Yamaha MBK X-MAX 300 2017 User manual

2017
SERVICE MANUAL
X-MAX 300
EVOLIS 300
CZD300-A
CZD300-AH
B74-F8197-E0

EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing Ltd. primarily for use by
Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me-
chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these
types of vehicles. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing Ltd. is continually striving to improve all of its models. Mod-
ifications and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry 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
NOTICE
TIP
EAS20002
CZD300-A/CZD300-AH
SERVICE MANUAL
©2017 by PT Yamaha Indonesia Motor
Manufacturing Ltd.
First edition, January 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing Ltd.
is expressly prohibited.

EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
4
6
2

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
Silicone fluid
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S

EAS10003 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
MULTI-FUNCTION DISPLAY....................................................................1-2
SPECIAL TOOLS ............................................................................................1-8

IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EAS30003
MODEL LABEL
The model label “1” is affixed to the inside of the
storage box.
1
1

FEATURES
1-2
EAS20008
FEATURES
EAS30618
MULTI-FUNCTION DISPLAY
WARNING
EWA12423
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The “TRIP/INFO” switch is located on the right
side of the handlebar. This switch allows you to
control or change the settings of the multi-func-
tion meter unit. To use the “TRIP” switch, move
the “TRIP/INFO” switch in direction “a”. To use
the “INFO” switch, move the “TRIP/INFO” switch
in direction “b”.
The multi-function display is equipped with the
following:
•clock
• fuel meter
• coolant temperature meter
• tripmeter display
• information display
TIP
For the UK: To switch the displays between kilo-
meters and miles, turn the main switch to “ON”
while pushing the “INFO” switch, and then con-
tinue to push the “INFO” switch for eight sec-
onds.
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 “TRIP” switch to set the hours.
5. Push the “TRIP” switch for three seconds,
and then release it. The minute digits will start
flashing.
6. Use the “TRIP” switch to set the minutes.
7. Push the “TRIP” switch for three seconds,
and then release it to start the clock.
Fuel meter
1. Fuel meter
2. Information display
3. Coolant temperature meter
4. Clock
5. Tripmeter display
6. Icy road warning indicator “ ”
1. “TRIP/INFO” switch
2
3
4
1
6
5
1
ba
1. Clock
1. Fuel meter
1
1

FEATURES
1-3
The fuel meter indicates the amount of fuel in the
fuel tank. The segments of the fuel meter disap-
pear from “F” (full) towards “E” (empty) as the
fuel level decreases. When the last segment of
the fuel meter starts flashing, refuel as soon as
possible.
TIP
• If a problem is detected in the fuel meter, the all
segments will flash repeatedly. If this occurs,
check the electrical circuit. Refer to “SIGNAL-
ING SYSTEM” on page 8-19.
• When approximately 2.4 L (0.63 US gal, 0.53
Imp.gal) of fuel remains in the fuel tank, the last
segment of the fuel meter will start flashing.
The display will automatically change to the
fuel reserve tripmeter “F Trip” and start count-
ing the distance traveled from that point.
Coolant temperature meter
The coolant temperature meter indicates the
temperature of the coolant.
If the top segment flashes, stop the vehicle, then
stop the engine, and let the engine cool.
NOTICE
ECA10022
Do not continue to operate the engine if it is
overheating.
TIP
• If a problem is detected in the coolant tempera-
ture meter, all segments will flash repeatedly. If
this occurs, check the electrical circuit. Refer to
“COOLING SYSTEM” on page 8-27.
• The coolant temperature varies with changes
in the weather and engine load.
Tripmeter display
The tripmeter display is equipped with the fol-
lowing:
• odometer
• tripmeter
• time tripmeter
• fuel reserve tripmeter
• oil change tripmeter
• V-belt replacement tripmeter
Push the “TRIP” switch to change the display
between the odometer “Odo”, tripmeter “Trip”,
time tripmeter “Trip Time”, oil change tripmeter
“Oil Trip”, and V-belt replacement tripmeter “V-
Belt Trip” in the following order:
Odo →Trip →Trip Time →Oil Trip →V-Belt
Trip →Odo
TIP
When approximately 2.4 L (0.63 US gal, 0.53
Imp.gal) of fuel remains in the fuel tank, the last
segment of the fuel meter will start flashing. The
display will automatically change to the fuel re-
serve tripmeter “F Trip” and start counting the
distance traveled from that point.
Odometer “Odo” and tripmeter “Trip”
The odometer shows the total distance traveled
by the vehicle.
The tripmeter shows the distance traveled since
it was last reset.
To reset the tripmeter, select it by pushing the
“TRIP” switch, and then push the “TRIP” switch
for three seconds.
TIP
• The odometer will lock at 999999.
• The tripmeter will reset and continue counting
after 9999.9 is reached.
1. Coolant temperature meter
1
1. Tripmeter display
1

FEATURES
1-4
Time tripmeter “Time”
The time tripmeter displays the time that has
elapsed while the main switch was in the “ON”
position since it was last reset.
The maximum time that can be shown is 99:59.
TIP
To reset the time tripmeter, select it by pushing
the “TRIP” switch, and then push the “TRIP”
switch for three seconds.
Fuel reserve tripmeter “F Trip”
When approximately 2.4 L (0.63 US gal, 0.53
Imp.gal) of fuel remains in the fuel tank, the last
segment of the fuel meter will start flashing. The
display will automatically change to the fuel re-
serve tripmeter “F Trip” and start counting the
distance traveled from that point. In this case,
push the “TRIP” switch to switch the display in
the following order:
F Trip →Oil Trip →V-Belt Trip →Odo →Trip →
Trip Time →F Trip
To reset the fuel reserve tripmeter, select it by
pushing the “TRIP” switch, and then push the
“TRIP” switch for three seconds.
The fuel reserve tripmeter will reset automatical-
ly and disappear after refueling and traveling 5
km (3 mi).
Oil change tripmeter “Oil Trip”
The oil change tripmeter shows the distance
traveled since the oil was last changed.
The oil change indicator “OIL” flashes at the ini-
tial 1000 km (600 mi), then at 4000 km (2400 mi)
and every 5000 km (3000 mi) thereafter to indi-
cate 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 tripme-
ter, and then push the “TRIP” switch for three
seconds.
While the oil change tripmeter is flashing, push
the “TRIP” switch for 15 to 20 seconds. Release
the “TRIP” switch, and the oil trip value will reset
to zero.
TIP
If the engine oil is changed before the oil change
indicator comes on (i.e., before the periodic oil
change interval has been reached), the oil
change tripmeter must be reset for the oil
change indicator to come on at the correct time.
V-belt replacement tripmeter “V-Belt Trip”
The V-belt replacement tripmeter shows the dis-
tance traveled since the V-belt was last re-
placed.
1. Time tripmeter
1. Fuel reserve tripmeter
1
1
1. Oil change indicator “Oil”
2. Oil change tripmeter
1. V-belt replacement indicator “V-Belt”
2. V-belt replacement tripmeter
1
2
1
2

FEATURES
1-5
The V-belt replacement indicator “V-Belt” will
flash every 20000 km (12000 mi) to indicate that
the V-belt should be replaced.
After replacing the V-belt, reset the V-belt re-
placement indicator and the V-belt replacement
tripmeter. To reset them both, select the V-belt
replacement tripmeter, and then push the “TRIP”
switch for three seconds.
While the V-belt replacement tripmeter is flash-
ing, push the “TRIP” switch for 15 to 20 seconds.
Release the “TRIP” switch, and the V-belt trip
value will reset to zero.
TIP
If the V-belt is replaced before the V-belt re-
placement indicator comes on (i.e., before the
periodic V-belt replacement interval has been
reached), the V-belt replacement tripmeter must
be reset for the V-belt replacement indicator to
come on at the correct time.
Information display
The information display is equipped with the fol-
lowing:
• 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 temperature display “Air-temp”,
battery voltage display “Battery”, traction control
system display “TCS ON” or “TCSOFF”, aver-
age fuel consumption display “Consumption/Av-
erage_ _._ km/L” or “Consumption/Average_
_._ L/100 km”, instantaneous fuel consumption
display “Consumption_ _._ km/L” or “Consump-
tion_ _._ L/100 km” and average speed display
“Average” in the following order:
Air-temp →Battery →TCS ON or TCSOFF →
Consumption/Average_ _._ km/L →Consump-
tion/Average_ _._ L/100 km →Consumption_
_._ km/L →Consumption_ _._ L/100 km →Av-
erage →Air-temp
For the UK:
Push the “TRIP” switch to change the display
between the air temperature display “Air-temp”,
battery voltage display “Battery”, traction control
system display “TCS ON” or “TCSOFF”, aver-
age fuel consumption display “Consumption/Av-
erage_ _._ km/L”, “Consumption/Average_ _._
L/100 km” or “Consumption/Average_ _
_._MPG”, instantaneous fuel consumption dis-
play “Consumption_ _._ km/L”, “Consumption_
_._ L/100 km” or “Consumption_ _ _._MPG” and
average speed display “Average” in the follow-
ing order:
Air-temp →Battery →TCS ON or TCSOFF →
Consumption/Average_ _._ km/L →Consump-
tion/Average_ _._ L/100 km →Consumption/
Average_ _ _._ MPG →Consumption_ _._ km/
L →Consumption_ _._ L/100 km →Consump-
tion_ _ _._ MPG →Average →Air-temp
TIP
• When kilometers are selected for the display
units, “Consumption/Average_ _ _._MPG” and
“Consumption_ _ _._MPG” are not displayed.
• When miles are selected for the display units,
“Consumption/Average_ _._ km/L”, “Con-
sumption/Average_ _._ L/100 km”, “Consump-
tion_ _._ km/L”, and “Consumption_ _._ L/100
km” are not displayed.
1. Information display
1

FEATURES
1-6
Air temperature display
This display shows the air temperature from –10
°C to 50 °C in 1 °C increments.
The icy road warning indicator “ ” will flash
when the temperature is below 4 °C.
The temperature displayed may vary from the
actual ambient temperature.
TIP
The accuracy of the temperature reading may
be affected by engine heat when riding slowly
(under 20 km/h [12 mi/h]) or when stopped at
traffic signals, etc.
Battery voltage display
This display shows the current charge state of
the battery.
TIP
• If the engine turns over slowly when using the
start switch, check the battery. Refer to
“CHECKING AND CHARGING THE BAT-
TERY” on page 8-128.
• If “---” appears in the battery voltage display,
check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on page 8-128.
Traction control system mode display
This display shows the current status of the trac-
tion control system.
• “TCS ON”: the system is on
• “TCSOFF”: the system is off
TIP
If only “TCS” is displayed, there is a communica-
tion error within the vehicle. Check the electrical
circuit. Refer to “SIGNALING SYSTEM” on page
8-19.
Average fuel consumption display
This function calculates the average fuel con-
sumption since it was last reset.
The average fuel consumption can be displayed
as either “Consumption/Average_ _._ km/L”,
“Consumption/Average_ _._ L/100 km” or “Con-
sumption/Average_ _ _._ MPG” (for the UK).
• “Consumption/Average_ _._ km/L”: The aver-
age distance that can be traveled on 1.0 L of
fuel is shown.
• “Consumption/Average_ _._ L/100 km”: The
average amount of fuel necessary to travel 100
km is shown.
• “Consumption/Average_ _ _._ MPG” (for the
UK): The average distance that can be trav-
eled on 1.0 Imp.gal of fuel is shown.
To reset the average fuel consumption, push the
“INFO” switch for at least three seconds.
1. Air temperature display
2. Icy road warning indicator “ ”
1. Battery voltage display
1
2
1
1. Traction control system mode display
1. Average fuel consumption display
1
1

FEATURES
1-7
TIP
After resetting the average fuel consumption, “_
_._” will be shown until the vehicle has traveled
1 km (0.6 mi).
Instantaneous fuel consumption display
This function calculates the fuel consumption
under current riding conditions.
The instantaneous fuel consumption can be dis-
played as either “Consumption_ _._km/L”, “Con-
sumption_ _._L/100 km” or “Consumption_ _
_._MPG” (for the UK).
• “Consumption_ _._km/L”: The distance that
can be traveled on 1.0 L of fuel under the cur-
rent riding conditions is shown.
• “Consumption_ _._L/100 km”: The amount of
fuel necessary to travel 100 km under the cur-
rent riding conditions is shown.
• “Consumption_ _ _._MPG” (for the UK): The
distance that can be traveled on 1.0 Imp.gal of
fuel 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” or “Av-
erage_ _ _MPH” (for the UK) is displayed.
The average speed is the total distance divided
by the total time (with the main switch in the “ON”
position) since the display was last reset to zero.
This display shows the average speed since it
was last reset.
To reset the average speed display, select it by
pushing the “INFO” switch, and then push the
“INFO” switch for three seconds.
Warning message function
This function displays a warning message corre-
sponding to the current warning.
“L FUEL”: Appears when the last segment of the
fuel meter starts flashing. If “L FUEL” is dis-
played, refuel as soon as possible.
“H TEMP”: Appears when the top segment of the
coolant temperature meter starts flashing. If “H
TEMP” is displayed, stop the vehicle, then stop
the engine, and let the engine cool.
“ICE”: Appears when the icy road warning indi-
cator “ ” starts flashing. If “ICE” is displayed, be
careful of icy roads.
“OIL SERV”: Appears when the oil change indi-
cator “OIL” starts flashing. If “OIL SERV” is dis-
played, change the engine oil, and then reset the
oil change indicator and oil change tripmeter.
“V-BELT SERV”: Appears when the V-belt re-
placement 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 are two or more warnings, the warn-
ing messages are displayed in the following or-
der:
L FUEL →H TEMP →ICE →OIL SERV →
VBELT SERV →L FUEL
1. Instantaneous fuel consumption display
1. Average speed display
1
1

SPECIAL TOOLS
1-8
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Tool name/Tool No. Illustration Reference
pages
Yamaha diagnostic tool USB
90890-03256
3-4, 3-7, 3-8,
4-68, 4-69, 7-17,
7-17, 7-18, 7-18,
8-34, 8-88,
8-110, 8-128
Yamaha diagnostic tool (A/I)
90890-03254
3-4, 3-7, 3-8,
4-68, 4-69, 7-17,
7-17, 7-18, 7-18,
8-34, 8-88,
8-110, 8-128
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
3-16, 4-89
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
4-32, 4-36
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-82, 4-84
Fork seal driver weight
90890-01184
Replacement hammer
YM-A9409-7
4-85, 4-85, 4-85
Fork seal driver attachment (ø33)
90890-01368
Replacement 33 mm
YM-A9409-4
4-85, 4-85

SPECIAL TOOLS
1-9
Compression gauge
90890-03081
Engine compression tester
YU-33223
5-5
Camshaft sprocket stopper
90890-04182
Camshaft sprocket stopper
YM-04182
5-17, 5-20
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
5-20, 5-51, 5-63
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
5-27, 5-31
Valve spring compressor attachment
90890-06320
5-27, 5-31
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
5-28
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
5-28
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
5-28
Tool name/Tool No. Illustration Reference
pages
90890-03081
YU-33223

SPECIAL TOOLS
1-10
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-33
Rotor holding tool
90890-01235
Universal magneto and rotor holder
YU-01235
5-40, 5-45
Rotor holding tool
90890-04166
Rotor holding tool
YM-04166
5-40, 5-40, 5-44,
5-45, 5-49, 5-49,
5-50, 5-51
Locknut wrench
90890-01348
Locknut wrench
YM-01348
5-40, 5-44
Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134
5-40, 5-43
Tool name/Tool No. Illustration Reference
pages
YU-01304

SPECIAL TOOLS
1-11
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
5-40, 5-43
Oil seal guide (40mm)
90890-01590
Sliding sheave guide 40mm
YM-01590
5-43
Flywheel puller
90890-01404
Flywheel puller
YM-01404
5-49
Rotor puller bolt M14 X L80
90890-04183
Rotor puller bolt M14 X L80
YM-04183
5-49
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachometer
YU-A1927
5-54, 8-128,
8-129, 8-130,
8-131, 8-131,
8-132, 8-133,
8-133, 8-133,
8-134, 8-134,
8-135, 8-135,
8-136, 8-137,
8-137, 8-138
Crankshaft metal installation base set
90890-04181
Crankshaft metal installation base set
YM-04181
5-67, 5-72
Tool name/Tool No. Illustration Reference
pages
ø40
L80
M14×P1.5