2005 YAMAHA XMAX 250 check engine light

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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Cargo and accessory weight
should be kept as low and close
to the scooter as possible. Make
sure to distribute the weight as
evenly as possible on both sides
of the scooter to minimize imba-
lance or instability.
Shifting weights can create a
sudden imbalance. Make sure
that accessories and cargo are
securely attached to the scooter
before riding. Check accessory
mounts and cargo restraints fre-
quently.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a
slow steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot
test all other accessories that may be
available, you must personally be res-
ponsible for the proper selection, ins-
tallation and use of non-Yamaha
accessories. Use extreme cautionwhen selecting and installing any
accessories.
Keep the following guidelines in mind,
as well as those provided under “Loa-
ding” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your scooter. Care-
fully inspect the accessory befo-
re using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension tra-
vel, steering travel or control ope-
ration, or obscure lights or reflec-
tors.
• Accessories fitted to the hand-
lebar or the front fork area can
create instability due to impro-
per weight distribution or
aerodynamic changes. If
accessories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum.• Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodyna-
mic effects. Wind may attempt
to lift the scooter, or the scoo-
ter may become unstable in
cross winds. These accesso-
ries may also cause instability
when passing or being passed
by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the fre-
edom of movement of the ope-
rator and may limit control abi-
lity, therefore, such
accessories are not recom-
mended.
Use caution when adding electri-
cal accessories. If electrical
accessories exceed the capacity
of the scooter’s electrical system
an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
1
SAFETY INFORMATION t
1-3
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NOTE:
Be sure to use the standard key
(black bow) for regular use of the
vehicle. To minimize the risk of losing
the code re-registering key (red bow),
keep it in a safe place and only use it
for code re-registering.
EAU10550
ON
All electrical circuits are supplied with
power, the meter lighting, taillight,
license plate light and auxiliary lights
come on, and the engine can be star-
ted. The key cannot be removed.
NOTE:
The headlights come on automatically
when the engine is started and stayon until the key is turned to “OFF”,
even if the engine stalls.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
WARNING
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 anaccident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
EAU33461
Indicators, indicator lights
and warning light
EAU11030
Turn signal indicator lights “c” and
“
d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11350
Fuel level warning light “z”
This warning light comes on when the
fuel level drops below approximately
2.0L (0.44USgal)(1.76Imp.gal). When
this occurs, refuel as soon as possi-
ble.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
IGNITION
LOCK
OFFONOPENPUSH
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
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1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the centers-
tand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal 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 signal off.
EAU16780
Acceleration and
deceleration
The speed can be adjusted by ope-
ning and closing the throttle. To incre-ase the speed, turn the throttle grip in
direction (a). To reduce the speed,
turn the throttle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
EWA10300
s s
WARNING
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the sco-
oter may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manholecovers 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 bra-
king downhill can be very diffi-
cult.
EAU16820
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Avoid high engine speeds during
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
traffic lights or at railroad cros-
sings).
5
OPERATION AND IMPORTANT RIDING POINTS
5-2
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
8*Brake hose• Check for cracks or damage.√√√√ √• Replace. Every 4 years
9*Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
10 *Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
11 *Wheel bearings• Check bearing for looseness or damage.√√√√
12 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 20000 km
13 *Chassis fasteners• Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
15 *Sidestand switch• Check operation.√√ √ √√ √
16 *Front fork• Check operation and for oil leakage.√√√√
17 *Shock absorber
• Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 *Carburetor• Adjust engine idling speed.√√ √ √√ √
• Change. (See page 3-6.)√When the oil change
19Engine oilindicator light comes on (every 3000 km)• Check oil level and vehicle for oil leakage. Every 3000 km√
20 *Engine oil strainer• Clean.√
21 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
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3. Remove the spark plug cap.
4. Remove the spark plug asshown, with the spark plug
wrench included in the owner’s
tool kit.
To check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug 1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
2. Clean the surface of the spark plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4 ~
1/2 turn past finger tight. However,
the spark plug should be tightened to
the specified torque as soon as pos-
sible.
4. Install the spark plug cap.
Tightening torque:Spark plug:18 Nm (1,8 m•kgf, 13,01 ft•lbf)
Spark plug gap:0,7mm (0,027in)
Specified spark plug:NGK DR8EA6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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NOTE:
Make sure the spark plug wire is fas-
tened in the clamp as shown.
5. Install the storage compartment
by installing the bolts.
6. Close the seat.
EAUM1550
Engine oil
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the
service indicator light comes on.
To check the engine oil level
1. Place the scooter on the centers-
tand.
NOTE:
Make sure that the scooter is positio-
ned straight up when checking the oil
level. 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.
1. Dipstick
2. Max-min marks
3. Oil filler cap
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (wit-
hout screwing it in), and then
remove it again to check the oil
level.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to rai-
se it to the correct level.5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
1. Oil drain bolt
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the washer for damage
and replace it if necessary.
5. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
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6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUS1270
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Maximum level
2. Minimum level
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir cap
1
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0,25 L (0,05 US qt) (0,21 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2,2 m•kgf, 15,91 ft•lbf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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