YAMAHA XMAX 250 2010 Repair Manual

EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
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.
Recommended brake fluid:DOT 4

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EAU22731
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 master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
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.
EAU23172
Lubricating the front and
rear brake levers
Front brake lever
Rear brake lever
The pivoting points of the front and
rear brake levers must be lubricated

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at the intervals specified in the perio-
dic maintenance and lubrication
chart.EAU23213
Checking and lubricating the
centerstand and sidestand
1. Sidestand
1. Centerstand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-metal contact surfaces should be
lubricated if necessary.
EWA10741
If the centerstand or sidestand
does not move up and down smo-
othly, have a Yamaha dealer check
or repair it. Otherwise, the centers-
tand or sidestand could contact the
ground and distract the operator,
resulting in a possible loss of con-
trol.
Recommended lubricant:
Lithium-soap-based grease

WARNING

Recommended lubricant:Silicone grease
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EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU45511
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 maintenance and lubrica-
tion chart.1. Place the vehicle on the centers- tand. WARNING! To avoid
injury, securely support the
vehicle so there is no danger of
it falling over.
[EWA10751]
2. Hold the lower ends of the front fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.

NOTICE

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EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
check the wheel bearings.
EAU34224
Battery
1. Battery
The battery is located behind cowling
A. (See page 6-8).
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the elec-
trolyte or to add distilled water. Howe-
ver, the battery lead connections
need to be checked and, if necessary,
tightened.
EWA10760
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
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 pro-
vide sufficient ventilation when
charging it in an enclosed spa-
ce.
KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.

WARNING

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To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
ECA16520
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (cons-
tant-voltage) battery charger is
required. Using a conventional bat-
tery charger will damage the bat-
tery. If you do not have access to a
constant-voltage battery charger,
have a Yamaha dealer charge your
battery.
To store the battery1. If the vehicle will not be used for more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place. NOTI-
CE: When removing the battery,
be sure the key is turned to
“OFF”, then disconnect the
negative lead before discon-
necting the positive lead.
[ECA16302]
2. If the battery will be stored for more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that the battery leads are properly
connected to the battery termi-
nals.
ECA16530
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
EAUS1771
Replacing the fuses
1. Fuse box
2. Hazard fuse
The fuse box, which contains the
fuses for the individual circuits, is
located behind cowling A. (See page
6-8).
TIP
The main fuse, which is in a different
and hard-to-reach location, must be
replaced by a Yamaha dealer.
If a fuse for the individual circuits 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

NOTICE

NOTICE

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amperage. WARNING! Do not
use a fuse of a higher ampera-
ge rating than recommended
to avoid causing extensive
damage to the electrical sys-
tem and possibly a fire.
[EWA15131]
TIP
Fuse tongs and a bag containing spa-
re fuses are included in the owner’s
tool kit. Use the tongs to remove and
install a fuse.
1. Radiator fan fuse
2. ECU fuse
3. Backup fuse
4. Signaling system fuse
5. Headlight fuse
6. Ignition fuse
7. Spare fuse
8. Spare fuse
9. Spare fuse
3. Turn the key to “ON” and turn on the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again, have a Yamaha dealer
check the electrical system.
EAU34240
Replacing a headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, have a Yamaha dealer
replace it and, if necessary, adjust the
headlight beam.
Specified fuses:Main fuse:30.0 A
Headlight fuse: 15.0 A
Signaling system fuse: 10.0 A
Ignition fuse: 10.0 A
Radiator fan fuse: 7.5 A
Hazard fuse: 10.0 A
ECU fuse: 5.0 A
Backup fuse: 5.0 A

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EAU43051
Replacing a front turn signal
light bulb
1. Place the scooter on the centers-tand.
2. Remove the socket (together with the bulb) by turning it coun-
terclockwise.
1. Turn signal light bulb
2. Turn signal light bulb socket
3. Remove the burnt-out bulb bypulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the bulb) by turning it clockwise.
EAUS1781
Replacing a tail/brake light
bulb or a rear turn signal
light bulb
1. Place the vehicle on the centers-tand.
2. Remove panel A. (See page 6-8).
3. Remove the tail/brake light unit by removing the screws.
1. Screw
4. Remove the tail/brake light andturn signal light bulb holder
together with the dust protector
by pressing the tabs, and then
pulling both outward.
1. Dust protector
2. Tabs
1. Turn signal light bulb
2. Tail/brake light bulb
5. Remove the burnt-out bulb bypushing it in and turning it coun-
terclockwise.


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6. Insert a new bulb into the socket,push it in, and then turn it clock-
wise until it stops.
7. Install the bulb holder together with the dust protector by pus-
hing both into the original posi-
tion.
TIP
Place the bulb holder and dust cover
correctly in its position to avoid dust
and water entering.
8. Install the screws and thetail/brake light unit.
9. Install the panel.
EAU47910
Replacing the license plate
light bulb
1. Remove the license plate light cover by removing the screw.
1. Screw
2. License plate light bulb socket
2. Remove the burnt-out bulb bypulling it out from the socket.
3. Insert a new bulb into the socket.
4. Install the license plate light cover by installing the screw.
EAU43231
Replacing an auxiliary light
bulb
This model is equipped with two auxi-
liary lights. If an auxiliary light bulb
burns out, replace it as follows.1. Remove the socket (together with the bulb) by pulling it out.
1. Auxiliary light bulb socket
2. Remove the burnt out bulb bypulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with the bulb) by pushing it in.





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EAU25881
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition sys-
tems, for example, can cause poor
starting and loss of 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 are often
inferior, have a shorter service life and
can lead to expensive repair bills.
EWA15141
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in thearea, including pilot lights from
water heaters or furnaces. Gasoli-
ne or gasoline vapors can ignite or
explode, causing severe injury or
property damage.

WARNING

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