brake YAMAHA XMAX 250 2009 Owner's Manual

EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU22400
Front brake pads
1. Lining thickness
Check each front brake pad for
damage and measure the lining thick-
ness. If a brake pad is damaged or if
the lining thickness is less than 0.5
mm (0.02 in), have a Yamaha dealer
replace the brake pads as a set.
EAU22460
Rear brake pads
1. Brake pad wear indicator groove
The rear brake is provided with a
check plug, which, if it is removed,
allows you to check the brake pad
wear without disassembling the bra-
ke. To check the brake pad wear,
check the position of the wear indica-
tor while applying the brake. If a bra-
ke pad has worn to the point that the
wear indicator almost touches the
brake disc, have a Yamaha dealer
replace the brake pads as a set.
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 61

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.
EAU22721
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 brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are
damaged or leaking.
●Oil seals: Replace every two
years.
●Brake hose: Replace every four
years.
Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 62

EAU23101
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. WARNING! Damage to the
outer sheath may interfere with
proper cable operation and will
cause the inner cable to rust.
Replace a damaged cable as soon
as possible to prevent unsafe con-
ditions.
[EWA10721]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
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:
Silicone grease
ZAUM0061
Recommended lubricant:
Engine oil
PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 63

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
NOTICE
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.
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.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 65

EAUS1442
Replacing a tail/brake light
bulb or a rear turn signal
light bulb
1. Place the scooter on the centers-
tand.
2. Open the seat, and then remove
the rear storage compartment.
(See page 3-17).
1. Rear storage compartment
2. Bolt
3. Remove the tail/brake light and
turn signal light bulb holder by
pulling it outward.
1. Turn signal light bulb socket/ Tail/brake light
bulb socket
1. Unlock.1. Remove
4. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.
1. Turn signal light bulb
2. Tail/brake light bulb
PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
1C0-F8199-E5.QXD 3/10/08 05:56 Página 71

SCOOTER CARE AND STORAGE
7-2
7with water may be used. Be
sure to rinse off any detergent
residue using plenty of water,
as it is harmful to plastic parts.
●Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
●Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
●For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leavescratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas. Stub-
born dirt and insects will come off
more easily if the area is covered with
a wet cloth for a few minutes before
cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
TIP
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down. WAR-
NING! Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces to prevent corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
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.
1C0-F8199-E5.QXD 3/10/08 05:56 Página 78

4. Use spray oil as a universal clea-
ner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing or covering it.
EWA10941
s s
WARNING
Contaminants on the brakes or
tires can cause loss of control.
●Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
●Before operating the scooter
test its braking performance
and cornering behavior.
ECA10800
NOTICE
●Apply spray oil and wax spa-
ringly and make sure to wipe
off any excess.
●Never apply oil or wax to any
rubber and plastic parts, buttreat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
●Consult a Yamaha dealer for
advice on what products to use.
●Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from
the lens.
EAU36561
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10820
NOTICE
●Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for seve-
ral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
SCOOTER CARE AND STORAGE
7-3
7
1C0-F8199-E5.QXD 3/10/08 05:56 Página 79

Chassis:Frame type:
Steel tube underbone
Caster angle:
28.00 º
Trail:
100.0 mm (3.94 in)
Front tire:Type:
Tubeless
Size:
120/70-15 M/C 56S(Michelin -
Continental)
120/70-15 M/C 56P(Pirelli)
Manufacturer/model:
MICHELIN/GOLD STANDARD
Manufacturer/model:
PIRELLI/GTS23
Manufacturer/model:
CONTINENTAL/CONTITWIST TL
Rear tire:Type:
Tubeless
Size:
140/70-14 M/C 68S(Michelin -
Continental)
140/70-14 M/C 68P(Pirelli)
Manufacturer/model:
MICHELIN/GOLD STANDARD
Manufacturer/model:
PIRELLI/GTS24
Manufacturer/model:
CONTINENTAL/CONTITWIST TL
Loading:Maximum load:
180 kg (397 lb)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
190 kPa (1.90 kgf/cm
2, 28 psi, 1.90 bar)
Rear:
220 kPa (2.20 kgf/cm
2, 32 psi, 2.20 bar)
Loading condition:
90 kg - maximum load
Front:
210 kPa (2.10 kgf/cm
2, 30 psi, 2.10 bar)
Rear:
250 kPa (2.50 kgf/cm
2, 36 psi, 2.50 bar)
Front wheel:Wheel type:
Cast wheel
Rim size:
15 x MT3.5
Rear wheel:Wheel type:
Cast wheel
Rim size:
14 x MT3.75
Front brake:Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
94.0 mm (3.70 in)
Rear suspension:Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
83.0 mm (3.27 in)
Electrical system:Ignition system:
TCI (digital)
Charging system:
AC magneto
Battery:Model:
YTX9-BS
Voltage, capacity:
12 V, 8.0 Ah
Headlight:Bulb type:
Halogen bulb
SPECIFICATIONS
8-2
8
1C0-F8199-E5.QXD 3/10/08 05:56 Página 82

Bulb voltage, wattage x quantity:Headlight:
12 V, 35 W/35.0 W x 2
Tail/brake light:
12 V, 5.0 W/21.0 W x 2
Front turn signal light:
12 V, 10.0 W x 2
Rear turn signal light:
12 V, 10.0 W x 2
Auxiliary light:
12 V, 5.0 W x 2
License plate light:
12 V, 5.0 W x 1
Meter lighting:
LED
High beam indicator light:
LED x1
Turn signal indicator light:
LED x2
Fuel level warning light:
LED x1
Engine trouble warning light:
LED x1
Immobilizer system indicator light:
LED x1
Fuses:Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
15.0 A
Ignition fuse:
10.0 ARadiator fan fuse:
10.0 A
ECU (Electronic Control Unit) fuse:
5.0 A
Backup fuse:
5.0 A
SPECIFICATIONS
8-3
8
1C0-F8199-E5.QXD 3/10/08 05:56 Página 83

AAcceleration and deceleration ...................5-2
Air filter and V-belt case air filter
elements ................................................6-13
Anti-theft alarm (optional) ..........................3-9
Auxiliary light bulb, replacing ...................6-31
BBattery......................................................6-24
Brake fluid level, checking .......................6-19
Brake fluid, changing ...............................6-20
Brake lever, front ......................................3-10
Brake lever, rear .......................................3-10
Brake levers, lubricating ..........................6-21
Braking .......................................................5-3
CCables, checking and lubricating ............6-21
Care............................................................7-1
Catalytic converter ...................................3-13
Centerstand and sidestand, checking
and lubricating .......................................6-22
Coolant.....................................................6-12
Coolant temperature gauge .......................3-5
Cowlings and panel, removing and
installing ...................................................6-6
DDimmer switch ...........................................3-9
Display, multi-function ...............................3-6
EEngine break-in ..........................................5-4
Engine oil ...................................................6-9
Engine trouble warning light ......................3-4
FFinal transmission oil ...............................6-11
Front and rear brake lever free play.........6-18Front and rear brake pads, checking ......6-19
Front fork, checking .................................6-22
Fuel ..........................................................3-12
Fuel consumption, tips for reducing ..........5-3
Fuel gauge .................................................3-5
Fuel level warning light ..............................3-4
Fuel tank cap ...........................................3-11
Fuses, replacing .......................................6-26
HHandlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-27
High beam indicator light...........................3-3
Horn switch ................................................3-9
I
Identification numbers ...............................9-1
Ignition circuit cut-off system ..................3-19
Immobilizer system ....................................3-1
Immobilizer system indicator light .............3-4
Indicator and warning lights ......................3-3
KKey identification number ..........................9-1
LLicense plate light bulb, replacing ...........6-30
MMain switch/steering lock ..........................3-2
Matte color, caution ...................................7-1
Model label ................................................9-2
PParking .......................................................5-4
Part locations .............................................1-1
Periodic maintenance and lubrication
chart .........................................................6-2
SSafe-riding points.......................................1-1
Safety information ......................................1-1
Seat ..........................................................3-14
Securing bracket ......................................3-14
Shock absorber assemblies, adjusting....3-18
Sidestand .................................................3-18
Spark plug, checking .................................6-8
Specifications.............................................7-3
Speedometer .............................................3-5
Start switch ................................................3-9
Starting off .................................................5-2
Starting the engine.....................................5-1
Steering, checking ...................................6-23
Storage.......................................................7-3
Storage compartment ..............................3-16
Storage compartment (rear) .....................3-17
Storage compartments ............................3-15
TTail/brake light bulb or rear turn signal
light bulb, replacing ...............................6-29
Throttle cable free play, adjusting ............6-15
Throttle grip and cable, checking and
lubricating ..............................................6-21
Tires .........................................................6-16
Tool kit ........................................................6-1
Troubleshooting .......................................6-31
Troubleshooting charts ............................6-33
Turn signal indicator lights .........................3-3
Turn signal light bulb (front), replacing ....6-28
Turn signal switch ......................................3-9
VValve clearance ........................................6-15
INDEX
1C0-F8199-E5.QXD 3/10/08 05:56 Página 86