2006 YAMAHA XMAX 250 brake fluid

SAFETY INFORMATION.....................1-1
Further safe-riding points .................1-4
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 .................3-2
Indicators, indicator lights and
warning light ..................................3-3
Fuel gauge ........................................3-4
Coolant temperature gauge..............3-5
Speedometer ....................................3-5
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-8
Handlebar switches ..........................3-9
Front brake lever.............................3-10
Rear brake lever..............................3-10
Fuel tank cap ..................................3-11
Fuel .................................................3-12
Catalytic converter..........................3-13
Seat.................................................3-13
Front storage compartment............3-14
Storage compartment.....................3-14
Adjusting the shock absorber
assemblies...................................3-15
Sidestand ........................................3-16
Ignition circuit cut-off system .........3-17PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication
chart ..............................................6-3
Removing and installing cowlings
and panels .....................................6-6
Checking the spark plug ..................6-7
Engine oil ..........................................6-8
Final transmission oil ......................6-10
Coolant ...........................................6-11
Air filter and V-belt case air filter
elements ......................................6-12
Adjusting the carburetor .................6-14
Adjusting the throttle cable free play ..6-14
Valve clearance ...............................6-15
Tires ................................................6-15
Cast wheels ....................................6-17
Front and rear brake lever free play ..6-17Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Checking and lubricating the throttle
grip and cable .............................6-20
Lubricating the front and rear brake
levers ...........................................6-20
Checking and lubricating the
centerstand and sidestand .........6-21
Checking the front fork ...................6-21
Checking the steering.....................6-22
Checking the wheel bearings .........6-22
Battery ............................................6-23
Replacing the fuses ........................6-24
Replacing a headlight bulb .............6-25
Replacing a front turn signal light
bulb .............................................6-26
Replacing the tail/brake light bulb or a
rear turn signal light bulb ............6-27
Replacing the license plate light bulb..6-27
Replacing the auxiliary light bulb ...6-28
Troubleshooting ..............................6-28
Troubleshooting charts ...................6-29
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage .............................................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ......................9-1
TABLE OF CONTENTS
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4
PRE-OPERATION CHECKS
4-2
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-11, 3-12
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-8
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-10
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-11
• 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. 3-10, 6-17, 6-18, 6-19
• 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. 3-10, 6-17, 6-18, 6-19
• 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.
6-14, 6-20
• If necessary, have Yamaha dealer adjust cable free play
and lubricate cable and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-15, 6-17
• Check air pressure.
• Correct if necessary.
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
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.
ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
1*Fuel line•Check fuel 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 filter •Clean.√√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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6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
21Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
22 *V-belt•Replace. Every 20000 km
23 *Front and rear brake
switches•Check operation.√√ √ √√ √
24Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing •Check operation and free play.
25 * •Adjust the throttle cable free play if necessary.
and cable
•Lubricate the throttle grip housing and cable.√√√√ √
26 *Mufflers and exhaust
pipes•Check the screw clamps for looseness.√√ √ √√ √
27 *Lights, signals •Check operation.
and switches•Adjust headlight beam.√√ √ √√ √
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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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
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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
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EAU26090
Care
While the open design of a scooter
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go
unnoticed on a car, however, it
detracts from the overall appearance
of a scooter. Frequent and proper
care does not only comply with the
terms of the warranty, but it will also
keep your scooter looking good,
extend its life and optimize its perfor-
mance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-ducts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA10780
CAUTION:
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent orthinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
7
SCOOTER CARE AND STORAGE
7-1
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Operation
Centrifugal automatic type
ChassisFrame type
Steel tube underbone
Caster angle
28 º
Trail
100 mm (3.94 in)
Front tireType
Tubeless
Size
120/70-15 M/C 56P or 56S
Manufacturer/model
Michelin / Gold Standard
Rear tireType
Tubeless
Size
140/70-14 M/C 68P or 68S
Manufacturer/model
Michelin / Gold Standard
LoadingMaximum load
181 kg (399.1 lb)
Load is total weight of the equipement, dri-
ver, passenger and accessories
Tire air pressure (measured on cold
tires)
Loading condition
0–90 kg (0–198 lb)
Front
190 kPa (27 psi) (1.9 kgf/cm
2)Rear
220 kPa (31 psi) (2.2 kgf/cm
2)
Loading condition
90 kg (198 lb)–Maximum load
Front
210 kPa (30 psi) (2.1 kgf/cm
2)
Rear
250 kPa (36 psi) (2.5 kgf/cm2)
Front wheelWheel type
Aluminium wheel
Rim size
15 x MT3.5
Rear wheelWheel type
Aluminium wheel
Rim size
14 x MT3.75
Front brakeType
Single disc brake
Operation
Right hand operation
Recommended fluid
DOT 4
Rear brakeType
Single disc brake
Operation
Left hand operation
Recommended fluid
DOT 4
Front suspensionType
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
110 mm (4.33 in)
Rear suspensionType
Unit swing
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
95 mm (3.74 in)
Electrical systemIgnition system
Transistorized coil ignition (digital)
Charging system
AC magneto
BatteryManufacturer/model
Yuasa/YTX9-BS
Voltage, capacity
12 V, 8.0 Ah
Bulb voltage, wattage x quantityHeadlight
12 V, 35.0 W / 35.0 W x 2
Auxiliary light
12 V, 5.0 W x 2
Tail/brake light
12 V, 21.0 W / 5.0 W x 2
Front turn signal light
12 V, 10.0 W x 2
8
SPECIFICATIONS
8-2
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