YAMAHA XMAX 250 2007 Repair Manual

EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
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.
EAU23171
Lubricating the front and
rear brake levers
The pivoting points of the front and
rear brake levers must be lubricated
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Engine oil
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EAU23211
Checking and lubricating the
centerstand and sidestand
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.
EWA10740
s s
WARNING
If the centerstand or sidestand
does not move up and down smo-
othly, have a Yamaha dealer check
or repair it.
EAU23271
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
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
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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
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 maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
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.
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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.
EAUT1401
Battery
This model is equipped with a sealed-
type (MF) battery, which does not
require any maintenance. There is no
need to check the electrolyte or to
add distilled water.
ECA10630
CAUTION:
Always keep the battery char-
ged. Storing a discharged bat-
tery can cause permanent bat-
tery damage.
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EWA10760
s s
WARNING
lectrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothingand 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.
atteries 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.
EEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
DREN.
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
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optional electrical accessories.
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.
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.
To remove the battery 1. Remove panel A (See page 6-6).
1. Battery support
2. Battery
3. Screw
2. Remove the battery holder brac- ket by removing the bolt. 3. Pull the battery out from the bat-
tery box, and then disconnect the
battery couplers.
To install the battery 1. Connect the battery couplers, and then place the battery in the
original position.
2. Install the battery holder bracket by installing the bolt.
3. Install the panel by installing the screw.
4. Fully charge the battery before installation.
EAU23524
Replacing the fuses
1. Fuse box
The main fuse and the fuse box,
which contains the fuses for the indi-
vidual circuits, are located behind
cowling B. (See page 6-6.)
1
1 2
3
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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 causing extensive damage to
the electrical system and possibly a
fire.
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.
EAU23730
Replacing a headlight bulb
This model is equipped with two
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.1. Remove cowling B. (See page 6-6.)
2. Disconnect the headlight coupler, and then remove the bulb cover.
1. Headlight coupler
2. Headlight bulb cover
3. Unhook the headlight bulb hol-der, and then remove the defecti-
ve bulb.
1
2
Specified fuses:Main fuse:30 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 5 A
Ecu fuse (backup): 5 A
Radiator fan fuse: 10 A
Backup fuse (backup): 5 A
Reserve fuse: 30 A
15 A
10 A
5 A
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1. Headlight bulb cover
2. Headlight bulb holder
EWA10790
s sWARNING
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 headlight bulb into position, and then secure it with
the bulb holder.
1. Do not touch the glass part of the bulb.
ECA10650
CAUTION:
Take care not to damage the follo-
wing parts:
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it
free from oil, otherwise the
transparency of the glass, the
luminosity of the bulb, and the
bulb life will be adversely affec-
ted. Thoroughly clean off any
dirt and fingerprints on the
headlight bulb using a cloth
moistened with alcohol or thin-
ner.
Headlight lens
• Do not affix any type of tinted film or stickers to the head-
light lens.
• Do not use a headlight bulb of a wattage higher than spe-
cified.
5. Install the headlight bulb cover, and then connect the coupler.
6. Install the cowling.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
1
2
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EAU24240
Replacing a front turn signal
light bulb
1. Place the scooter on the centers-tand.
2. Remove cowling A. (See page 6-6.)
3. Remove the socket (together with the turn signal light bulb) by
turning it counterclockwise.
1. Turn signal light bulb socket
4. Remove the defective bulb bypushing 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 removing the screw.
2. Remove the defective bulb by pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screw. Rear turn signal light bulb
1. Remove the tail/brake light lens by removing the screw.
2. Remove the turn signal light bulb lens by removing the screw.
3. Remove the defective bulb by pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
5. Install the turn signal light bulb lens by installing the screw.
6. Install the tail/brake light bulb lens by installing the screw.
1
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ECA10680
CAUTION:
Do not overtighten the screws,
otherwise the lens may break.
EAUM1460
Replacing the license plate
light bulb
1. Remove the license plate light cover by removing the screw.
2. Remove the socket (together with the bulb) by pulling it out.
3. Remove the defective bulb by pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the bulb) by pushing it in.
6. Install the license plate light cover by installing the screw.
EAUS1260
Replacing the auxiliary light
bulb
If the auxiliary light bulb burns out,
replace it as follows.1. Remove cowling B. (See page 6- 6.).
1. Auxiliary light bulb socket
1. Auxiliary light bulb.
1
1
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2. Remove the socket (together
with the bulb) by pulling it out.
3. Remove the defective bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with
the bulb) by pushing it in.
6. Install the cowling B.EAU25880
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.
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