2007 YAMAHA XMAX 250 brake

ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
22 Final transmission oil • Check vehicle for oil leakage.
√√ √• Change.√√√√
23 *V-belt • Replace. Every 20000 km
24 * Front and rear brake
switches • Check operation.
√√ √ √√ √
25Moving parts and cables • Lubricate. √√√√ √
Throttle grip housing • Check operation and free play.
26 * • Adjust the throttle cable free play if necessary.
√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
27 * Lights, signals and
• Check operation.
switches • Adjust headlight beam. √√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6EAUM2070
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 change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
1C0-F8199-E3.qxd 10/1/07 18:13 Página 12

Check the tire condition and air
pressure before each ride.
1. Tire tread depth
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This motorcycle is equipped with
tubeless tires.
EWA10470
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
Front tire:
Size:
120/70-15 M/C 56S(Michelin)
120/70-15 M/C 56P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Pirelli/GTS23
Rear tire:
Size:
140/70-14 M/C 68S(Michelin)
140/70-14 M/C 68P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Pirelli/GTS24
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
1
ZAUM0054
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 23

EAU21960
Cast wheels
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpage
before each ride. If any damage
is found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or crac-
ked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAU33453
Front and rear brake lever
free play
Front
RearThere 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.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 24

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.
EAU22520
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. To check the brake pad wear,
check the position of the wear indica-
tor while applying the brake. If a bra-
ke pad has worn to the point that the
wear indicator almost touches the
brake disc, have a Yamaha dealer
replace the brake pads as a set.
EAU22580
Checking the brake fluid
level
Front brake
Rear brake
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.11
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 25

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.
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.
Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 26

EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
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.
EAU23171
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-pur-
pose grease)
Recommended lubricant:
Engine oil
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 27

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
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 29

EAU24240
Replacing a front turn signal
light bulb
1. Place the scooter on the centers-tand.
2. Remove cowling A. (See page 6-6.)
3. Remove the socket (together with the turn signal light bulb) by
turning it counterclockwise.
1. Turn signal light bulb socket
4. Remove the defective bulb bypushing it in and turning it coun-
terclockwise.
5. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
6. Install the socket (together with the bulb) by turning it clockwise.
7. Install the cowling.
EAUS1250
Replacing the tail/brake light
bulb or a rear turn signal
light bulb
Tail/brake light bulb
1. Remove the tail/brake light bulb lens by removing the screw.
2. Remove the defective bulb by pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screw. Rear turn signal light bulb
1. Remove the tail/brake light lens by removing the screw.
2. Remove the turn signal light bulb lens by removing the screw.
3. Remove the defective bulb by pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
5. Install the turn signal light bulb lens by installing the screw.
6. Install the tail/brake light bulb lens by installing the screw.
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
1C0-F8199-E3.qxd 4/11/06 09:44 Página 34