YAMAHA XMAX 250 2006 Service Manual

have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any chan-
ges.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 41

6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
EAU17705
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
1*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
•Check condition.
2Spark plug•Clean and regap.√√
•Replace.√√
3*Valves•Check valve clearance.
•Adjust.√√
4Air filter element•Replace.√√
5*V-belt case air filter •Clean.√√elements•Replace.√√
6*Front brake•Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √•Replace brake pads. Whenever worn to the limit
7*Rear brake•Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
•Replace brake pads. Whenever worn to the limit
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 42

6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
8*Brake hose•Check for cracks or damage.√√√√ √•Replace. Every 4 years
9*Wheels•Check runout and for damage.√√√√
•Check tread depth and for damage.
10 * Tires•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11 *Wheel bearings•Check bearing for looseness or damage.√√√√
12 *Steering bearings•Check bearing play and steering for roughness.√√ √ √√•Lubricate with lithium-soap-based grease. Every 20000 km
13 *Chassis fasteners•Make sure that all nuts, bolts and screws are properly
tightened.√√√√ √
14Sidestand, centerstand•Check operation.
•Lubricate.√√√√ √
15 *Sidestand switch•Check operation.√√ √ √√ √
16 *Front fork•Check operation and for oil leakage.√√√√
17 *Shock absorber
assemblies•Check operation and shock absorbers for oil leakage.√√√√
18 *Carburetor•Adjust engine idling speed.√√ √ √√ √
•Change. (See page 6-8.)√When the oil change indicator light comes
19Engine oilon (every 3000 km)
•Check oil level and vehicle for oil leakage. Every 3000 km√
20 *Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change. Every 3 years
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 43

6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
21Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
22 *V-belt•Replace. Every 20000 km
23 *Front and rear brake
switches•Check operation.√√ √ √√ √
24Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing •Check operation and free play.
25 * •Adjust the throttle cable free play if necessary.
and cable
•Lubricate the throttle grip housing and cable.√√√√ √
26 *Mufflers and exhaust
pipes•Check the screw clamps for looseness.√√ √ √√ √
27 *Lights, signals •Check operation.
and switches•Adjust headlight beam.√√ √ √√ √
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 years replace the internal components of the brake master cylinder and caliper, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 44

EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
EAU18900
Cowling A
T
o remove the cowling
1. Screws
1. Remove the cowling bolts.
2. Disconnect the turn signal light
lead connectors, and then take
the cowling off.T
o install the cowling
1. Connect the turn signal light lead
connectors.
2. Place the cowling in the original
position.
3. Install the cowling bolts.
EAU18790
Cowling B
T
o remove the cowling
Screws
Remove the screws, and then take
the cowling off.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAUM1250
Panel A
T
o remove the panel
1. Open the front storage compart-
ment. (See page 3-14.)
Screws
2. Remove the screw, and then take
the panel off.
T
o install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Close the front storage compart-
ment.
116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 45

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 maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Open the seat. (See page 3-13.)
2. Remove the storage compart-
ment under the seat by removing
the bolts.
1. Storage compartment
2. Screws
3. Remove the spark plug cap.
4. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode ofthe spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the motorcy-
cle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug
1. Spark plug gap
Specified spark plug:
NGK / DR8EA
2
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 46

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 installing a spark plug, a good
estimate of the correct torque is 1/4 ~
1/2 turn past finger tight. However,
the spark plug should be tightened to
the specified torque as soon as pos-
sible.
4. Install the spark plug cap.5. Install the storage compartment
by installing the bolts.
6. Close the seat.
EAUM1550
Engine oil
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the
service indicator light comes on.
To check the engine oil level
1. Place the scooter on the centers-
tand.
NOTE:
Make sure that the scooter is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
Tightening torque:
Spark plug:
18 Nm (1.8 m•kgf, 13.0 ft•lbf)
Spark plug gap:
0.6 ~ 0.7 mm (0.023 ~ 0.027 in)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 47

1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
3. Wait a few minutes until the oil
settles, remove the 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
hole, and then tighten the oil filler
cap.
To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
1. Engine oil drain bolt
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
1. Engine oil drain bolt
2. Washer
4. Check the washer for damage
and replace it if necessary.
5. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
NOTE:
Make sure that the washer is properly
seated.
6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
2
1
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 48

ECA11670
CAUTION:
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSER-
VING II” or higher.
Be sure no foreign material
enters the crankcase.
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 3-8.)
EAU20061
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.
1. Final transmission oil filler cap
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
1. Final transmission oil drain bolt
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
1
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
1.2 L (1.27 US qt) (1.05 Imp.qt)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 49

6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
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.
EAUS1272
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
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.
1. Maximum level mark
2. Minimum level mark
NOTE:
The coolant should be between the
minimum and maximum level marks.
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.
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:
22 Nm (2.2 m•kgf, 15.9 ft•lbf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1C0-F8199-E2.qxd 06/03/2006 13:08 Página 50