2005 YAMAHA XMAX 250 belt

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-1
Indicators, indicator lights and
warning light .....................................3-2
Speedometer ....................................3-3
Fuel gauge ........................................3-3
Coolant temperature gauge..............3-4
Multi-function display .......................3-4
Anti-theft alarm (optional) .................3-7
Handlebar switches ..........................3-7
Front brake lever...............................3-8
Rear brake lever................................3-8
Fuel tank cap ....................................3-8
Fuel ...................................................3-9
Catalytic converter..........................3-10
Seat.................................................3-10
Front storage compartment............3-11
Storage compartment.....................3-11
Adjusting the shock absorber
assemblies ......................................3-11
Sidestand ........................................3-12
PRE-OPERATION CHECKS..............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-1
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Tips for reducing fuel consumption..5-2
Engine break-in.................................5-3
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication
chart ..................................................6-2
Removing and installing cowlings and
panels ...............................................6-5
Checking the spark plug ..................6-5
Engine oil ..........................................6-7
Final transmission oil ........................6-8
Coolant .............................................6-9
Air filter V-Belt case air filter
elements .........................................6-10
Adjusting the carburetor .................6-11
Adjusting the throttle cable free play ..6-12
Valve clearance ...............................6-12
Tires ................................................6-12
Cast wheels ....................................6-14
Front and rear brake lever free play....6-14
Checking the front and rear brake ........
pads ................................................6-14
Checking the brake fluid level ........6-15Changing the brake fluid ................6-16
Checking and lubricating the throttle
grip cable ........................................6-16
Lubricating the front and rear brake
levers ..............................................6-16
Checking and lubricating the
centerstand and sidestand .............6-16
Checking the front fork ...................6-17
Cheking the steering.......................6-17
Checking the wheel bearings .........6-18
Battery ............................................6-18
Replacing the fuses ........................6-19
Replacing a headlight bulb .............6-20
Replacing a front turn signal light .........
bulb .................................................6-21
Replacing the tail/brake light bulb or a
rear turn signal light bulb ................6-21
Replacing the license plate light bulb ...6-22
Replacing the auxiliary light bulb ...6-22
Troubleshooting ..............................6-23
Troubleshooting charts ...................6-24
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage compartment.......................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
Key identification number .................9-1
Vehicle identification number............9-1
Model label .......................................9-1
TABLE OF CONTENTS
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EAU10410
Left view
DESCRIPTION
2-1
21
23
4
5
1. Storage compartment (page 3-11)
2. Spring preload (page 3-11)
3. Air filter (page 6-10)4. V-Belt filter (page 6-10)
5. Sidestand (page 3-12)
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EAU17705
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
1*Fuel line• Check fuel and vacuum hoses for cracks or damage.√√√√ √
• Check condition.
2Spark plug• Clean and regap.√√• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4Air filter element• Replace.√√
5*V-belt case air • Clean.√√filter elements• Replace.√√
6*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
7*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
• Replace brake pads. Whenever worn to the limit
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
22Final transmission oil• Check vehicle for oil leakage.√√ √• Change.√√√
23 *V-belt• Replace. Every 20000 km
24 *Front and rear brake
• Check operation.√√ √ √√ √
switches
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
26 *
and cable• Adjust the throttle cable free play if necessary.√√√√ √
• Lubricate the throttle grip housing and cable.
27 *Muffler and exhaust pipe• Check the screw clamp for looseness.√√ √ √√
28 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
EAU18660
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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3. If the coolant is at or below theminimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then add coolant to the maximum
level mark.
ECA10470
CAUTION
If coolant is not available, 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 coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
EWA10380
s s WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Close the reservoir cap.
6. Place the floorboard mat in the original position and push it
downward to secure it.
EAU33030
Changing the coolantEWA10380
s s WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAUS1330
Air filter and V-belt case air
filter elements
The air filter should be replaced and
the V-belt case air filter element
should be cleaned at the intervals
specified in the periodic maintenance
and lubrication chart. Replace or cle-
an the according filter element more
frequently if you are riding in unu-
sually wet or dusty areas.
Replacing air filter element 1. Place the scooter on the centers- tand.
Screws
Coolant reservoir capacity:0,46 L (0,07 US qt) (0,24 Imp.qt)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
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2. Remove the air filter case cover
by removing the screws.
3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case.
5. Install the air filter case cover by
installing the screws.Cleaning the V-belt case air filter
element
1. Screw (x3)
2. V-Belt air filter case cover
1. Remove the V-belt case air filter
cover by removing the screws.
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.3. Check the air filter element for
damage and replace it if neces-
sary.
4. Install the air filter element with
the colored side facing outward.
5. Install the V-belt case air filter
cover by installing the screws.
ECA10530
CAUTION
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
EAU21300
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all car-
buretor adjustments should be left to
a Yamaha dealer, who has the neces-
sary professional knowledge and
experience.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
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DimensionsOverall length
2210 mm
Overall width
790 mm
Overall height
1380 mm
Seat height
775 mm
Wheelbase
1545 mm
Ground clearance
113 mm
WeightDry (without oil and fuel)
164.0 kg
With oil and fuel
174.0 kg
Maximum load
235 kg
EngineEngine type
Liquid cooled 4-stroke, SOHC
Cylinder arrangement
Forward-inclined single cylinder
Displacement
249.7 cm
3
Bore x stroke
69.0 x 66.8 mm
Compression ratio
10.00 :1
Starting system
Electric starterLubrication system
Wet sump
Oil type or gradeEngine oil
SAE10W30SE
Recommended engine oil grade
API service SE, SF, SG type or higher
Engine oil quantityQuantity
1.4 L
Periodic oil change
1.20 L
Final gear oilQuantity
0.25 L
Cooling systemRadiator capacity
0.34 L
Coolant reservoir capacity (up to the maxi-
mum level mark)
0.46 L
Air filterAir filter element
Oil-coated paper element
Recommended fuelRecommended fuel
Unleaded fuel
Fuel tank capacity
12.0 L
Fuel reserve amount
2.0 L
CarburetorType x quantity
1C0 x 1
Manufacturer
KEIHIN
Spark plug (s)Manufacturer/model
NGK DR8EA
Spark plug gap
0.6-0.7 mm
Clutch type
Transmission
Primary reduction system
Helical gear
Primary reduction ratio
40 x 15 (2.666)
Secondary reduction system
Helical gear
Secondary reduction ratio
40 x 14 (2.857)
Transmission type
V-belt automatic8
SPECIFICATIONS
8-1
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AAcceleration and deceleration ...................5-2
Adjusting the carburetor ..........................6-11
Adjusting the shock absorber
assemblies .............................................3-11
Adjusting the throttle cable free play .......6-12
Air filter V-Belt case air filter elements.....6-10
Anti-theft alarm (optional) ..........................3-7
BBattery......................................................6-18
Braking .......................................................5-2
CCare............................................................7-1
Cast wheels .............................................6-14
Catalytic converter ...................................3-10
Changing the brake fluid..........................6-16
Checking and lubricating the
centerstand and sidestand ....................6-16
Checking and lubricating the
throttle grip cable ..................................6-16
Checking the brake fluid level .................6-15
Checking the front and rear brake pads.....6-14
Checking the front fork ............................6-17
Checking the spark plug ............................6-5
Checking the wheel bearings ..................6-18
Cheking the steering ................................6-17
Controls and instruments ..........................2-3
Coolant.......................................................6-9
Coolant temperature gauge .......................3-4
EEngine break-in ..........................................5-3
Engine oil ...................................................6-7
FFinal transmission oil .................................6-8Front and rear brake lever free play.........6-14
Front brake lever ........................................3-8
Front storage compartment .....................3-11
Fuel ............................................................3-9
Fuel gauge .................................................3-3
Fuel tank cap .............................................3-8
HHandlebar switches ...................................3-7
IImmobilizer system ....................................3-1
Indicators, indicator lights and warning
light ..........................................................3-2
KKey identification number ..........................9-1
LLeft view .....................................................2-1
Lubricating the front and rear brake
levers .....................................................6-16
MMain switch/steering lock ..........................3-1
Model label ................................................9-1
Multi-function display ................................3-4
OOwner’s tool kit ..........................................6-1
PParking .......................................................5-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear brake lever .........................................3-8
Removing and installing cowlings and
panels ......................................................6-5
Replacing a front turn signal light bulb....6-21Replacing a headlight bulb ......................6-20
Replacing the auxiliary light bulb .............6-22
Replacing the fuses .................................6-19
Replacing the license plate light bulb......6-22
Replacing the tail/brake light bulb or a
rear turn signal light bulb.......................6-21
Right view ..................................................2-2
SSeat ..........................................................3-10
Sidestand .................................................3-12
Speedometer .............................................3-3
Starting a cold engine ................................5-1
Starting off .................................................5-1
Storage compartment ..............................3-11
Storage compartment ................................7-3
TTips for reducing fuel consumption ...........5-2
Tires .........................................................6-12
Troubleshooting .......................................6-22
Troubleshooting charts ............................6-24
VValve clearance ........................................6-12
Vehicle identification number .....................9-1
INDEX
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