2007 YAMAHA XMAX 250 transmission oil

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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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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EAU16841
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1600 km
(1000 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clea-
rances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAU17050
0~1000 km (0~600 mi)
Avoid prolonged operation above 1/3
throttle.
1000~1600 km (600~1000 mi)
Avoid prolonged operation above 1/2
throttle.
ECA11660
CAUTION:
After 1000 km (600 mi) of operation,
be sure to replace the engine oil
and final transmission oil.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA11650
CAUTION:
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
s s
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
OPERATION AND IMPORTANT RIDING POINTS
5-4
5
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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.
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ECA11670
CAUTION:
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSER-
VING II” or higher.
Be sure no foreign material
enters the crankcase.
7. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the cau-
se.
8. Reset the oil change indicator.
(See page 3-8.)
EAU20061
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final trans-
mission oil must be changed as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm up the
final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
1. Final transmission oil filler cap
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil drain bolt
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
Recommended engine oil:
See page 8-1.
Oil change quantity:
1.2 L (1.27 US qt) (1.06 Imp.qt)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
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6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUS1272
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Check the coolant level through
the check window.
1. Maximum level mark
2. Minimum level mark
3. Coolant level window
NOTE:
The coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m•kgf, 15.9 ft•lbf)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
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DimensionsOverall length2210 mm (87.0 in)
Overall width 790 mm (31.1 in)
Overall height 1380 mm (54.3 in)
Seat height 785 mm (30.9 in)
Wheelbase 1545 mm (60.8 in)
Ground clearance 112.7 mm (4.44 in)
Minimum turning radius 3650 mm (143.7 in)
WeightWith oil and fuel176 kg (388 lb)
EngineEngine typeLiquid cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 249.7 cm
3(15.24 cu*in)
Bore x stroke 69.0 x 66.8 mm (2.71 x 2.63 in)
Compression ratio 10:01
Starting system Electric starter
Lubrication system Wet sump
Oil type or gradeEngine oilSAE 10W30
Recommended engine oil grade API service SE, SF, SG type or higher
Engine oil quantityPeriodic oil change1.2 L (1.27 US qt) (1.06 Imp qt)
Final transmission oilTypeYAMALUBE 4 (10W30) of SAE10W30
type SE motorolie
Quantity 0.25 L (0.26 US qt) (0.22 Imp qt)
Cooling systemRadiator capacity (including all routes)0.34 L (0.36 US qt) (0.30 Imp qt)
Coolant reservoir capacity (up to the
maximum level mark) 0.26 L (0.23 Imp qt, 0.28 US qt)
Air filterAir filter elementDry element
Recommended fuelRecommended fuelUnleaded fuel
Fuel tank capacity 12.5 L (3.30 US gal) (2.75 Imp gal)
Fuel reserve amount 2 L (0.53 US gal) (0.44 Imp gal)
Fuel injectionManufacturerAISAN Type x quantity
EFI System x 1
Spark plug (s)Manufacturer/modelNGK/DPR8EA-9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)
ClutchClutch typeDry, automatic centrifugal
TransmissionPrimary reduction systemHelical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction system Helical gear
Secondary reduction ratio 40/14 (2.857)
Transmission type V-belt automatic
Operation Centrifugal automatic type
ChassisFrame typeSteel tube underbone
Caster angle 28 º
Trail 100 mm (3.94 in)
Front tireTypeTubeless
SPECIFICATIONS
8-1
8
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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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