2005 YAMAHA XMAX 250 oil level

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
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 4

EAU10420
Right view
DESCRIPTION
2-2
2
78910
61514 13 1211
6. Rear brake pads (page 6-14)
7. Grab bar
8. Fuel cap (page 3-8)
9. Battery (page 6-18)
10. Fuse box and main fuse (page 6-19)11. Front brake pads (page 6-14)
12. Coolant reservoir cap (page 6-9)
13. Coolant level window (page 6-9)
14. Centerstand (page 6-16)
15. Oil filler cap (page 6-7)
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 13

4
PRE-OPERATION CHECKS
4-2
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.3-9
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-7
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-8
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-9
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-8, 6-14
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 3-8, 6-14
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-12
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
Control cables• Make sure that operation is smooth.
• Lubricate if necessary. —
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 29

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
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 36

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.
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 37

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
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 40

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
6-9
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 42

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.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAUM1360
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the brake
hose replaced every four years or
whenever it is damaged or leaking.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated at the intervals specified in the
periodic maintenance chart.
EAU23170
Lubricating the front and
rear brake levers
The pivoting points of the front and
rear brake levers must be lubricated
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
EAU23211
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-
to-metal contact surfaces should be
lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1C0-F8199-E0.qxd 13/04/2005 16:58 Página 49