2009 YAMAHA XMAX 250 brake pads

SAFETY INFORMATION .....................1-1
Further safe-riding points .................1-1
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
Turn signal indicator lights ...............3-3
High beam indicator light ................3-3
Fuel level warning light ....................3-4
Engine trouble warning light ............3-4
Immobilizer system indicator light ....3-4
Speedometer ....................................3-5
Fuel gauge ........................................3-5
Coolant temperature gauge..............3-5
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Dimmer switch .................................3-9
Turn signal switch ............................3-9
Horn switch .....................................3-9
Start switch ......................................3-9
Hazard switch , ..............................3-10
Front brake lever.............................3-10
Rear brake lever..............................3-10Fuel tank cap ..................................3-11
Fuel .................................................3-12
Catalytic converter..........................3-13
Securing bracket ............................3-14
Seat.................................................3-14
Storage compartments ...................3-15
Storage compartment.....................3-16
Rear storage compartment.............3-17
Adjusting the shock absorber
assemblies...................................3-18
Sidestand ........................................3-18
Ignition circuit cut-off system .........3-19
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ...............4-1
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
ADJUSTMENT ....................................6-1
Owner’s tool kit .................................6-1Periodic maintenance and
lubrication chart ............................6-2
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 ...............................6-15
Tires ................................................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
throttle 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
TABLE OF CONTENTS
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EAU10372
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.
●Always wear a helmet, gloves,
trousers (tapered around the cuff
and ankle so they do not flap),
and a bright colored jacket.
●Do not carry too much luggage
on the scooter. An overloaded
scooter is unstable. Use a strong
cord to secure any luggage to the
carrier (if equipped). A loose load
will affect the stability of the sco-
oter and could divert your atten-
tion from the road. (See page
1-1).
1
SAFETY INFORMATION
1-5
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EAU10420
Right view
DESCRIPTION
2-2
2
1. Grab bar (page 5-2)
2. Seat (page 3-14)
3. Battery (page 6-24)
4. Fuses (page 6-26)
5. Front brake pads (page 6-19)
6. Coolant level check window (page 6-12)
7. Passenger footrest
8. Centerstand (page 6-22)9. Engine oil filler cap (page 6-9)
10. Rear brake pads (page 6-19)
1C0-F8199-E5.QXD 3/10/08 05:56 Página 14

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.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 lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-19
• Replace if necessary.
• 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. 6-18, 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.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable 6-15, 6-21
and grip housing.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU1770A
Periodic maintenance and lubrication chart
TIP
●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.
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM 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 and vacuum hoses
for cracks or damage.√√√ √√
• Check condition.
2Spark plug• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4Air filter element• Replace.√√
5V-belt case air filter
element• Clean.√√√ √
• Check operation, fluid level and
6*Front brakevehicle for fluid leakage.√√ √√ √ √
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM 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
7*Rear brakeand vehicle for fluid leakage.√√ √√ √ √
• Replace brake pads. Whenever worn to the limit
8*Brake hoses• 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.√√√ √
• Check bearing play and
12 *Steering bearingssteering 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.√√√ √√
14Front brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
15Rear brake lever
pivot shaft• Lubricate with silicone grease.√√√ √√
16Sidestand, • Check operation.
centerstand• Lubricate.√√√ √√
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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 thickness
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.
EAU22460
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
1. Minimum level mark
Rear brake
1. Minimum level mark
PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
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Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
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.
EAU22721
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
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 ADJUSTMENT
6-20
6
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