2012 YAMAHA XMAX 250 transmission

SAFETY INFORMATION .....................1-1
Further safe-riding points .................1-5
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments .................2-5
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-4
Turn signal indicator lights ...............3-4
High beam indicator light ................3-4
Engine trouble warning light ............3-4
ABS warning light
(for ABS models) ...........................3-4
Immobilizer system indicator light ....3-5
Speedometer ....................................3-5
Tachometer .......................................3-6
Multi-function display .......................3-6
Anti-theft alarm (optional) ...............3-11
Handlebar switches ........................3-11
Pass switch ....................................3-12
Dimmer switch ...............................3-12
Turn signal switch ..........................3-12
Horn switch ...................................3-12
Start switch ....................................3-12
Hazard switch ................................3-12
Front brake lever.............................3-12Rear brake lever..............................3-13
ABS (for ABS models) ....................3-13
Fuel tank cap ..................................3-14
Fuel .................................................3-15
Catalytic converters ........................3-16
Securing bracket ............................3-17
Seat.................................................3-17
Storage compartments ...................3-18
Adjusting the shock absorber
assemblies...................................3-19
Sidestand ........................................3-20
Ignition circuit cut-off system .........3-20
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 ..........5-3
Braking..............................................5-3
Tips for reducing fuel
consumption..................................5-4
Engine break-in.................................5-4
Parking ..............................................5-5
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................6-1
Owner’s tool kit .................................6-2Periodic maintenance chart for the
emission control system ...............6-3
General maintenance and lubrication
chart ..............................................6-4
Removing and installing the cowling
and panel.......................................6-8
Checking the spark plug ..................6-9
Engine oil ........................................6-10
Final transmission oil ......................6-12
Coolant ...........................................6-13
Air filter and V-belt case air filter
elements ......................................6-15
Adjusting the throttle cable free
play ..............................................6-16
Valve clearance ...............................6-17
Tires ................................................6-17
Cast wheels ....................................6-19
Checking the front and rear
brake lever free play ....................6-19
Checking the front and rear
brake pads ..................................6-20
Checking the brake fluid level ........6-21
Changing the brake fluid ................6-22
Checking and lubricating the
throttle grip and cable .................6-22
Lubricating the front and rear
brake levers .................................6-22
Checking and lubricating the
centerstand and sidestand .........6-23
Checking the front fork ...................6-24
Checking the steering.....................6-24
TABLE OF CONTENTS

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEM CHECKS PAGE

Fuel3-15


Engine oil 6-10

Final transmission oil 6-12

Coolant 6-13




Front brake 6-19, 6-20, 6-21

Front
RearEAU16820
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Avoid high engine speeds during
acceleration.
Avoid high engine speeds with no
load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cros-
sings).
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.
EAUS1810
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min. 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
6000 r/min.
OPERATION AND IMPORTANT RIDING POINTS
5-4
5

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)

19 *Cooling systemfor coolant leakage.333 33
Every 3 years
Final transmission 33 320
oil
33 3
21 *V-beltWhen the V-belt replacement indicator flashes
[every 20000 km (12000 mi)]
22 *Front and rear brake
switches33 3 3 3 3
23Moving parts and
cables333 33

Throttle grip
24 *housingif necessary.333 33
and cable
housing and cable.
25 *Lights, signals and
switches33 3 3 3 3

1. “OIL CHANGE” button
3. Release the “OIL CHANGE” but-
ton, and the oil change indicator
will go off.
TIP
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator must
be reset after the oil change for the
next periodic oil change to be indica-
ted at the correct time. To reset the oil
change indicator before the periodic
oil change interval has been reached,
follow the above procedure, but note
that the indicator will come on for 1.4
seconds after releasing the “OILCHANGE” button, otherwise repeat
the procedure.
EAU20065
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 its O-ring from the
final transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6

1. Final transmission oil filler cap
2. O-ring
6. Install the final transmission oil
drain bolt and its new gasket,
and then tighten the bolt to the
specified torque.
1. Final transmission oil drain bolt
7. Refill with the specified amount
of the recommended final trans-
mission oil. WARNING! Make
sure that no foreign material
enters the final transmission
case. Make sure that no oil
gets on the tire or wheel.
[EWA11311]
8. Install the final transmission oil
filler cap and its new O-ring, and
then tighten the oil filler cap.
9. 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.
EAUS1670
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.
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:

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6

Dimensions:Overall length:
2201 mm (86.7 in)
Overall width:
776 mm (30.6 in)
Overall height:
YP250R 1337 mm (52.6 in)
YP250RA 1337 mm (52.6 in)
YP250R Sport 1186 mm (46.7 in)
Seat height:
792 mm (31.2 in)
Wheelbase:
1545 mm (60.8 in)
Ground clearance:
135 mm (5.31 in)
Minimum turning radius:
1805 mm (71.1 in)
Weight:With oil and fuel:
YP250R 180 kg (397 lb)
YP250RA 184 kg (406 lb)
YP250R Sport 181.5 kg (400 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
249 cm
3
Bore x stroke:
69.0 x 66.8 mm (2.72 x 2.63 in)
Compression ratio:
10.00 :1
Starting system:
Electric starterLubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade:
API service SF, SG type or higher, JASO
standard MA
Engine oil quantity:Periodic oil change:
1.30 L (1.37 US qt, 1.14 Imp.qt)
Final transmission oil:Type:
YAMALUBE 10W-40 or 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):
0.25 L (0.26 US qt, 0.22 Imp.qt)Radiator capacity (including all routes):
1.00 L (1.06 US qt, 0.88 Imp.qt)
Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
11.8 L (3.12 US gal, 2.60 Imp.gal)
Fuel reserve amount:
2.0 L (0.53 US gal, 0.44 Imp.gal)
Spark plug(s):Manufacturer/model:
NGK/DPR8EA-9
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
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40
SAE 20W-40
SAE 20W-50
SAE 10W-40
SAE 10W-50
SPECIFICATIONS
8-1
8

Secondary reduction ratio:
40/14 (2.857)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:Frame type:
Steel tube underbone
Caster angle:
28.00 º
Trail:
100.0 mm (3.94 in)
Front tire:Type:
Tubeless
Size:
120/70-15 M/C 56P(PIRELLI-METZE-
LER)-56S(MICHELIN)
Manufacturer/model:
PIRELLI / GTS23
MICHELIN / GOLD STANDARD
MICHELIN / CITYGRIP
METZELER / FEELFREE
Rear tire:Type:
Tubeless
Size:
140/70-14 M/C 68P(PIRELLI-METZE-
LER)-68S(MICHELIN)
Manufacturer/model:
PIRELLI / GTS24
MICHELIN / GOLD STANDARD
MICHELIN / CITYGRIPMETZELER / FEELFREE
Loading:Maximum load:
YP250R 175 kg (386 lb)
YP250RA 171 kg (377 lb)
YP250R Sport 173.5 kg (383 lb)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
190 kPa (1.90 kgf/cm
2, 28 psi, 1.90 bar)
Rear:
220 kPa (2.20 kgf/cm
2, 32 psi, 2.20 bar)
Loading condition:
90 kg - maximum load
Front:
210 kPa (2.10 kgf/cm
2, 30 psi, 2.10 bar)
Rear:
250 kPa (2.50 kgf/cm
2, 36 psi, 2.50 bar)
Front wheel:Wheel type:
Cast wheel
Rim size:
15 x MT3.5
Rear wheel:Wheel type:
Cast wheel
Rim size:
14 x MT3.75
Front brake:Type:
Single disc brakeOperation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)
Rear suspension:Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
95.0 mm (3.74 in)
Electrical system:Ignition system:
TCI
Charging system:
AC magneto
Battery:Model:
GTX9-BS
SPECIFICATIONS
8-2
8