Yamaha YP250R X-MAX 2005 Bedienungs- und Montageanleitung

SERVICE

INFORMATION

1C01-SE0

’05

YP250R

X-MAX

SERVICE INFORMATION

1st edition, May 2005

Any reproduction or unauthorized use

without written permission from YAMAHA

MOTOR ESPAÑA S.A. is strictly prohibited.

Printed in Spain.

WARNING

This manual has been edited by Yamaha Motor España, S.A. principally for use by

YAMAHA dealers and their qualified mechanics. It is not possible to include the comple-

te training for a mechanic in one volume, it has been assumed, therefore, that the per-

sons that use this manual for the repair and maintenance of YAMAHA motorcycles alre-

ady have the basic knowledge and understanding of the mechanics and of the repair

techniques involved in the processes.

Without such previous knowledge, any attempt to carry out repairs or maintenance work

on this model may render it inadequate for use or even dangerous.

YAMAHA MOTOR ESPAÑA, S.A. is continually striving to improve its products. All

YAMAHA dealers will be notified about significant modifications and changes introduced

in specifications and procedures, and when necessary, these changes will be included in

future editions of this manual.

NOTE:

The design and specifications are subject to modification without prior notice.

IMPORTANT INFORMATION

Particularly important information are indicated by the following notations:

This warning symbol means: “ WARNING!”, “BE AWARE!”, “

YOUR SAFETY IS AT RISK!”

Disregard for the instructions given in the WARNING may result

in serious injury or even death for the motorcycle user, for bys-

tanders, or the person in charge of inspection, revision or

repairs of the vehicle.

This indication means that special procedures must be applied

in order to avoid damage to a motorcycle.

The NOTES supply information in order to facilitate or clarify

the procedures that must be applied.



WARNING:

CAUTION:

NOTE :

SYMBOL USE

The symbols from to are used to

identify the different chapters and to indi-

cate their content.

General information

Specifications

Inspection and periodic adjustments

Engine

Cooling system

Fuel

Chassis

Electric system

Fault finding.

The symbols from 10 to 17 may be used to

identify the specifications found in the text.

10 Possible motorcycle engine

maintenance

11 Liquid to be added

12 Lubricant

13 Special tools

14 Tightening

15 Wear limits, play

16 Engine idle speed

17 Ω, V, A

The symbols from 18 to 23 are used for

disassembly indicate the lubricant applica-

tion points and the type of lubricant speci-

fied.

18 Apply engine oil

19 Apply gear oil

20 Apply molybdenum disulphide oil

21 Apply wheel bearing grease

22 Apply light lithium soap base grease

23 Apply molybdenum disulphide grease

The symbols 24 and 25 are used for disas-

sembly to indicate locations application of

locking agent 24, and when to install new

parts 25 .

24 Apply thread locking agent

(THREADLOCK®)

25 Use a new part

CHK/

ADJ

COOL

CHAS

TRBL

SHTG

SPEC

ENG

CARB

ELEC

GEN

INFO

NEW











11

13

18

21

24









10

12

14

25

20

23

19

22

15 1716

INDEX

GENERAL INFORMATION ……………………………………………………………………7

SCOOTER IDENTIFICATION ………………………………………………………………7

SPECIAL TOOLS …………………………………………………………………………8

SPECIFICATIONS ……………………………………………………………………………12

GENERAL SPECIFICATIONS ……………………………………………………………12

MAINTENANCE SPECIFICATIONS ……………………………………………………13

ENGINE ……………………………………………………………………………………13

TIGHTENING TORQUES (ENGINE) ……………………………………………………19

CHASSIS …………………………………………………………………………………21

TIGHTENING TORQUES (CHASSIS) …………………………………………………23

ELECTRICAL SPECIFICATIONS ………………………………………………………25

CABLE ROUTES ………………………………………………………………………………27

INSPECTIONS AND PERIODIC ADJUSTMENTS ………………………………………36

INTRODUCTION / PERIODIC MAINTENANCE

LUBRICATION INTERVALS ……………………………………………………………36

ELECTRICS DIAGRAM ………………………………………………………………………38

SCOOTER IDENTIFICATION GEN/

INFO

GENERAL INFORMATION

SCOOTER IDENTIFICATION

FRAME NUMBER

The frame number is stamped underne-

ath the carpet of the right-hand side foo-

trest.

NOTE:

The frame number is used to identify the

motorcycle and may be used for the regis-

tration with any administration.

MODEL LABEL

The model label is located underneath

the seat. This information is necessary to

order spare parts.

NOTE:

The design and characteristics may be

modified without prior notice.



SPECIAL TOOLS GEN/

INFO

SPECIAL TOOLS

The following special tools are essential for a complete and precise repair and fitting. Only

use the adequate special tools; this will prevent damage caused by an inappropriate tools

or incorrect procedures.

When making an order, consult the following list to avoid possible errors.

Tool Nº Tool Name / Function Illustration

90890-01016 Spacer 

90890-01274 Crankshaft calibrated spacer 

90890-01275 Crankshaft installation pin 

90890-01280 Adapter (M16) 

90890-01288 Spacer 

90890-01478 Adapter (M14) 

These tools are used for installing

the crankshaft.

90890-01083 Sliding hammer bolt

90890-01084 Counterweight

These tools are used to extract or install

the rocker shafts.

90890-01135 Crankcase separation tool

These tools are used for extracting the

crankshaft.

90890-01235 Rotor retention tool

This tool to machetes to hold the fixed

primary pulley.

90890-01268 Ring nut wrench

This tool is used to loosen and tighten the

steering ring nuts.

90890-01294 Shock absorber rod bracket

90890-01460 T sleeve

These tools are used to hold a shock

absorber bar bracket for it in and

removing the same.

SPECIAL TOOLS GEN/

INFO

Tool Nº Tool Name / Function Illustration

90890-01304 Spring pin extractor assembly

These tools are used for extracting pins.

90890-01311 Valve tappet adjustment tool

This tool is used for valve adjustment. .

90890-01312 Fuel level indicator

This indicator is used to measure the fuel

level in the floater chamber.

90890-01337 Clutch spring bracket

90890-01464 Clutch spring bracket arm

These tools are used to support the

compression spring when the clutch

bracket nut is being fitted or removed.

90890-01348 Counter nut wrench

This tool is used to remove or fit the

clutch bracket nut.

90890-01362 Fly Wheel extractor

This tool is used for extracting the

alternator rotor..

90890-01367 Guide weight for the fork seal

90890-01372 Holder for the fork seal (ø38)

These tools are used to fit the oil seal,

the dust guard and the outer seals for

one of the front fork arms.

90890-01403 Steering nut wrench

This tool is used to loosen and tighten

the steering ring nuts.

SPECIAL TOOLS GEN/

INFO

Tool Nº Tool Name / Function Illustration

90890-01996 Cylinder cup installation tool

This tool is used to install the cylinder cup

on the piston of the main cylinder.

90890-03008 Micrometer (50 ~ 75 mm)

This tool is used to measure the diameter

of the piston skirt.

90890-03079 Thickness gauge

This tool is used to measure the valve

clearance.

90890-03081 Pressure manometer

These tools are used to measure engine

compression.

90890-03112 Pocket tester

This tool is used for tests on the electrical

system.

90890-03113 Engine tachometer

This tool is used to measure engine speed.

90890-03132 Pocket tester

This tool is used to measure engine oil

temperature.

90890-03134 Exhaust accessory

This tool is used to measure the carbon

monoxide gas density.

90890-03141 Stroboscope

This tool is used to measure ignition

distribution.

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