engine YAMAHA XMAX 250 2015 Owner's Manual

Operation and important riding points
5-6
5
EAU17214
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10312
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans 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, increasing the
risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
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Periodic maintenance and adjustment
6-1
6
EAUS1824
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
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 ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading todeath. See page 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA10331
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty, mud-
dy or wet conditions, the air filter el-
ement should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result. Con-
sult a Yamaha dealer for proper
maintenance intervals.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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Periodic maintenance and adjustment
6-2
6
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and
equipped to perform these particular
services.
EAU17382
Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-20.)
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 preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1.
ZAUM1020
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Periodic maintenance and adjustment
6-3
6
EAU46862
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.
EAU63321
Periodic maintenance chart for the emission control system
NO. ITEM
1*Fuel line• Check fuel hoses for cracks or
damage.√√√√√
2Spark plug• Check condition.
• Clean and regap.√√
• Replace.√√
3*Va l v e s• Check valve clearance.
•Adjust.√√
4*Fuel injection• Check engine idle speed.√√√√√
5*Muffler and ex-
haust pipe• Check the screw clamp(s) for
looseness.√√√√√X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
1 10203040
0.6 6 12 18 24
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Periodic maintenance and adjustment
6-5
6
14Rear brake lever
pivot shaft• Lubricate with silicone grease.√√√√√
15Sidestand, center-
stand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
16*Sidestand switch• Check operation.√√√√√√
17*Front fork• Check operation and for oil
leakage.√√√√
18*Shock absorber
assemblies• Check operation and shock ab-
sorbers for oil leakage.√√√√
19 Engine oil• Change. (See pages 3-8 and
6-10.)√When the oil change indi-
cator light flashes (3000
km (1800 mi) after the ini-
tial 1000 km [600 mi] and
every 3000 km (1800 mi)
thereafter)
• Check oil level and vehicle for
oil leakage.Every 3000 km (1800 mi)√
20*Engine oil strainer• Clean.√
21*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
22Final transmission
oil• Check vehicle for oil leakage.√√ √
• Change.√√√
23*V-belt• Replace.When the V-belt replacement
indicator flashes [every 20000
km (12500 mi)]
24*Front and rear
b
rake switches• Check operation.√√√√√√
25Moving parts and
cables• Lubricate.√√√√√
26*Throttle grip• Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip hous-
ing.√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance and adjustment
6-6
6
EAU38263
TIP
Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated pa-
per element, 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
elements need to be serviced more frequently when riding in unusually wet
or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always
change the fluid. Regularly check the brake fluid levels and fill the reser-
voirs as required.
• Every two years replace the internal components of the brake master cyl-
inders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
6-9
6
EAUM3360
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plug
1. Place the vehicle on the center-
stand
2. Open the seat. (See page 3-20.)
3. Remove the rear storage com-
partment by removing the bolts.
4. Remove the spark plug cap.5. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIP
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
1. Storage compartment
2. Bolt
3. Rubber cap
1. Spark plug cap
ZAUM1040
23
1
ZAUM1117
1
1. Spark plug wrench
Specified spark plug:
NGK/DPR8EA-9
ZAUM1118
1
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Periodic maintenance and adjustment
6-10
6 To install the spark plug
1. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
2. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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. However, the
spark plug should be tightened to the
specified torque as soon as possible.
3. Install the spark plug cap.
4. Place the rear storage compart-
ment in the original position and
install the bolts.
5. Close the seat.
EAUM1553
Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec-
ified in the periodic maintenance and
lubrication chart and when the service
indicator light comes on.
To check the engine oil level
1. Place the scooter on the center-
stand. 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 set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
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.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
1
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
1
3
2
1
ZAUM0685
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Periodic maintenance and adjustment
6-11
65. 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.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the washer for damage and
replace it if necessary.
5. Install the washer and the engine
oil 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 amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
NOTICE
ECA11671
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 CONSERVING II” or
higher.
Be sure no foreign material en-
ters 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.
(See page 3-8.)
1. Engine oil drain bolt
1. Engine oil drain bolt
2. Washer
11
ZAUM0686
1
2
ZAUM0129
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil change quantity:
1.30 L (1.37 US qt, 1.14 Imp.qt)
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Periodic maintenance and adjustment
6-12
6
EAU20067
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 transmis-
sion 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 center-
stand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the fi-
nal transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the speci-
fied torque.
7. Refill with the specified amount of
the recommended final transmis-
sion oil. WARNING! Make sure
that no foreign material enters
the final transmission case.
Make sure that no oil gets on
the tire or wheel.
[EWA11312]
8. Install the final transmission oil fill-
er cap and its new O-ring, and
then tighten the oil filler cap.
9. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
1. Final transmission oil filler cap
2. O-ring
ZAUM1123
1. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf, 16 ft·lbf)
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
11
ZAUM0659
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