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Yamaha YP250R X-MAX 2005, Service Information

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Yamaha YP250R X-MAX 2005 Service Information Download Page 11

11

Tool Nº

Tool Name / Function

Illustration

90890-04016 

Valve guide installation and removal tool 
(5,5 ø)

These tools are used to extract or install 
the valve guides.

90890-04019 

Valve spring compressor

90890-04108 

Valve spring compressor accessory

These tools are used for extracting or 
installing the valve and the valve spring. 

90890-04058 

Intermediate driven shaft bearing 
installation tool

90890-04078 

Mechanical seal installation tool 

These tools are used to install mechanical 
seals.

90890-04066 

Valve guide reamer (6 ø)

This tool is used to rectify new valve 
guides.

90890-04101 Valve 

grinder

This tool is used to extract and install the 
lift and also to polish the valve.

90890-06754 Ignition 

tester

This tool is used to test the ignition system 
components. 

90890-06756 

Manometer/vacuum pump set

This tool is used to check the air 
cut-off valve. 

90890-85505 

Yamaha adhesive, Nº 1215

This adhesive is used to seal two 
coupling services (for example the 
engine sump coupling surfaces). 

SPECIAL TOOLS

GEN/

INFO

Summary of Contents for YP250R X-MAX 2005

Page 1: ...SERVICE INFORMATION 1C01 SE0 05 YP250R X MAX ...

Page 2: ...NFORMATION 2005 Yamaha Motor España S A 1st edition May 2005 All rights reserved Any reproduction or unauthorized use without written permission from YAMAHA MOTOR ESPAÑA S A is strictly prohibited Printed in Spain ...

Page 3: ...ll YAMAHA dealers will be notified about significant modifications and changes introduced in specifications and procedures and when necessary these changes will be included in future editions of this manual NOTE The design and specifications are subject to modification without prior notice IMPORTANT INFORMATION Particularly important information are indicated by the following notations This warnin...

Page 4: ...ts play 16 Engine idle speed 17 Ω V A The symbols from 18 to 23 are used for disassembly indicate the lubricant applica tion points and the type of lubricant speci fied 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulphide oil 21 Apply wheel bearing grease 22 Apply light lithium soap base grease 23 Apply molybdenum disulphide grease The symbols 24 and 25 are used for disas sembly to...

Page 5: ...L SPECIFICATIONS 12 MAINTENANCE SPECIFICATIONS 13 ENGINE 13 TIGHTENING TORQUES ENGINE 19 CHASSIS 21 TIGHTENING TORQUES CHASSIS 23 ELECTRICAL SPECIFICATIONS 25 CABLE ROUTES 27 INSPECTIONS AND PERIODIC ADJUSTMENTS 36 INTRODUCTION PERIODIC MAINTENANCE LUBRICATION INTERVALS 36 ELECTRICS DIAGRAM 38 ...

Page 6: ......

Page 7: ...pet of the right hand side foo trest NOTE The frame number is used to identify the motorcycle and may be used for the regis tration with any administration MODEL LABEL The model label is located underneath the seat This information is necessary to order spare parts NOTE The design and characteristics may be modified without prior notice ...

Page 8: ...in 90890 01280 Adapter M16 90890 01288 Spacer 90890 01478 Adapter M14 These tools are used for installing the crankshaft 90890 01083 Sliding hammer bolt 90890 01084 Counterweight These tools are used to extract or install the rocker shafts 90890 01135 Crankcase separation tool These tools are used for extracting the crankshaft 90890 01235 Rotor retention tool This tool to machetes to hold the fixe...

Page 9: ...pring bracket arm These tools are used to support the compression spring when the clutch bracket nut is being fitted or removed 90890 01348 Counter nut wrench This tool is used to remove or fit the clutch bracket nut 90890 01362 Fly Wheel extractor This tool is used for extracting the alternator rotor 90890 01367 Guide weight for the fork seal 90890 01372 Holder for the fork seal ø38 These tools a...

Page 10: ...ool is used to measure the valve clearance 90890 03081 Pressure manometer These tools are used to measure engine compression 90890 03112 Pocket tester This tool is used for tests on the electrical system 90890 03113 Engine tachometer This tool is used to measure engine speed 90890 03132 Pocket tester This tool is used to measure engine oil temperature 90890 03134 Exhaust accessory This tool is use...

Page 11: ...78 Mechanical seal installation tool These tools are used to install mechanical seals 90890 04066 Valve guide reamer 6 ø This tool is used to rectify new valve guides 90890 04101 Valve grinder This tool is used to extract and install the lift and also to polish the valve 90890 06754 Ignition tester This tool is used to test the ignition system components 90890 06756 Manometer vacuum pump set This ...

Page 12: ... 790 mm 31 1 in Overall height 1 380 mm 54 3 in Seat height 775 mm 30 51 in Wheelbase 1 545 mm 60 8 in Minimum ground clearance 113 mm 4 45 in Minimum turning radius 3 650 mm 143 7 in Weight Wet with oil and a full fuel tank 174 kg 383 67 lb Maximum load total of cargo rider passenger and accessories 164 kg 361 62 lb GENERAL SPECIFICATIONS ...

Page 13: ...gasoline only Fuel tank capacity Total 12 0 L 2 64 Imp gal 3 17 US gal Engine oil Lubrication system Wet sump Recommended oil SAE 10W30 SAE 10W40 SAE 15W40 SAE 20W40 or SAE 20W50 Refer to the chart for the engine oil grade Recommended engine oil grade API service SG and also JASO MA type or higher Quantity Total amount 1 60 L 1 41 Imp qt 1 69 US qt Periodic oil change 1 42 L 1 05 Imp qt 1 27 US qt...

Page 14: ...ne capacity 0 70 L 0 62 Imp qt 0 74 US qt Radiator cap opening pressure 100 0 120 0 kPa 1 00 1 20 kg cm2 14 2 17 1 psi Radiator core Width 229 0 mm 9 02 in Height 111 5 mm 4 39 in Depth 23 0 mm 0 91 in Coolant reservoir Capacity up to the maximum level mark 0 26 L 0 23 Imp qt 0 28 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 37 22 25 37 Coolant temperature 80 90...

Page 15: ...nt B 30 021 30 121 mm 1 1819 1 1858 in 29 920 mm 1 1779 in Exhaust camshaft lobe dimensions Measurement A 36 547 36 647 mm 1 4388 1 4428 in 36 450 mm 1 4350 in Measurement B 30 067 30 167 mm 1 1837 1 1876 in 29 170 mm 1 1484 in Maximum camshaft runout 0 030 mm 0 0012 in Timing chain Model number of links SC A 0404A SDH 104 Tensioning system Automatic Item Standard Limit A B A B ...

Page 16: ...in Exhaust 28 40 28 60 mm 1 1181 1 1259 in Valve face width B Intake 3 394 3 960 mm 0 1336 0 1559 in Exhaust 3 394 3 960 mm 0 1336 0 1559 in Valve seat width C Intake 0 90 1 10 mm 0 0354 0 0433 in 1 6 mm 0 06 in Exhaust 0 90 1 10 mm 0 0354 0 0433 in 1 6 mm 0 06 in Valve margin thickness D Intake 0 80 1 20 mm 0 0314 0 0472 in Exhaust 0 80 1 20 mm 0 0314 0 0472 in Valve stem diameter Intake 5 975 5 ...

Page 17: ...1 10 mm 0 0354 0 0433 in 1 6 mm 0 06 in Valve springs Free length Intake and exhaust inner 38 10 mm 1 50 in 36 10 mm 1 42 in Intake and exhaust outer 36 93 mm 1 45 in 35 00 mm 1 38 in Installed length valve closed Intake 30 10 mm 1 18 in Exhaust 30 10 mm 1 18 in Compressed spring force installed Intake and exhaust inner 76 5 88 3 N 7 80 9 00 kg 436 83 504 21 lb Intake and exhaust outer 115 133 N 1...

Page 18: ... to cylinder clearance 0 020 0 040 mm 0 0007 0 0015 in 0 15 mm 0 0059 in Diameter D 68 965 68 980 mm 2 7151 2 7157 in Height H 5 0 mm 0 20 in Piston pin bore in the piston Diameter 17 004 17 015 mm 0 6694 0 6698 in 17 045 mm 0 6710 in Offset 0 5 mm 0 0197 in Offset direction Intake side Piston pin Outside diameter 16 991 17 000 mm 0 6689 0 6692 in 16 975 mm 0 6683 in Piston pin to piston pin bore ...

Page 19: ... 0 20 0 70 mm 0 0079 0 0276 in Ring side clearance 0 060 0 150 mm 0 0023 0 0059 in Crankshaft Width A 59 95 60 00 mm 2 3602 2 3622 in Maximum runout C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 850 mm 0 0137 0 0334 in Big end radial clearance E 0 010 0 025 mm 0 0003 0 001in Automatic centrifugal clutch Clutch shoe thickness 3 3 mm 0 1299 in 2 0 mm 0 078 in Clutch shoe spring free length 2...

Page 20: ...n type V belt automatic Operation Centrifugal automatic type Single speed automatic 2 440 0 830 1 Air filter Air filter element Wet element Fuel pump Pump type Electrical Model manufacturer 2GV MITSUBISHI I Output pressure 12 5 kPa 0 13 kg cm2 1 85 psi Carburettor Model x qty CVEK30 x 1 Manufacturer KEIHIN Needle jet 2 6 Main jet 122 Main air jet 90 Jet needle JPBL ID mark 1C0C00 Guide air jet 1 3...

Page 21: ...runout 1 0 mm 0 04 in Wheel axle bending limit 0 03 mm 0 0012 in Rear wheel Wheel type Cast wheel Rim Size 14 MT3 75 Material Aluminum Wheel travel 83 0 mm 3 27 in Wheel runout Maximum radial wheel runout 1 0 mm 0 04 in Maximum lateral wheel runout 1 0 mm 0 04 in Front tire Tire type Tubeless Size 120 70 15M C 56P or 56S Model manufacturer GOLD STANDARD MICHELIN Tire pressure cold 0 90 kg 0 198 lb...

Page 22: ...ng thickness inner 4 5 mm 0 18 in 0 5 mm 0 02 in Brake pad lining thickness outer 4 5 mm 0 18 in 0 5 mm 0 02 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 25 00 mm 1 and 28 00 mm 1 0 98 in 1 and 1 10 in 1 Rear brake Brake type Single disc brake Operation Left hand operation Recommended fluid DOT 4 Brake disc Diameter thickness 240 0 5 0 mm 9 45 0 20 in Minimu...

Page 23: ...g 195 0 cm3 6 86 Imp oz 6 59 US oz Level from the top of the inner tube with the inner tube fully com pressed and without the fork spring 105 0 mm 4 13 in Steering Steering bearing type Angular bearing Lock to lock angle left 62 Lock to lock angle right 62 Rear suspension Suspension type Unit swing Rear shock absorber assembly type Coil spring oil damper Rear shock absorber assembly travel 95 0 mm...

Page 24: ...2 13 SPEC CHASSIS SPECIFICATIONS Spring preload adjusting positions Standard 1 Minimum 1 Maximum 4 Item Standard Limit ...

Page 25: ...sistance 1 89 2 31 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ at 20 C 68 F Charging system System type A C magneto Model manufacturer 5425 E MITSUBA Nominal output 14 V 18 A at 4 000 r min Stator coil resistance color 0 38 0 41 Ω at 20 C 68 F white white Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH678 M SHINDENGEN No load regulated vol...

Page 26: ... Electric starting system System type Constant mesh Starter motor Model manufacturer SM13 454 MOTOR UNIT START S P Power output 0 65 kW Brushes Overall length 18 mm 0 709 in 4 0 mm 0 15 in Spring force 7 65 10 01 N 780 1021 gf 27 54 36 02 oz Armature coil resistance 0 0017 0 0027 Ω at 20 C 68 F Insulation resistance Above 1 MΩ at 20 C 68 F Commutator diameter 17 6 mm 0 69 in 16 6 mm 0 65 in Mica u...

Page 27: ...use 30 0 A 1 15 0 A 1 10 0 A 1 5 0 A 1 Fuel gauge Model manufacturer 1B9 BITRON Sender unit resistance full 0 7 Ω at 20 C 68 F Sender unit resistance empty 87 103 Ω at 20 C 68 F Starting circuit cut off relay Model manufacturer ACA12115 1 MATSUSHITA Coil resistance 72 88 Ω Headlight relay Coil resistance 96 Ω Fuel injection system relay Coil resistance 96 Ω Radiator fan motor Model manufacturer VA...

Page 28: ...2 17 SPEC ELECTRICAL SPECIFICATIONS Speed sensor Output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less Item Standard Limit ...

Page 29: ...fied tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb o...

Page 30: ...2 19 TIGHTENING TORQUES SPEC Crankcase tightening sequence Cylinder head tightening sequence ...

Page 31: ...32 3 2 Carburettor seal M6 10 0 1 Air induction system tube M6 12 1 2 Air supply cut off valve assembly M6 10 1 0 Sump M6 10 1 0 Cylinder head pin M8 12 5 1 25 Transmission oil drain bolt M8 22 2 2 Gearbox oil filler plug M14 3 0 3 Transmission box cover M8 16 1 6 Trapezoidal belt housing cover left M6 10 1 0 Trapezoidal belt housing filter cover M5 1 2 0 12 Trapezoidal belt housing cover protecti...

Page 32: ... absorbers to frame M10 31 5 3 1 Guide hose to rear rocker arm nut M6 9 75 0 9 Seat lock M6 9 75 0 9 Rear wheel axle nut M14 135 13 5 Front wheel axle nut M14 69 5 6 9 Front brake calliper to fork M8 23 2 3 Rear brake calliper to rocker arm M10 23 2 3 Rear front brake hose M10 23 2 3 Steering shaft upper nut Crowned M25 75 7 5 Handlebar bracket nut M20 120 12 0 Handlebar bracket bolts M8 23 2 3 Ba...

Page 33: ...on interior surface Piston pin Annular canal and piston exterior Camshaft cam profile Valve stem IN EX Valve stem and end IN EX Rocker shaft Valve rocker interior surface Shaft Shaft oil pump assembly Seal oil pump assembly Bracket Intermediate gear 1 support surfaces Shaft 1 Intermediate gear 2 support surfaces Intermediate gear 2 interior surfaces Primary shaft support surfaces Engine shaft and ...

Page 34: ...t and right Steering bearings upper and lower Steering dust guard lips upper and lower Seat bracket pin Seat lock Throttle cable guide interior surface Engine bracket shaft Front rear brake cylinder Front support friction surface Centre stand friction surface and attachment pin Centre stands stop shaft Rear wheel seal lips left and right ...

Page 35: ...side handlebar switches cable Right hand side handle bar switches cable Right hand side indicator cable Front brake conduit Throttle cable 1 Front brake lever Throttle cable 2 Front brake cylinder Front brake switch cable A Inserted temperature probe cable all the way into the steering shaft B Connect and fit the rubber cap to the speedometer cabling A B ...

Page 36: ...ont brake ECU Starter relay Starter motor cable Neutral terminal Battery housing Regulator Horn Trip distance sensor cable Seat lock cable Main switch Relay Indicator relay Fuse box Main installation A Connect to the main installation B see detail B B A ...

Page 37: ...t terminal Trip sensor terminal Antenna terminal Flasher relay Main switch terminal A Allow sufficient clearance to turn the handle bars B Take by the flange Main switch cable flasher relay cable fuse box cable antenna cable trip counter cable A B ...

Page 38: ...ometer sensor cable Brake hose Thermal contact Ventilator terminal Fuel pump terminal Fuel pump Fuel tank line to pump Fuel tank line to carburettor Coolant expansion tank Spark plug hood Coil Earth terminal Fuel probe terminal Rear brake Main installation G H I K J L A B D C E F ...

Page 39: ...ube G Take by the flange Main installation rear brake starter motor cable generator cables H Take by the flange Main installation rear brake starter motor cable coil cables starter cables thermal contact cabling generator cabling I Take by the flange Main installation rear brake starter motor cable stand cable J Take by the welded flange Main installation rear brake starter motor cable K Take the ...

Page 40: ...light A Take by the flange The main installation rear light cables registration light B Take the main installation by the welded flange C Pass the brake hose by the guide D Pass the registration light according to the illustration D A B C ...

Page 41: ...ole in the frame Horn A Pass the starter motor cable by the window in the battery housing B Take in the back Seat lock cable throttle cable C Take by the flange Seat lock cable stand cable throttle cable D Pass the seat lock cable through the interior of the frame tubing E Take side stand cable with flange F Pass the horn cables behind the frame A F E C D B ...

Page 42: ... Connect and cover the generator cables with hood and position according to the illustration B Take by the welded flange motor cables coincide with mark starter motor cable C Pass seat lock cable through the frame D Pass the accelerator cables above the carburettor nozzle to the air filter E Fuel line from the carburettor stick to the rubber onto the welded bracket at the frame F Take the stand ca...

Page 43: ...SPEC CABLE ROUTES 2 32 Rear left hand side light terminal Seat lock Rear right hand side light terminal Seat lock cable A Take the rear left hand side light connection cable by the flanges A ...

Page 44: ...eaks Change brake pads Always when the wear limit is reached 8 Brake line Check for cracks and damage Replace Every 4 years 9 Wheels Check off centre and damage 10 Tyres Check tread depth check for damage Change if necessary Check tyre pressure Correct if necessary 11 Wheel bearings Check if the bearings are loose or damaged 12 Steering Check the bearing play and if the steering is difficult beari...

Page 45: ...the bolted flange is correctly tightened exhaust tube 28 Lights signals Check operation and witches Adjust the headlight NOTE The air filter requires more frequent servicing when the vehicle is used in especially humid or dusty areas Maintenance of hydraulic brakes Check the brake fluid level regularly and corrected it if necessary Every two years change the internal components of the break cylind...

Page 46: ...38 ELECTRIC DIAGRAM YP250R X MAX ...

Page 47: ...2 front left hand side indicator 33 front right hand side indicator 34 fuse ECU 35 fuse backup 36 fuse ignition 37 fuse signals 38 fuse front headlight 39 fuse ventilator 40 horn 41 speedometer 42 starter motor switch 43 warning light switch 44 horn switch 45 indicator switch 46 light switch 47 DC CDI 48 Immobiliser 10 antenna 49 flasher relay 50 earth connection 51 fuel pump 52 Capacity gauge sti...

Page 48: ...IMPRESO EN ESPAÑA OPTEL S L 05 2005 E Aiguaders 10 16 Pol Ind Riera de Caldes 08184 Palau Solità i Plegamans Barcelona Spain ...

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