2009 YAMAHA XMAX 250 transmission

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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EAU10410
Left view
DESCRIPTION
2-1
2
1. Fuel tank cap (page 3-11)
2. Owner’s tool kit (page 6-1)
3. V-belt case air filter element (page 6-13)
4. Rear storage compartment (page 3-17)
5. Air filter case (page 6-13)
6. Shock absorber assembly spring preload adjusting ring (page 3-18)
7. Transmission oil filler cap (page 6-11)
8. Engine oil drain bolt (page 6-9)9. Sidestand (page 6-22)
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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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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.
EAUM2011
0–1000 km (0–600 mi)
●Avoid prolonged operation above
1/3 throttle. NOTICE:After 1000
km (600 mi) of operation, be
sure to replace the engine oil
and final transmission oil.
[ECA11661]
1000–1600 km (600–1000 mi)
●Avoid prolonged operation above
1/2 throttle.
1600 km (1000 mi) and beyond
●The vehicle can now be operated
normally.
ECA10270
NOTICE
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
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 and be burned.
●Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
●Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
5-4
5
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
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)
17 *Front fork• Check operation and for oil
leakage.√√√ √
18 *Shock absorber • Check operation and shock
assembliesabsorbers for oil leakage.√√√ √
19 *Fuel injection• Check engine idle speed.√√ √√ √ √
20Engine oil• Change. (See page 6-9). √When the oil change indicator light comes
on [every 3000 km (1800 mi)]
• Check oil level and vehicle
for oil leakage.Every 3000 km (1800 mi)√
21 *Engine oil strainer• Clean.√
• Check coolant level and vehicle
22 *Cooling systemfor coolant leakage.√√√ √√
• Change. Every 3 years
23Final transmission • Check vehicle for oil leakage.√√ √oil
• Change.√√√
24 *V-belt• Replace. Every 20000 km (12000 mi)
25 *Front and rear brake
switches• Check operation.√√ √√ √ √
26Moving parts
and cables• Lubricate.√√√ √√
• Check operation and free play.
Throttle grip • Adjust the throttle cable free
27 *housingplay if necessary.√√√ √√
and cable• Lubricate the throttle grip
housing and cable.
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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 3-6). EAU20064
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.
4. Remove the final transmission oil
filler cap and final transmission
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil filler cap
2. O-ring
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf, 15.9 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
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6. Refill with the specified amount
of the recommended final trans-
mission oil, and then install and
tighten the oil filler cap. WAR-
NING! Make sure that no
foreign material enters the final
transmission case. Make sure
that no oil gets on the tire or
wheel.
[EWA11311]
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.
EAUS1274
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
TIP
●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.
TIP
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. Coolant level check window
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. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA15161]. NOTICE: If coolant
is not available, use distilled
water or soft tap water instead.
FULL
LOW
Recommended final transmission
oil:
See page 8-1
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 54

Dimensions:Overall length:
2210 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 mm (4.44 in)
Minimum turning radius:
3650 mm (143.7 in)
Weight:With oil and fuel:
176.0 kg (388 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
249.7 cm
3
Bore x stroke:
69.0 x 66.8 mm (2.72 x 2.63 in)
Compression ratio:
10.10 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
Engine oil quantity:Periodic oil change:
1.20 L (1.27 US qt, 1.06 Imp.qt)
Final transmission oil:Type:
SAE 10W-30 type SE motor oil
Quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Cooling system:Coolant reservoir capacity (up to the maxi-
mum level mark):
0.26 L (0.27 US qt, 0.23 Imp.qt)
Radiator capacity (including all routes):
1.40 L (1.48 US qt, 1.23 Imp.qt)
Air filter:Air filter element:
Dry element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
12.5 L (3.30 US gal, 2.75 Imp.gal)
Throttle body:Type/quantity:
EFI 1C04 / 1
Manufacturer:
AISAN
Spark plug (s):Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Clutch:Clutch type:
Dry, centrifugal automatic
Transmission:Primary reduction system:
Helical gear
Primary reduction ratio:
40/15 (2.666)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
40/14 (2857)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
SPECIFICATIONS
8-1
8
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