2007 YAMAHA XMAX 250 brake pads

INTRODUCTION
IMPORTANT MANUAL INFORMATION
TABLE OF CONTENTS
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
Indicator and warning lights .............3-3
Speedometer ....................................3-4
Fuel gauge ........................................3-4
Coolant temperature gauge..............3-5
Multi-function display .......................3-5
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
Storage compartments ...................3-14Front storage compartment............3-15
Rear storage compartment.............3-16
Adjusting the shock absorber
assemblies...................................3-17
Sidestand ........................................3-17
Ignition circuit cut-off system .........3-18
PRE-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..............................................5-3
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-4
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 the
cowlings and panel .......................6-6
Checking the spark plug ..................6-7
Engine oil ..........................................6-8
Final transmission oil ......................6-10
Coolant ...........................................6-11Air filter and V-belt case air filter
elements ......................................6-12
Adjusting the throttle cable free
play ..............................................6-14
Valve clearance ...............................6-14
Tires ................................................6-15
Cast wheels ....................................6-17
Front and rear brake lever free
play ..............................................6-17
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-18
Changing the brake fluid ................6-19
Checking and lubricating the
cables ..........................................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 .........6-23
Battery ............................................6-23
Replacing the fuses ........................6-24
Replacing a headlight bulb .............6-25
Replacing a front turn signal light
bulb .............................................6-27
Replacing the tail/brake light bulb or a
rear turn signal light bulb ............6-27
TABLE OF CONTENTS
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• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
scooter in an area that has ade-
quate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the
main switch. When parking the
scooter, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,
park the scooter in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the scooter on a
slope or soft ground, otherwise
it may fall over.
• Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.EAU10371
Further safe-riding points
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard bra-
king, because the scooter could
slide. Apply the brakes slowly
when stopping on a wet surface.
Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Slow down and
cross them with caution. Keep
the scooter upright, otherwise it
could slide out from under you.
The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
1
SAFETY INFORMATION
1-4
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EAU10420
Right view
DESCRIPTION
2-2
2
12
34
5
6
789 11101213
1. Rear turn signal light (page 6-27)
2. Grab bar
3. Seat (page 3-13)
4. Battery (page 6-23)
5. Front turn signal light (page 6-27)
6. Fuses (page 6-24)
7. Front brake pads (page 6-18)8. Radiator
9. Coolant level window (page 6-11)
10. Coolant reservoir cap (page 6-11)
11. Passenger footrest
12. Engine oil filler cap (page 6-8)
13. Rear brake pads (page 6-18)
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EAU15605
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-4, 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 ~ 6-19
• 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 ~ 6-19
• 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.
5-2, 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, 6-23
• Check air pressure.
• Correct if necessary.
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EAU17706
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.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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.
2 Spark plug • Clean and regap. √√• Replace.
√√
3* Valves • Check valve clearance.
• Adjust. √√
4
Air filter element • Replace. √√
5 V-belt case air filter
element • Clean.
√√√√
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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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
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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
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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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