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Yamaha XMAX 250 YP250R Owner'S Manual Download Page 58

Engine overheating

EWA10400

s

s

WARNING

●

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

●

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.

1C0-F8199-E0.qxd  13/04/2005 16:58  Página 58

Summary of Contents for XMAX 250 YP250R

Page 1: ...1C0 F8199 E1 YP250R OWNER S MANUAL 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 1 ...

Page 2: ...1C0 F8199 E0 qxd 13 04 2005 16 58 Página 2 ...

Page 3: ...joy all advantages of your YP250 The owner s manual does not only instruct you in how to operate inspect and maintain your scooter but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha...

Page 4: ... product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your scooter and this manual If you have any questions concerning this manual please consult your Yamaha dealer EWA12410 s s WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER s s WARNING...

Page 5: ...MANUAL 2005 by YAMAHA MOTOR SPAIN S A 1st edition May 2005 All rights reserved Any reprinting or unauthorized use without the written permission of YAMAHA MOTOR SPAIN S A is expressly prohibited Printed in Spain 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 3 ...

Page 6: ...ing the spark plug 6 5 Engine oil 6 7 Final transmission oil 6 8 Coolant 6 9 Air filter V Belt case air filter elements 6 10 Adjusting the carburetor 6 11 Adjusting the throttle cable free play 6 12 Valve clearance 6 12 Tires 6 12 Cast wheels 6 14 Front and rear brake lever free play 6 14 Checking the front and rear brake pads 6 14 Checking the brake fluid level 6 15 Changing the brake fluid 6 16 ...

Page 7: ... this type of accident Therefore Wear a brightly colored jacket Use extra caution when appro aching and passing through intersections since intersec tions are the most likely places for scooter accidents to occur Ride where other motorists can see you Avoid riding in anot her motorist s blind spot Many accidents involve inexpe rienced operators In fact many operators who have been invol ved in acc...

Page 8: ...Never wear loose fitting clothes otherwise they could catch on the control levers or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet Passengers should also observe the above precautions Modifications Modifications made to this scoo...

Page 9: ... the accessory befo re using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension tra vel steering travel or control ope ration or obscure lights or reflec tors Accessories fitted to the hand lebar or the front fork area can create instability due to impro per weight distribution or aerodynamic changes If accessories are added to the handlebar...

Page 10: ...an open flame otherwise it could catch fire If you should swallow any gasoli ne inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immedia tely If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clot hes EAU10371 Further safe riding points Be sure to signal clearly when making turns Braking can ...

Page 11: ...ers 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 1 SAFETY INFORMATION t 1 5 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 11 ...

Page 12: ...Left view DESCRIPTION 2 1 2 1 2 3 4 5 1 Storage compartment page 3 11 2 Spring preload page 3 11 3 Air filter page 6 10 4 V Belt filter page 6 10 5 Sidestand page 3 12 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 12 ...

Page 13: ...e 6 14 7 Grab bar 8 Fuel cap page 3 8 9 Battery page 6 18 10 Fuse box and main fuse page 6 19 11 Front brake pads page 6 14 12 Coolant reservoir cap page 6 9 13 Coolant level window page 6 9 14 Centerstand page 6 16 15 Oil filler cap page 6 7 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 13 ...

Page 14: ...rake lever page 3 8 17 Left handlebar switches page 3 7 18 Speedometer and multi function panel page 3 4 19 Storage compartment page 3 11 20 Main switch page 3 1 21 Right handlebar switch page 3 7 22 Throttle grip page 6 12 23 Front brake lever page 3 8 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 14 ...

Page 15: ...n the standard keys is impossible The stan dard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key and keep the code re registering key in a safe place Do not submerse any key in water Do not expose a...

Page 16: ...ve the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EWA10060 s s WARNING Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehi cle is stopped before turning the key to OFF or LOCK EAU33461 Indicators indicator lights a...

Page 17: ... system is still enabled This model is also equipped with a self diagnosis device for the immobi lizer system EAU11591 Speedometer 1 Fuel level gauge 2 High bearn indicator light 3 Left turning signal light 4 Right turning signal light 5 Coolant temperature gauge The speedometer shows the riding speed EAU12110 Fuel gauge 1 Fuel gauge 2 Fuel warning light The fuel gauge indicates the amount of fuel...

Page 18: ... traveled two tripmeters which show the distance traveled since they were last set to zero the time passed since the tripmeters were set to zero and the average speed tra veled during this time a fuel reserve tripmeter which shows the distance traveled sin ce the fuel level warning light came on a clock an ambient temperature display a service indicator which is dis played when periodic maintenan ...

Page 19: ...ipmeter mode Trip fuel and start counting the distance traveled from that point In that case pushing the SET button switches the display between the various tripmeter and odometer modes in the following order Trip Fuel Trip 1 Trip 2 Total Trip fuel To reset a tripmeter select it by pus hing the MODE button and then push the SET button for at least one second If you do not reset the fuel reserve tr...

Page 20: ...periodic maintenance and lubri cation is necessary See page 6 3 OIL will appear in the display until the Service indicator reset is made To reset the service indicator 1 Turn the key to ON 2 Hold the MODE and SET but ton pushed for two to five seconds 3 Release the buttons and the ser vice indicator will go off NOTE The service indicator will come on at the initial 1000 km and every 3000 km therea...

Page 21: ...nd turn push this switch to c When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position EAU12500 Horn switch a Press this switch to sound the horn EAUM1131 Start switch g 1 Starting switch 2 Hazard switch Push this switch while applying the front or rear brake to crank the engine with the starter ECA1005...

Page 22: ...TION Do not use the hazard light for an extended length of time otherwise the battery may discharge EAU12900 Front brake lever 1 Front brake lever The front brake lever is located on the right handlebar grip To apply the front brake pull this lever toward the handlebar grip EAU12950 Rear brake lever 1 Rear brake lever The rear brake lever is located on the left handlebar grip To apply the rear bra...

Page 23: ... Filler tube 2 Fuel level EWA10990 s s WARNING Since gasoline is flammable the following precautions must be observed Stop the engine before refue ling Never attempt to refuel the scooter while smoking or near an open flame Take special care not to spill gasoline over the engine or muffler when refueling imme diately after operation Before starting the engine quickly wipe off any gasoline spilled ...

Page 24: ...e doing any maintenance work ECA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near possible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU13931 Seat To...

Page 25: ...ocated under the seat See page 3 10 EWA10961 s s WARNING Do not exceed the load limit of 5kg 11 02 lb for the storage compartment Do not exceed the maximum load of 235kg 518 17lb for the vehicle When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water e...

Page 26: ...ight 1 Sidestand switch 2 Sidestand NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system EWA10240 s s WARNING The vehicle must not be ridden with the sidestand down or if the sides tand cannot be properly moved up or does not stay up otherwise the si...

Page 27: ...3 INSTRUMENT AND CONTROL FUNCTIONS 3 13 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 3 13 ...

Page 28: ...sequences Therefore it is very important in addition to a thorough visual inspection to check the follo wing points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accom plished in a very short time and the added safety it assures is more than worth the time involved EWA11150 s s WARNING If any item in the Pre operation check list i...

Page 29: ...stem Check brake pads for wear Front brake Replace if necessary 3 8 6 14 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 8 6 14 Check fluid level in reservoir If necessary add recommende...

Page 30: ...essary Centerstand sidestand Make sure that operation is smooth 3 12 6 16 Lubricate pivots if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals Check operation and switches Correct if necessary Sidestand switch Check operation of ignition circuit cut off system 3 12 If system is defective have Yamaha dealer c...

Page 31: ...rom the rear wheel EAUM1210 Starting a cold engine ECA10250 CAUTION See page 5 3 for engine break in instructions prior to operating the vehicle for the first time 1 Turn the key to f 2 Close the throttle completely 3 Start the engine by pushing the start switch while applying the front or rear brake NOTE If the engine fails to start release the start switch wait a few seconds and then try again E...

Page 32: ...ING Avoid braking hard or suddenly especially when leaning over to one side otherwise the sco oter may skid or overturn Railroad crossings streetcar rails iron plates on road cons truction sites and manhole covers become extremely slip pery when wet Therefore slow down when approaching such areas and cross them with cau tion Keep in mind that braking on a wet road is much more difficult Ride slowl...

Page 33: ... 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 ECA10270 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17212 Parking When parking stop the engine and then remove the ke...

Page 34: ...uddy or wet conditions the air fil ter element should be cleaned or replaced more frequently otherwi se rapid engine wear may result Consult a Yamaha dealer for proper maintenance intervals EAU17380 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located under the seat See page 3 10 The service information included in this manual and the tools provided in the owner s tool kit are inten...

Page 35: ...R 6 2 ODOMETER READING x 1000 Km ANNUAL CHECK No ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40 1 Fuel line Check fuel and vacuum hoses for cracks or damage Check condition 2 Spark plug Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 V belt case air Clean filter elements Replace 6 Front brake Check operation fluid level and vehicle for fluid leakage Replac...

Page 36: ...ners Make sure that all nuts bolts and screws are properly tightened 14 Sidestand 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 Carburetor Adjust engine idling speed Change See page 3 6 When the oil change 19 Engine oil indicator light co...

Page 37: ...using and cable 27 Muffler and exhaust pipe Check the screw clamp for looseness 28 Lights signals Check operation and switches Adjust headlight beam 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 4 EAU18660 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 yea...

Page 38: ...w and then take the panel off To install the panel 1 Place the panel in the original position and then install the screw 2 Close the storage compartment EAUS1280 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic ...

Page 39: ... install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to spe cification 2 Clean the surface of the spark plug gasket and its mating surfa ce and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque NOTE If a torque wrench is not available when in...

Page 40: ...oil filler cap wipe the dipstick clean insert it back into the oil filler hole wit hout screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to rai se it to the correct level 5 Insert the dipstick into the oil filler hol...

Page 41: ...h 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 it up by riding the scooter for several minutes and then stop the engi ne 2 Place the scooter on the centers tand 3 Place an oil pan under the final tr...

Page 42: ... level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature 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 1 Maximum level 2 Minimum level 2 Check the coolant level through the che...

Page 43: ...ove the radia tor cap when the engine is hot 5 Close the reservoir cap 6 Place the floorboard mat in the original position and push it downward to secure it EAU33030 Changing the coolant EWA10380 s s WARNING Never attempt to remove the radia tor cap when the engine is hot The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer c...

Page 44: ...sary 4 Install the air filter element with the colored side facing outward 5 Install the V belt case air filter cover by installing the screws ECA10530 CAUTION Make sure that each filter ele ment is properly seated in its case The engine should never be operated without the filter ele ments installed otherwise the piston s and or cylinder s may become excessively worn EAU21300 Adjusting the carbur...

Page 45: ...e free play turn the adjusting nut in direction b 4 Tighten the locknut 5 Install the cowling EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mix ture and or engine noise To prevent this from occurring the valve clearan ce must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU21870 Tires To m...

Page 46: ... the heaviest items close to the center of the vehicle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride 1 Tire tread depth Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragmen...

Page 47: ...eformed or crac ked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse handling characteristics and a shortened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characte ristics EAU33451 Front...

Page 48: ...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 ...

Page 49: ...or whenever it is damaged or leaking EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubri cated at the intervals specified in the periodic maintenance chart EAU23170 Lubricating the front and rear brake levers The pivoting points of the front and rear brake levers must be lubricated...

Page 50: ...andle bars several times to check if the front fork compresses and rebounds smoothly ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steering must be checked as follows at the intervals specified in the periodic ...

Page 51: ...atteries In case of contact administer the following FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and immediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hydrogen gas Therefore keep sparks flames cigarettes etc away from the battery and provi de sufficient ventilation when...

Page 52: ...in fuse and the fuse box which contains the fuses for the indi vidual circuits are located behind cowling B See page 6 5 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage ECA10640 CAUTION Do not use a fuse of a higher ampe rage rating than recommended to avoid ...

Page 53: ...illustration and then remove the defective bulb 1 Headlight bulb cover NOTE The removal procedure depends on the type of bulb holder installed on your vehicle EWA10790 s s WARNING Headlight bulbs get very hot The refore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new bulb into position and then secure it with the bulb holder E...

Page 54: ...e the defective bulb by pushing it in and turning it coun terclockwise 5 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the cowling EAUS1250 Replacing the tail brake light bulb or a rear turn signal light bulb Tail brake light bulb 1 Remove the tail brake light bulb lens by removi...

Page 55: ... overtighten the screws otherwise the lens may break EAUS1150 Replacing the license plate light bulb 1 Remove the lens by removing the screw 2 Remove the defective bulb by pulling it out 3 Insert a new bulb into the socket 4 Install the lens by installing the screw ECA11190 CAUTION Do not overtighten the screw otherwise the lens may break EAUS1260 Replacing the auxiliary light bulb If the auxiliar...

Page 56: ...f power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your scooter require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the scooter properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they ...

Page 57: ...arting problems or poor engine performance EWA10840 s s WARNING Keep away open flames and do not smoke while checking or working on the fuel system 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 24 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 57 ...

Page 58: ...thick rag like a towel over the radiator cap and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape When the his sing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 25 NOTE If coolant is not available tap water can be temporarily used instead provided that it...

Page 59: ...area any longer than instructed Also tho roughly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or spon ge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or s...

Page 60: ...h 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...

Page 61: ...to the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug ...

Page 62: ...information on storing the bat tery see page 6 18 NOTE Make any necessary repairs before storing the scooter 7 SCOOTER CARE AND STORAGE 7 4 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 7 4 ...

Page 63: ...r higher Engine oil quantity Quantity 1 4 L Periodic oil change 1 20 L Final gear oil Quantity 0 25 L Cooling system Radiator capacity 0 34 L Coolant reservoir capacity up to the maxi mum level mark 0 46 L Air filter Air filter element Oil coated paper element Recommended fuel Recommended fuel Unleaded fuel Fuel tank capacity 12 0 L Fuel reserve amount 2 0 L Carburetor Type x quantity 1C0 x 1 Manu...

Page 64: ... type Cast wheel Rim size 15xMT3 50 Rim material Aluminum Rear wheel Wheel type Cast wheel Rim size 14xMT3 75 Rim material Aluminum Front disc brake Disc brake type Single Recommended fluid DOT 4 Rear disc brake Disc brake type Single Recommended fluid DOT 4 Front suspension Front fork travel 110 0 mm Rear suspension Rear shock absorber assembly travel 95 0 mm Electrical System voltage 12 V Batter...

Page 65: ... 15 0 A Ignition fuse 5 0 A Radiator fan fuse 10A ECU fuse 5 0 A Backup fuse 5 0 A Reserve fuse 5 0 A Reserve fuse 10 A Reserve fuse 15 0 A Reserve fuse 15 0 A Reserve fuse 30 0 A 8 SPECIFICATIONS 8 3 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 8 3 ...

Page 66: ... stamped into the frame NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing autho rity in your area EAU26470 Model label The model label is affixed to the frame under the rider seat See page 3 10 Record the information on this label in the space provided This information will be needed when ordering spare parts f...

Page 67: ...auge 3 3 Fuel tank cap 3 8 H Handlebar switches 3 7 I Immobilizer system 3 1 Indicators indicator lights and warning light 3 2 K Key identification number 9 1 L Left view 2 1 Lubricating the front and rear brake levers 6 16 M Main switch steering lock 3 1 Model label 9 1 Multi function display 3 4 O Owner s tool kit 6 1 P Parking 5 3 Periodic maintenance and lubrication chart 6 2 Pre operation che...

Page 68: ...YAMAHA MOTOR ESPAÑA S A PRINTED IN SPAIN 2005 05 Bengar Gràfiques S L E 1C0 F8199 E0 qxd 13 04 2005 16 58 Página 68 ...

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