2007 YAMAHA XMAX 250 check engine

1. Air filter element
3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case.
5. Install the air filter case cover by
installing the screws.
Cleaning the V-belt case air filter
element
1. Screws1. Screws
1. Remove the V-belt case air filter
cover by removing the screws.
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.
3. Check the air filter element for
damage and replace it if neces-
sary.4. Install the air filter element with
the colored side facing outward.
5. Install the V-belt case air filter
cover by installing the screws.
ECA10530
CAUTION:
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
1
1
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 20

EAUS1290
Adjusting the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 3~5 mm (0.12~0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Remove cowling A (See page 6-6).
2. Loosen the locknut.3. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
4. Tighten the locknut.
5. Install the cowling.
EAU21401
Valve clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clearan-
ce must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
b
a
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
1C0-F8199-E3.qxd 2/11/06 20:46 Página 21

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

EAU42130
Troubleshooting charts
Starting problems or poor engine performanceEWA10840
s s
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
We tOperate the electric starter.
1C0-F8199-E3.qxd 2/11/06 20:46 Página 37

Engine overheatingEWA10400
s s
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
1C0-F8199-E3.qxd 2/11/06 20:46 Página 38

3. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap and
spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit sparking
during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from
the spark plug, and then install
the spark plug and the spark plug
cap.
EWA10950
s s
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alter-
natively, turn the wheels a little
every month in order to prevent
the tires from becoming degra-
ded in one spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery in
an excessively cold or warm pla-
ce [less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more
information on storing the bat-
tery, see page 6-24.
NOTE:
Make any necessary repairs before
storing the scooter.
SCOOTER CARE AND STORAGE
7-4
7
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AAcceleration and deceleration ...................5-2
Air filter and V-belt case air filter
elements ................................................6-12
Anti-theft alarm (optional) ..........................3-8
Auxiliary light bulb, replacing ...................6-28
BBattery......................................................6-23
Brake fluid level, checking .......................6-18
Brake fluid, changing ...............................6-19
Brake lever, front ......................................3-10
Brake lever, rear .......................................3-10
Brake levers, lubricating ..........................6-20
Braking .......................................................5-3
CCables, checking and lubricating ............6-20
Care............................................................7-1
Catalytic converter ...................................3-13
Centerstand and sidestand, checking
and lubricating .......................................6-21
Coolant.....................................................6-11
Coolant temperature gauge .......................3-5
Cowlings and panel, removing and
installing ...................................................6-6
DDimmer switch ...........................................3-9
Display, multi-function ...............................3-5
EEngine break-in ..........................................5-4
Engine oil ...................................................6-8
Engine trouble warning light ......................3-3
FFinal transmission oil ...............................6-10
Front and rear brake lever free play.........6-17
Front and rear brake pads, checking ......6-18Front fork, checking .................................6-21
Fuel ..........................................................3-12
Fuel consumption, tips for reducing ..........5-3
Fuel gauge .................................................3-4
Fuel level warning light ..............................3-3
Fuel tank cap ...........................................3-11
Fuses, replacing .......................................6-24
HHandlebar switches ...................................3-9
Hazard switch ............................................3-9
Headlight bulb, replacing .........................6-25
High beam indicator light...........................3-3
Horn switch ................................................3-9
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-18
Immobilizer system ....................................3-1
Immobilizer system indicator light .............3-4
Indicator and warning lights ......................3-3
KKey identification number ..........................9-1
LLicense plate light bulb, replacing ...........6-28
MMain switch/steering lock ..........................3-2
Matte color, caution ...................................7-1
Model label ................................................9-2
PParking .......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart .........................................................6-3
Pre-operation check list .............................4-2
SSafe-riding points.......................................1-4Safety information ......................................1-1
Seat ..........................................................3-13
Shock absorber assemblies, adjusting....3-17
Sidestand .................................................3-17
Spark plug, checking .................................6-7
Specifications.............................................8-1
Speedometer .............................................3-4
Start switch ................................................3-9
Starting a cold engine ................................5-1
Starting off .................................................5-2
Steering, checking ...................................6-22
Storage.......................................................7-3
Storage compartment (front) ...................3-15
Storage compartment (rear) .....................3-16
Storage compartments ............................3-14
TTail/brake light bulb or rear turn signal
light bulb, replacing ...............................6-27
Throttle cable free play, adjusting ............6-14
Throttle grip and cable, checking and
lubricating ..............................................6-20
Tires .........................................................6-15
Tool kit ........................................................6-1
Troubleshooting .......................................6-29
Troubleshooting charts ............................6-30
Turn signal indicator lights .........................3-3
Turn signal light bulb (front), replacing ....6-27
Turn signal switch ......................................3-9
VValve clearance ........................................6-14
Vehicle identification number .....................9-1
WWheel bearings, checking........................6-23
Wheels .....................................................6-17
INDEX
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