YAMAHA XMAX 250 2010 Workshop Manual

TIP
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. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
EAUS1711
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 level1. Place the scooter on the centers- tand. 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.
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.
TIP
The engine oil should be between the
minimum and maximum level marks.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
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
3
2
1
ZAUM0685

Tightening torque:Spark plug:17.5 Nm (1.75 m•kgf,
12.7 ft•lbf)
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3. Remove the engine oil filler capand the engine oil drain bolt to
drain the oil from the crankcase.
1. Engine oil drain bolt
4. Check the washer for damageand replace it if necessary.
1. Engine oil drain bolt
2. Washer
5. Install the washer and the engineoil drain bolt, and then tighten the
drain bolt to the specified torque.
TIP
Make sure that the washer is properly
seated.
6. Refill with the specified amountof the recommended engine oil,
and then install and tighten the oil
filler cap.
ECA11670
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 cause.
8. Reset the oil change indicator.
To reset the oil change indicator 1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button pushed for 15 to 20 seconds.
1. “OIL CHANGE” button

1
NOTICE

Recommended engine oil:See page 8-1
Oil change quantity: 1.30 L (1.37 US qt, 1.14 Imp.qt)
Tightening torque:Engine oil drain bolt:20 Nm (2.0 m•kgf, 14 ft•lbf)

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1. “OIL CHANGE” button
3. Release the “OIL CHANGE” but-ton, and the oil change indicator
will go off.
TIP
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator must
be reset after the oil change for the
next periodic oil change to be indica-
ted at the correct time. To reset the oil
change indicator before the periodic
oil change interval has been reached,
follow the above procedure, but note
that the indicator will come on for 1.4
seconds after releasing the “OIL CHANGE” button, otherwise repeat
the procedure.
EAU20064
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.
4. Remove the final transmission oil filler cap and final transmission
drain bolt to drain the oil from the
final transmission case.

1

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1. Final transmission oil filler cap
2. O-ring
5. Install the final transmission oildrain bolt, and then tighten it to
the specified torque.
1. Final transmission oil drain bolt
6. Refill with the specified amountof the recommended final trans-
mission oil, and then install and
tighten the oil filler cap. WAR-
NING! Make sure that no
foreign material enters the final
transmission case. Make sure
that no oil gets on the tire or
wheel.
[EWA11311]
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.
EAUS1670
To check the coolant level1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion.
TIP
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 throughthe check window.
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, 16 ft•lbf)

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TIP
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. Coolant level check window
3. If the coolant is at or below theminimum level mark, lift up the
right floorboard mat as shown.
1. Floorboard mat
4. Open the reservoir cap, and thenadd coolant to the maximum
level mark. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA15161]
NOTICE: If coolant is not avai-
lable, use distilled water or soft
tap water instead. Do not use
hard water or salt water since it
is harmful to the engine. If
water has been used instead of
coolant, replace it with coolant
as soon as possible, otherwise
the cooling system will not be
protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
[ECA10472]
1. Coolant reservoir cap
5. Close the reservoir cap
6. Place the floorboard mat in the original position and push it
downward to secure it.
EAU33031
Changing the coolant
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant. WARNING! Never attempt
to remove the radiator cap when
the engine is hot.
[EWA10381]
Coolant reservoir capacity: 0.25 L (0.26 US qt, 0.22 Imp.qt)

FULL
LOW

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EAUS1334
Air filter and V-belt case air
filter elements
The air filter element should be repla-
ced and the V-belt case air filter ele-
ment should be cleaned at the inter-
vals specified in the periodic
maintenance and lubrication chart.
Service the air filter elements more
frequently if you are riding in unu-
sually wet or dusty areas.
Replacing the air filter element1. Place the scooter on the centers- tand.
1. Air filter case cover
2. Screw
3. Air filter element
2. Remove the air filter case coverby removing the screws.
3. Pull the air filter element out.
4. Insert a new air filter element into the air filter case.
5. Install the air filter case cover by installing the screws.
Cleaning the V-belt case air filter
element 1. Remove the V-belt case air filter cover by removing the screws.
1. V-belt case air filter cover
2. Screw
2. Remove the air filter element, andthen blow out the dirt with com-
pressed air as shown.
1. V-belt case air filter cover
2. V-belt case air filter element
3. Check the air filter element fordamage and replace it if neces-
sary.
4. Install the air filter element with the colored side facing outward.
NOTICE: Make sure that each
filter element is properly sea-
ted in its case. The engine
should never be operated wit-
hout the filter elements insta-
lled, otherwise the piston(s)
and/or cylinder(s) may become
excessively worn.
[ECA10531]
5. Install the V-belt case air filter cover by installing the screws.

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EAU21382
Checking the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 3.0–5.0 mm (0.12–0.20 in) at
the throttle grip. Periodically check
the throttle cable free play and, if
necessary, have a Yamaha dealer
adjust it.
EAU21401
Valve clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clearan-
ce must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU21873
Tires
To maximize the performance, durabi-
lity, and safe operation of your vehi-
cle, note the following points regar-
ding the specified tires.
Tire air pressure
The tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
EWA10501
Operation of this vehicle with
improper tire pressure may cause
severe injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold

WARNING

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tires (i.e., when the temperatu-
re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories appro-
ved for this model.
EWA10511
Never overload your vehicle. Ope-
ration of an overloaded vehicle
could cause an accident.
Tire inspection
1. Tire tread depth
2. Tire sidewall
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
TIP
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires lis-
ted below have been approved for
this model by Yamaha Motor Co., Ltd.
Front tire:Size:120/70-15 56S
Manufacturer/model: MICHELIN/GOLD STANDARD
PIRELLI/GTS23
Rear tire: Size:140/70-14 68P - 68S
Manufacturer/model: MICHELIN/GOLD STANDARD
PIRELLI/GTS24
Minimum tire tread depth (front
and rear): 1.6 mm (0.06 in)

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ZAUM0054

WARNING

Tire air pressure (measured on
cold tires): 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)
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)
Maximum load*: 186 kg (410 lb)
* Total weight of rider, passenger, cargo and accessories
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EWA10470
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
EAU21960
Cast wheels
To maximize the performance, durabi-
lity, and safe operation of your vehi-
cle, note the following points regar-
ding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpage
before each ride. If any damage
is found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or crac-
ked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAUM2061
Checking the front and rear
brake lever free play
1. Brake lever free play
1. Brake lever free play
The brake lever free play should mea-
sure 3.0-3.5 mm (0.12-0.20 in) as
shown. Periodically check the brake

WARNING

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lever free play and, if necessary, have
a Yamaha dealer check the brake sys-
tem.
EWA10641
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate
the vehicle until the brake system
has been checked or repaired by a
Yamaha dealer.
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.
EAU22430
Front brake pads
1. Wear indicator groove
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the
wear indicator grooves have almostdisappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22520
Rear brake pads
1. 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.

WARNING

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