engine YAMAHA XMAX 250 2012 Service Manual

EAU37833
Matte color cautionECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use
before cleaning the vehicle.
Using a brush, harsh chemical pro-
ducts or cleaning compounds
when cleaning these parts will
scratch or damage their surface.
Wax also should not be applied to
any matte colored finished parts.
EAU26094
Care
While the open design of a scooter
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go
unnoticed on a car, however, it
detracts from the overall appearance
of a scooter. Frequent and proper
care does not only comply with the
terms of the warranty, but it will also
keep your scooter looking good,
extend its life and optimize its perfor-
mance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and abrush, but never apply such pro-
ducts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA10783
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with
water to clean plastic. Howe-
ver, if the plastic parts cannot
be thoroughly cleaned with
water, diluted mild detergent
NOTICE
NOTICE
SCOOTER CARE AND STORAGE
7-1
7

with 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. NOTI-
CE: 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.)
SCOOTER CARE AND STORAGE
7-2
7

fuel from deteriorating.
3. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a Remove the spark plug cap
and spark plug.
b Pour a teaspoonful of engine
oil into the spark plug bore.
c Install the spark plug cap
onto the spark plug, and then
place the spark plug on the
cylinder head so that the
electrodes are grounded.
(This will limit sparking during
the next step.)
d Turn the engine over several
times with the starter. (This
will coat the cylinder wall with
oil.)
e Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING!
To prevent damage or injury
from sparking, make sure
to ground the spark plug
electrodes while turning the
engine over.
[EWA10951]
4. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alter-
natively, turn the wheels a little
every month in order to prevent
the tires from becoming degra-
ded in one spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery in
an excessively cold or warm pla-
ce [less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more
information on storing the bat-
tery, see page 6-25.
TIP
Make any necessary repairs before
storing the scooter.
SCOOTER CARE AND STORAGE
7-4
7

Dimensions:Overall length:
2201 mm (86.7 in)
Overall width:
776 mm (30.6 in)
Overall height:
YP250R 1337 mm (52.6 in)
YP250RA 1337 mm (52.6 in)
YP250R Sport 1186 mm (46.7 in)
Seat height:
792 mm (31.2 in)
Wheelbase:
1545 mm (60.8 in)
Ground clearance:
135 mm (5.31 in)
Minimum turning radius:
1805 mm (71.1 in)
Weight:With oil and fuel:
YP250R 180 kg (397 lb)
YP250RA 184 kg (406 lb)
YP250R Sport 181.5 kg (400 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
249 cm
3
Bore x stroke:
69.0 x 66.8 mm (2.72 x 2.63 in)
Compression ratio:
10.00 :1
Starting system:
Electric starterLubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade:
API service SF, SG type or higher, JASO
standard MA
Engine oil quantity:Periodic oil change:
1.30 L (1.37 US qt, 1.14 Imp.qt)
Final transmission oil:Type:
YAMALUBE 10W-40 or SAE 10W-30 type
SE motor oil
Quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Cooling system:Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)Radiator capacity (including all routes):
1.00 L (1.06 US qt, 0.88 Imp.qt)
Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
11.8 L (3.12 US gal, 2.60 Imp.gal)
Fuel reserve amount:
2.0 L (0.53 US gal, 0.44 Imp.gal)
Spark plug(s):Manufacturer/model:
NGK/DPR8EA-9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Clutch:Clutch type:
Dry, centrifugal automatic
Transmission:Primary reduction system:
Helical gear
Primary reduction ratio:
40/15 (2.666)
Secondary reduction system:
Helical gear
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40
SAE 20W-40
SAE 20W-50
SAE 10W-40
SAE 10W-50
SPECIFICATIONS
8-1
8

Voltage, capacity:
12 V, 8.0 Ah
Headlight:Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:Low beam headlight:
12 V, 55.0 W x 1
High beam headlight:
12 V, 55.0 W x 1
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:
12 V, 2.0 W x 3
High beam indicator light:
12 V, 1.4 W x 1
Turn signal indicator light:
12 V, 1.4 W x 2
Engine trouble warning light:
12 V, 1.4 W x 1
ABS warning light (for ABS models):
12 V, 1.4 W x 1
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
7.5 A
Hazard fuse:
10.0 A
ECU fuse:
5.0 A
ABS control unit fuse (for ABS models):
5.0 A
ABS motor fuse (for ABS models):
30.0 A
ABS solenoid fuse (for ABS models):
20.0 A
Backup fuse:
5.0 A
SPECIFICATIONS
8-3
8

AABS (for ABS models)..............................3-13
ABS warning light (for ABS models) ..........3-4
Acceleration and deceleration ...................5-3
Air filter and V-belt case air filter
elements ................................................6-15
Anti-theft alarm (optional) ........................3-11
Auxiliary light bulb, replacing ...................6-30
BBattery......................................................6-25
Brake fluid level, checking .......................6-21
Brake fluid, changing ...............................6-22
Brake lever, front ......................................3-12
Brake lever, rear .......................................3-12
Brake levers, lubricating ..........................6-22
Braking .......................................................5-3
CCare............................................................7-1
Catalytic converters .................................3-16
Centerstand and sidestand, checking
and lubricating .......................................6-23
Coolant.....................................................6-13
Cowlings and panels, removing and
installing ...................................................6-8
DDimmer switch .........................................3-11
EEngine break-in ..........................................5-4
Engine oil .................................................6-10
Engine trouble warning light ......................3-4
FFinal transmission oil ...............................6-12
Front and rear brake lever free play.........6-19
Front and rear brake pads, checking ......6-20Front fork, checking .................................6-24
Fuel ..........................................................3-15
Fuel consumption, tips for reducing ..........5-4
Fuel tank cap ...........................................3-14
Fuses, replacing .......................................6-26
HHandlebar switches .................................3-11
Hazard switch ..........................................3-12
Headlight bulb, replacing .........................6-28
High beam indicator light...........................3-4
Horn switch ..............................................3-12
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-20
Immobilizer system ....................................3-1
Indicator and warning lights ......................3-4
LLicense plate light bulb, replacing ...........6-30
MMain switch/steering lock ..........................3-2
Maintenance and lubrication, periodic ......6-4
Maintenance, emission control system .....6-3
Matte color, caution ...................................7-1
Model label ................................................9-1
Multi-function display ................................3-6
PParking .......................................................5-5
Part locations .............................................2-1
Pass switch ..............................................3-12
SSafe-riding points.......................................1-5
Safety information ......................................1-1
Seat ..........................................................3-17
Securing bracket ......................................3-17Shock absorber assemblies, adjusting....3-19
Sidestand .................................................3-20
Spark plug, checking .................................6-9
Specifications.............................................8-1
Speedometer .............................................3-5
Start switch ..............................................3-12
Starting off .................................................5-2
Starting the engine.....................................5-1
Steering, checking ...................................6-24
Storage.......................................................7-3
Storage compartments ............................3-18
TTachometer ................................................3-6
Tail/brake light bulb or rear turn signal
light bulb, replacing ...............................6-29
Throttle cable free play, adjusting ............6-16
Throttle grip and cable, checking and
lubricating ..............................................6-22
Tires .........................................................6-17
Tool kit ........................................................6-2
Troubleshooting .......................................6-30
Troubleshooting charts ............................6-32
Turn signal indicator lights .........................3-4
Turn signal light bulb (front), replacing ....6-29
Turn signal switch ....................................3-12
VValve clearance ........................................6-17
Vehicle identification number .....................9-1
WWheel bearings, checking........................6-25
Wheels .....................................................6-19
INDEX