YAMAHA XMAX 250 2010 Service Manual

EAU16841
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1600 km
(1000 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clea-
rances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUS1810
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min. NOTICE: After 1000
km (600 mi) of operation, be
sure to replace the engine oil
and final transmission oil.
[ECA11661]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min. 1600 km (1000 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
Do not park near grass or other
flammable materials which
might catch fire.

WARNING

NOTICE

OPERATION AND IMPORTANT RIDING POINTS
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EAUS1820
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, depending on
the weather, terrain, geographical
location, and individual use, the main-
tenance intervals may need to be
shortened.
EWA10321
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15121
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA10330
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.Consult a Yamaha dealer for proper
maintenance intervals.

WARNING

WARNING

WARNING

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAUS1830
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-15).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
TIP
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
TIP
Fuse tongs and a bag containing spa-
re fuses are included in the owner’s
tool kit. Be careful not to lose these
items when opening the tool kit.

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46861
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK,
a mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
EAU46910
Periodic maintenance chart for the emission control system
PERIODIC MAINTENANCE AND ADJUSTMENT
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ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1* Fuel line • Check fuel hoses for cracks or
damage. √√√ √√
• Check condition.
2 Spark plug • Clean and regap. √√
• Replace.
√√
3* Valves • Check valve clearance.
• Adjust. √√
4*
Fuel injection • Check engine idle speed. √√ √ √ √ √
5* Muffler and exhaust
• Check the screw clamp(s)
√√ √ √ √
pipe for looseness.

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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU1770C
General maintenance and lubrication chart
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1
Air filter element • Replace. √√
2 V-belt case air filter
element • Clean.
√√√ √
• Check operation, fluid level and
3* Front brake vehicle for fluid leakage. √√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
4* Rear brake • Check operation, fluid level and
vehicle for fluid leakage.
√√ √ √ √
√
• Replace brake pads. Whenever worn to the limit
5*Brake hoses • Check for cracks or damage.
√√√ √√• Replace. Every 4 years
6*Wheels • Check runout and for damage. √√√ √
• Check tread depth and for damage.
7* Tires • Replace if necessary. √√√ √√
• Check air pressure.
• Correct if necessary.
8* Wheel bearings • Check bearing for looseness or
damage. √√√ √

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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check bearing play and steering
9* Steering bearings for roughness. √√ √ √ √
• Lubricate with lithium-soap-
based grease. Every 20000 km (12000 mi)
10 * Chassis fasteners • Make sure that all nuts, bolts and
screws are properly tightened. √√√ √
√
11 Front brake lever
pivot shaft • Lubricate with silicone grease.
√√√ √
√
12 Rear brake lever
pivot shaft • Lubricate with silicone grease.
√√√ √
√
13 Sidestand,
• Check operation.
centerstand• Lubricate. √√√ √
√
14 *Sidestand switch • Check operation. √√ √ √ √ √
15 * Front fork • Check operation and for oil
leakage. √√√ √
16 * Shock absorber
• Check operation and shock
assemblies absorbers for oil leakage. √√√ √
• Change. (See pages 3-6 When the oil change indicator flashes
17 Engine oil and 6-10.) √
[At 4000 km (2500 mi) and every 3000 km (1800 mi) thereafter]
• Check oil level and vehicle for oil
leakage. Every 3000 km (1800 mi)
√
18 * Engine oil strainer • Clean. √

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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check coolant level and vehicle
19 * Cooling system for coolant leakage. √√√ √√
• Change. Every 3 years
20Final transmission
• Check vehicle for oil leakage.
√√ √oil
• Change. √√ √
21 * V-belt • Replace. When the V-belt replacement indicator flashes
[every 20000 km (12000 mi)]
22 * Front and rear brake
switches • Check operation.
√√ √ √ √ √
23 Moving parts and
cables • Lubricate.
√√√ √√
• Check operation and free play.
Throttle grip • Adjust the throttle cable free
24 * housing play if necessary. √√√ √√
and cable • Lubricate the throttle grip
housing and cable.
25 * Lights, signals and
• Check operation.
switches • Adjust headlight beam. √√ √ √
√√

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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU38262
TIP
Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated paper eleme\
nt, which must not be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter element needs to be serviced more fre- quently when riding in unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always chan\
ge the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change th\
e bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU18740
Removing and installing the
cowling and panel
1. Cowling A
2. Panel
1. Panel A
The cowling and panel shown above
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.
EAUS1790
Cowling A
T
o remove the cowling
1. Remove the panel by pushing itout from the back side of the
cowling as shown.
1. Panel
2. Push
2. Remove the screws, and thenpull the cowling off as shown.
1. Cowling A
To install the cowling
1. Place the cowling in the originalposition, and then install the
screws.
2. Install the panel by pushing it in.
EAU47890
Panel A
T
o remove the panel
Remove the screws, and then pull the
panel outward.



PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Screw
To install the panel
Place the panel in the original posi-
tion, and then install the screws.
EAU19622
Checking the spark plug
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be operating improperly. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
1. Spark plug gap
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)

1
ZAUM0037

Specified spark plug:NGK/DPR8EA-9

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