2008 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
Indicator and warning lights .............3-3
Self-diagnosis device .......................3-3
Speedometer ....................................3-4
Fuel gauge ........................................3-5
Coolant temperature gauge..............3-5
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Front brake lever.............................3-10
Rear brake lever..............................3-10
Fuel tank cap ..................................3-11
Fuel .................................................3-12
Catalytic converters ........................3-13
Seat.................................................3-13
Storage compartments ...................3-14
Front storage compartment............3-15
Rear storage compartment.............3-16
Adjusting the shock absorber
assemblies...................................3-17
Sidestand ........................................3-17Ignition 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 the 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 ..................6-8
Engine oil ..........................................6-9
Final transmission oil ......................6-11
Coolant ...........................................6-12
Air filter and V-belt case air filter
elements ......................................6-13
Adjusting the throttle cable free
play ..............................................6-15
Valve clearance ...............................6-15Tires ................................................6-16
Cast wheels ....................................6-18
Front and rear brake lever free
play ..............................................6-18
Checking the front and rear brake
pads.............................................6-19
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Checking and lubricating the
cables ..........................................6-21
Checking and lubricating the t
hrottle grip and cable ..................6-21
Lubricating the front and rear
brake levers .................................6-21
Checking and lubricating the
centerstand and sidestand .........6-22
Checking the front fork ...................6-22
Checking the steering.....................6-23
Checking the wheel bearings .........6-24
Battery ............................................6-24
Replacing the fuses ........................6-25
Replacing a headlight bulb .............6-27
Replacing a front turn signal light
bulb .............................................6-28
Replacing a tail/brake light bulb
or a rear turn signal light bulb .....6-28
Replacing the license plate light
bulb .............................................6-30
Replacing an auxiliary light bulb.....6-30
Troubleshooting ..............................6-30
Troubleshooting charts ...................6-31
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. 3-11, 3-12
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-9
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-11
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-12
• 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, 6-18~6-21
• 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, 6-18~6-21
• 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, 6-15, 6-21
• 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.
6-16~6-18
• Check air pressure.
• Correct if necessary.
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EAU1770A
Periodic maintenance and lubrication chart
NOTE:
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK,
a mileage-based maintenance, is performed instead.
●From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●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
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
Spark plug• Check condition.
2 • Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4Air filter element• Replace.√√
5V-belt case air filter
• Clean.√√√√
element
• Check operation, fluid level and vehicle for fluid
√√√√√ √
6*Front brakeleakage.
• Replace brake pads. Whenever worn to the limit
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check operation, fluid level and vehicle for fluid
√√√√√ √7*Rear brakeleakage.
• Replace brake pads. Whenever worn to the limit
8*Brake hose• Check for cracks or damage.√√√√ √• Replace. Every 4 years
9*Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
10 *Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
11 *Wheel bearings• Check bearing for looseness or damage.√√√√
12 *Steering bearings• Check bearing play and steering for roughness.√√√√√• Lubricate with lithium-soap-based grease. Every 20000 km (12000 mi)
13 *Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.√√√√ √
14Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
15 *Sidestand switch• Check operation.√√√√√ √
16 *Front fork• Check operation and for oil leakage.√√√√
17 *Shock absorber
• Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
19 *Fuel injection• Check engine idle speed.√√√√√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Change. (See page 6-9.)√When the oil change indicator light 20Engine oilcomes on (every 3000 km (1800 mi))
• Check oil level and vehicle for oil leakage. Every 3000 km (1800 mi)√
21 *Engine oil strainer• Clean.√
22Final transmission oil• Check vehicle for oil leakage.√√ √• Change.√√√
23 *V-belt• Replace. Every 20000 km (12000 mi)
24 *Front and rear brake
• Check operation.√√√√√ √
switches
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 • Check operation.
and switches• Adjust headlight beam.√√√√√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18670
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 cylinders and calipers, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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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 dea-
ler 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
1. Minimun level mark
1. Minimun level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
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 reservoirwhen 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
6-20
6
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cleaning products, solvent or
thinner, 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.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas. Stub-
born dirt and insects will come off
more easily if the area is covered with
a wet cloth for a few minutes before
cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it
increases the corrosive action of
the salt.
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces to prevent corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally indu-
ced discoloring of stainless-steel
exhaust systems can be removed
through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, inclu-
ding chrome- and nickel-plated,
surfaces.
4. Use spray oil as a universal clea-
ner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
SCOOTER CARE AND STORAGE
7-2
7
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