2006 YAMAHA XMAX 250 Owners Manual

There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
EWA14211
s s
WARNING
A soft or spongy feeling in the bra-
ke lever can indicate the presence
of air in the hydraulic system. If the-
re is air in the hydraulic system,
have a Yamaha dealer bleed the
system before operating the vehi-
cle. Air in the hydraulic system will
diminish the braking performance,
which may result in loss of control
and an accident.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU22400
Front brake pads
1. Lining thickeness
Check each front brake pad for
damage and measure the lining thick-
ness. If a brake pad is damaged or if
the lining thickness is less than 0.5
mm (0.02 in), have a Yamaha dealer
replace the brake pads as a set.
EAU22510
Rear brake pads
1. Brake pad wear indicator groove
The rear brake is provided with a
check plug, which, if it is removed,
allows you to check the brake pad
wear without disassembling the bra-
ke. If the lining thickness is less than
0.5 mm (0.02 in), have a Yamaha dea-
ler replace the brake pads as a set.
11
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 57

EAU22580
Checking the brake fluid
level
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
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.
Recommended brake fluid:
DOT 4
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 58

EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they are
damaged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
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.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 59

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.
EWA10740
s s
WARNING
If the centerstand or sidestand
does not move up and down smo-
othly, have a Yamaha dealer check
or repair it.
EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 60

2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
ECA10590
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication 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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 61

EAU23380
Battery
The battery is located behind panel A.
(See page 6-6.)
This model is equipped with a sealed-
type (MF) battery, which does not
require any maintenance. There is no
need to check the electrolyte or to
add distilled water.
ECA10620
CAUTION:
Never attempt to remove the bat-
tery cell seals, as this would per-
manently damage the battery.
EWA10760
s s
WARNING
lectrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk andimmediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
atteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed spa-
ce.
EEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
DREN.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.To store the battery
1. Battery
1. If the vehicle will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 62

ECA10630
CAUTION:
Always keep the battery char-
ged. Storing a discharged bat-
tery can cause permanent bat-
tery damage.
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EAU23613
Replacing the fuses
The main fuse and the fuse box,
which contains the fuses for the indi-
vidual circuits, are located behind
cowling B. (See page 6-6.)
If a fuse is blown, replace it as
follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
ECA10640
CAUTION:
Do not use a fuse of a higher ampe-
rage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
Specified fuses:
Main fuse:
30 A
Headlight fuse:
15 A
Signaling system fuse:
15 A
Ignition fuse:
5 A
Ecu fuse:
5 A
Radiator fan fuse:
10 A
Backup fuse:
5 A
Reserve fuse:
30 A
15 A
10 A
5 A
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 63

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.EAU23910
Replacing a headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
1. Remove cowling B. (See page 6-
6.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
1. Headlight coupler
3. Remove the headlight bulb hol-
der according to the following
illustration, and then remove the
defective bulb.
1. Headlight bulb cover
NOTE:
The removal procedure depends on
the type of bulb holder installed on
your vehicle.
EWA10790
s s
WARNING
Headlight bulbs get very hot. The-
refore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
4. Place a new bulb into position,
and then secure it with the bulb
holder.
1
11
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 64