chart... In addition, the condition of the spark plug can re- veal the condition of the engine...

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TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight... However, the spark plug should be tightened to the speci- fied torque as soon as possible...

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3... Wait a few minutes until the oil set- tles, remove the oil filler cap, wipe the dipstick clean, insert it back into the oil filler hole (without screwing it in), and then remove it again to check the oil level...

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Do not use oils with a diesel specification of CD or oils of a higher quality than specified... In addition, do not use oils labeled ENERGY CONSERVING II or higher... Be sure no foreign material en- ters the crankcase...

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The coolant level must be checked on a cold engine since the level varies with engine temperature... Make sure that the vehicle is posi- tioned straight up when checking the coolant level... A slight tilt to the side can result in a false reading...

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4... Add coolant or distilled water to raise the coolant to the maximum level mark, and install the coolant reservoir cap and the panel... NOTICE: If coolant is not avail- able, use distilled water or soft tap water instead... Do not use hard water or salt water since it is harmful to the engine... If water has been used instead of cool- ant, replace it with coolant as soon as possible, otherwise the cooling system will not be pro- tected against frost and corro- sion... If water has been added to the coolant, have a Yamaha dealer check the antifreeze con-

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ir filter and V-belt case air lter elements he air filter and V-belt case air filter el- ments should be cleaned or replaced t the intervals specified in the periodic aintenance and lubrication chart... heck both filter elements more fre- uently if you are riding in unusually et or dusty areas... The air filter check ose must be frequently checked and eaned if necessary...

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2... Pull the air filter element out, and then clean it with compressed air... NOTICE: To avoid damaging the air filter element, handle it gen- tly and carefully, and do not twist it... [ECA10522]

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Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise... To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart...

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worn-out tire... When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately... Brakes, tires and related wheel parts re- placement should also be left to a Yamaha dealer... Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics...

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for cracks, bends, warpage or oth- er damage before each ride... If any damage is found, have a Yamaha dealer replace the wheel... Do not attempt even the smallest repair to the wheel... A deformed or cracked wheel must be replaced...

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soft or spongy feeling in the brake ver can indicate the presence of air the hydraulic system... If there is air the hydraulic system, have a maha dealer bleed the system be- re operating the vehicle... Air in the draulic system will diminish the aking performance, which may re- lt in loss of control and an acci- nt...

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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 of the fluid and may result in vapor lock...

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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 lubricat- ed if necessary... If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it... WARNING! Damage to the outer housing of cables may result in in- ternal rusting and cause interfer- ence with cable movement... Replace damaged cables as soon as possi- ble to prevent unsafe condi- tions... [EWA10712]

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he centerstand or sidestand does t move up and down smoothly, ve a Yamaha dealer check or re- ir it... Otherwise, the centerstand or estand could contact the ground d distract the operator, resulting

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Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main- tenance and lubrication chart...

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Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica- tion chart... If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings...

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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 the key is turned to OFF, then discon- nect the negative lead before disconnecting the positive lead... [ECA16303]

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Fuse box The fuse box, which contains the fuses for the ignition, turn signal, and lighting systems, as well as the back-up fuse for the multi-function meter unit, is lo- cated underneath the windshield be- hind the front cowling... Have a Yamaha dealer check and replace these fuses if necessary...

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Auxiliary lights This model is equipped with LED-type auxiliary lights... If an auxiliary light does not come on, have a Yamaha dealer check it...

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4... Install the lens by installing the screw... NOTICE: Do not over- tighten the screw, otherwise the lens may break... [ECA11192]

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present quick and easy procedures r checking these vital systems your- lf... However, should your scooter re- ire any repair, take it to a Yamaha aler, whose skilled technicians have e necessary tools, experience, and ow-how to service the scooter prop- ly... e only genuine Yamaha replace-

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... Ignition Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug...

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Do not remove the radiator cap when the engine and radiator are hot... Scal blown out under pressure, which could cause serious injury... Be sure to wait Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the tent to allow any residual pressure to escape... When the hissing sound has while turning it counterclockwise, and then remove the cap...

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Avoid using strong acidic wheel cleaners, especially on spoked wheels... If such products are used on hard-to-remove dirt, do not leave the cleaner on the af- fected area any longer than in- structed... Also, thoroughly rinse the area off with water, immedi- ately dry it, and then apply a cor- rosion protection spray... Improper cleaning can damage plastic parts (such as cowlings, panels, windshields, headlight lenses, meter lenses, etc... ) and the mufflers... Use only a soft, clean cloth or sponge with wa- ter to clean plastic... However, if the plastic parts cannot be thor- oughly cleaned with water, di- luted mild detergent with water may be used... Be sure to rinse off any detergent residue using

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plenty of water, as it is harmful to plastic parts... Do not use any harsh chemical products on plastic parts... Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust re- movers or inhibitors, brake flu- id, antifreeze or electrolyte... Do not use high-pressure wash- ers or steam-jet cleaners since they cause water seepage and deterioration in the following ar- eas: seals (of wheel and swing- arm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents... For scooters equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching... Some cleaning com- pounds for plastic may leave scratches on the windshield... Test the product on a small hid-

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chrome, aluminum and stain- less-steel parts, including the ex- haust system... (Even the thermally induced discoloring of stain- less-steel exhaust systems can be removed through polishing... )

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Storing the scooter in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust... To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemi- cals are stored...

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Recommended engine oil grade: API service SG type or higher, JASO stan- dard MA or MB

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Halogen bulb b voltage, wattage quantity: eadlight: 12 V, 60... 0 W/55... 0 W 1

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ntification numbers cord the vehicle identification num- , engine serial number, model label rmation, and the key identification ber in the spaces provided below...

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he model label is affixed to the inside f the rear storage compartment... (See age 3-13... ) Record the information on is label in the space provided... This in- rmation will be needed when ordering are parts from a Yamaha dealer...

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eporting safety defects ou believe that your vehicle has a defect which could cause a crash or could cause inju orm the National Highway Traffic Safety Administration (NHTSA) in addition to no S... A... If NHTSA receives similar complaints, it may open an investigation, and if it finds vehicles, it may order a recall and remedy campaign... However, NHTSA cannot beco tween you, your dealer, or Yamaha Motor Corporation, U... S... A... contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 w... safercar... gov; or write to: Administrator, NHTSA, 1200 New Jersey Avenue, SE, We u can also obtain other information about motor vehicle safety from http://www... saferc

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otorcycle noise regulation AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: ederal law prohibits the following acts or the causing thereof: (1) The removal or rende an for purposes of maintenance, repair, or replacement of any device or element of d icle for the purpose of noise control prior to its sale or delivery to the ultimate purchase e vehicle after such device or element of design has been removed or rendered inop MONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACT

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aintenance has been completed in accordance with the emissions warranty... The char at maintenance work is required... It is not acceptable proof of maintenance work...

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EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, U... S... A... also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha scooter covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U... S... emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below... Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty...

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Y... E... S... is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits... There are no mileage limitations... Coverage isnt limited to moving parts or the drive train like many other plans... And Y... E... S... covers manufacturing defects just like the warranty... See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory- backed protection can be...

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We urge you to act now... Youll get the excellent benefits of TRIP coverage right away, and youll rest easy knowing youll have strong factory-backed protection even after your Yamaha Limited Warranty expires...

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chometer ... 3-3 il/brake light... 6-29 rottle grip and cable, checking and bricating ... 6-23 rottle grip free play, checking ... 6-18 es ... 6-18 ol kit... 6-2 oubleshooting ... 6-31 oubleshooting charts... 6-32 rn signal indicator lights ... 3-2

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Warranty, extended ... 9-9 Warranty, limited... 9-7 Wheel bearings, checking ... 6-26 Wheels... 6-20

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Genuine Yamaha Parts Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect... Why settle for aftermarket parts that may not provide full confidence and satisfaction?

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2SW-F8199-11_Cov... indd 42SW-F8199-11_Cov... indd 4 2015/07/22 11:22:092015/07/22 11:22:09

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