Yamaha YP250R X-MAX 2005 Operating and installation instructions

SERVICE
INFORMATION
1C01-SE0
’05
YP250R
X-MAX

2
SERVICE INFORMATION
© 2005 Yamaha Motor España, S.A.
1st edition, May 2005
All rights reserved.
Any reproduction or unauthorized use
without written permission from YAMAHA
MOTOR ESPAÑA S.A. is strictly prohibited.
Printed in Spain.

3
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
7
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
8
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
9
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
10
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.

11
Tool Nº Tool Name / Function Illustration
90890-04016 Valve guide installation and removal tool
(5,5 ø)
These tools are used to extract or install
the valve guides.
90890-04019 Valve spring compressor
90890-04108 Valve spring compressor accessory
These tools are used for extracting or
installing the valve and the valve spring.
90890-04058 Intermediate driven shaft bearing
installation tool
90890-04078 Mechanical seal installation tool
These tools are used to install mechanical
seals.
90890-04066 Valve guide reamer (6 ø)
This tool is used to rectify new valve
guides.
90890-04101 Valve grinder
This tool is used to extract and install the
lift and also to polish the valve.
90890-06754 Ignition tester
This tool is used to test the ignition system
components.
90890-06756 Manometer/vacuum pump set
This tool is used to check the air
cut-off valve.
90890-85505 Yamaha adhesive, Nº 1215
This adhesive is used to seal two
coupling services (for example the
engine sump coupling surfaces).
SPECIAL TOOLS GEN/
INFO

2 - 1
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code
1C01 ----
----
Dimensions
Overall length 2,210 mm (87.0 in) ----
Overall width 790 mm (31.1 in) ----
Overall height 1,380 mm (54.3 in) ----
Seat height 775 mm (30.51 in) ----
Wheelbase 1,545 mm (60.8 in) ----
Minimum ground clearance 113 mm (4.45 in) ----
Minimum turning radius 3,650 mm (143.7 in) ----
Weight
Wet (with oil and a full fuel tank) 174 kg (383.67 lb) ----
Maximum load (total of cargo, rider,
passenger, and accessories)
164 kg (361.62 lb) ----
GENERAL SPECIFICATIONS

2 - 2
SPEC
ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid cooled 4-stroke, SOHC ----
Displacement 249.7cm3(15.24 cu.in) ----
Cylinder arrangement Forward-inclined single cylinder ----
Bore ×stroke 69.0 ×66.8mm (2.72 ×2.63 in) ----
Compression ratio 10.1: 1 ----
Standard compression pressure
(at sea level)
1400 kPa (14.0kg/cm2)at
500 r/min
----
Starting system type Electric starter ----
Fuel
Recommended fuel Regular unleaded gasoline only ----
Fuel tank capacity
Total 12.0L (2.64 Imp gal, 3.17 US gal) ----
Engine oil
Lubrication system Wet sump ----
Recommended oil
SAE 10W30, SAE 10W40, SAE 15W40,
SAE 20W40 or SAE 20W50
Refer to the chart for the engine oil grade.
----
Recommended engine oil grade API service SG and also JASO MA type
or higher
----
Quantity
Total amount 1.60 L (1.41 Imp qt, 1.69 US qt) ----
Periodic oil change 1.42L (1.05 Imp qt, 1.27 US qt) ----
Engine oil temperature 75 ~ 85 °C (167 ~ 185 °F) ----
Final transmission oil
Type SAE 10W30 type SE motor oil ----
Periodic replacement 0.25L (0.21 Imp qt, 0.26 US qt) ----
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50 ˚C
SAE 10W-30
SAE 15W-40
SAE 20W-40
SAE 20W-50
SAE 10W-40

2 - 3
SPEC
ENGINE SPECIFICATIONS
Oil pump
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip clear-
ance
0.10 ~ 0.15 mm
(0.003~ 0.013 in)
0.40 mm
(0.0015 in)
Outer-rotor-to-oil-pump-housing
clearance
0.013 ~ 0.036 mm
(0.005 ~ 0.001in)
0.15 mm
(0.005in)
Oil-pump-housing-to-inner-and-outer
rotor clearance
0.04~ 0.09 mm
(0.0015 ~ 0.0035 in)
0.15mm
(0.005in)
Cooling system
Radiator and engine capacity 0.70 L (0.62 Imp qt, 0.74 US qt) ----
Radiator cap opening pressure 100.0 ~ 120.0 kPa
(1.00 ~ 1.20 kg/cm2, 14.2 ~ 17.1 psi)
----
Radiator core
Width 229.0 mm (9.02 in) ----
Height 111.5 mm (4.39 in) ----
Depth 23.0 mm (0.91 in) ----
Coolant reservoir
Capacity (up to the maximum level
mark)
0.26 L (0.23 Imp qt, 0.28 US qt) ----
Water pump
Water pump type Single suction centrifugal pump ----
Reduction ratio 37/22-25/37
Coolant temperature 80 ~ 90 °C (176 ~ 194 °F) ----
Spark plug
Model (manufacturer) ×quantity DR8EA (NGK) ×1----
Spark plug gap 0.6~ 0.7mm (0.023 ~ 0.027 in) ----
Cylinder head
Maximum warpage ---- 0.05 mm
(0.0020 in)
Item Standard Limit

2 - 4
SPEC
ENGINE SPECIFICATIONS
Camshaft
Drive system Chain drive (left) ----
Intake camshaft lobe dimensions
Measurement A36.545 ~ 36.645 mm (1.4387 ~ 1.4427 in)36.450 mm
(1.4350 in)
Measurement B30.021 ~ 30.121 mm (1.1819 ~ 1.1858 in)29.920 mm
(1.1779 in)
Exhaust camshaft lobe dimensions
Measurement A36.547 ~ 36.647 mm (1.4388 ~ 1.4428 in)36.450 mm
(1.4350 in)
Measurement B30.067 ~ 30.167 mm (1.1837 ~ 1.1876 in)29.170 mm
(1.1484 in)
Maximum camshaft runout ---- 0.030 mm
(0.0012 in)
Timing chain
Model/number of links SC.A-0404ASDH/104 ----
Tensioning system Automatic ----
Item Standard Limit
A
B
A
B

2 - 5
SPEC
ENGINE SPECIFICATIONS
Rocker arms/rocker arm shafts
Rocker arm inside diameter 12.000 ~ 12.0.18 mm (0.4724 ~ 0.4731 in) 12.030 mm
(0.4736 in)
Rocker arm shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4720 in) 11.950mm
(0.4704 in)
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.037mm (0.0004 ~ 0.0014in) 0.080 mm
(0.0031in)
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.08 ~ 0.12mm (0.0031~ 0.0047 in) ----
Exhaust 0.16 ~ 0.20mm (0.0062 ~ 0.0078 in) ----
Valve dimensions
Valve head diameter A
Intake 33.90 ~ 34.10 mm (1.3346 ~1.3425 in) ----
Exhaust 28.40 ~ 28.60 mm (1.1181 ~ 1.1259 in) ----
Valve face width B
Intake 3.394 ~ 3.960 mm (0.1336 ~ 0.1559 in) ----
Exhaust 3.394 ~ 3.960 mm (0.1336 ~ 0.1559 in) ----
Valve seat width C
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Valve margin thickness D
Intake 0.80~ 1.20 mm (0.0314 ~ 0.0472 in) ----
Exhaust 0.80~ 1.20 mm (0.0314 ~ 0.0472 in) ----
Valve stem diameter
Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.940 mm
(0.2338 in)
Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm
(0.2082 in)
Valve guide inside diameter
Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2366 in) 6.050 mm
(0.2381 in)
Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2366 in) 6.050 mm
(0.2381 in)
Item Standard Limit
BC
D
A
Head Diameter Face Width Seat Width Margin Thickness

2 - 6
SPEC
ENGINE SPECIFICATIONS
Valve-stem-to-valve-guide clearance
Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
(0.0031 in)
Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm
(0.0039 in)
Valve stem runout ---- 0.010 mm
(0.0004 in)
Cylinder head valve seat width
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Valve springs
Free length
Intake and exhaust (inner) 38.10 mm (1.50 in) 36.10 mm
(1.42 in)
Intake and exhaust (outer)36.93 mm (1.45in) 35.00mm
(1.38 in)
Installed length (valve closed)
Intake 30.10 mm (1.18 in) ----
Exhaust 30.10 mm (1.18 in) ----
Compressed spring force (installed)
Intake and exhaust (inner) 76.5 ~ 88.3 N
(7.80 ~ 9.00 kg, 436.83 ~ 504.21 lb)
----
Intake and exhaust (outer) 115 ~ 133 N
(11.7 ~ 13.5 kg, 655.47 ~ 756.31 lb)
----
Spring tilt
Inner ---- 2.5°/1.7mm
(2.5°/0.07 in)
Outer ---- 2.5°/1.6mm
(2.5°/0.06in)
Item Standard Limit

2 - 7
SPEC
ENGINE SPECIFICATIONS
Winding direction (top view)
Inner Counterclockwise ----
Outer Clockwise ----
Cylinder
Cylinder arrangement Forward-inclined single cylinder ----
Bore ×stroke 69.0 ×66.8mm (2.72 ×2.63 in) ----
Compression ratio 10.1: 1 ----
Bore 69.000 ~ 69.005 mm (2.7165 ~ 2.7167 in)69.100 mm
(2.7204 in)
Maximum taper ---- 0.050 mm
(0.0020 in)
Maximum out of round ---- 0.003mm
(0.0001in)
Piston
Piston-to-cylinder clearance 0.020 ~ 0.040mm (0.0007~ 0.0015in) 0.15 mm
(0.0059 in)
Diameter D 68.965 ~ 68.980 mm (2.7151 ~ 2.7157 in) ----
Height H 5.0 mm (0.20 in) ----
Piston pin bore (in the piston)
Diameter 17.004~ 17.015mm
(0.6694 ~ 0.6698 in)
17.045mm
(0.6710 in)
Offset 0.5 mm (0.0197 in) ----
Offset direction Intake side ----
Piston pin
Outside diameter16.991~ 17.000 mm
(0.6689 ~ 0.6692 in)
16.975 mm
(0.6683 in)
Piston-pin-to-piston-pin-bore clear-
ance
0.004~ 0.024 mm (0.0001 ~ 0.0009in) 0.068 mm
(0.0027 in)
Piston rings
Top ring
Ring type Barrel ----
Dimensions (B ×T) 1.00 ×2.60 mm (0.03 ×0.10 in) ----
Item Standard Limit
H
D
T
B

2 - 8
SPEC
ENGINE SPECIFICATIONS
End gap (installed) 0.15~ 0.30 mm (0.0059 ~ 0.0118 in) 0.45 mm
(0.0177 in)
Ring side clearance 0.040 ~ 0.080 mm (0.0015~ 0.0031 in) 0.120 mm
(0.0047in)
2nd ring
Ring type Taper ----
Dimensions (B ×T) 1.00×2.90 mm (0.03 ×0.11 in) ----
End gap (installed) 0.30 ~ 0.45mm (0.0118 ~ 0.0177 in) 0.70 mm
(0.0275 in)
Ring side clearance 0.030 ~ 0.070 mm (0.0011 ~ 0.0027in) 0.120 mm
(0.0047in)
Oil ring
Dimensions (B ×T) 1.50×2.50 mm (0.06 ×0.09in) ----
End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ----
Ring side clearance 0.060 ~ 0.150 mm (0.0023 ~ 0.0059 in) ----
Crankshaft
Width A 59.95 ~ 60.00 mm (2.3602 ~ 2.3622 in) ----
Maximum runout C ---- 0.030 mm
(0.0012 in)
Big end side clearance D 0.350 ~ 0.850 mm (0.0137 ~ 0.0334 in) ----
Big end radial clearance E 0.010 ~ 0.025 mm (0.0003~ 0.001in) ----
Automatic centrifugal clutch
Clutch shoe thickness 3.3mm (0.1299 in) 2.0 mm
(0.078 in)
Clutch shoe spring free length 28.1mm (1.1063 in) ----
Clutch housing inside diameter 145.0 mm (5.71 in) 145.5 mm
(5.73 in)
Compression spring free length 102.4mm (4.03 in) 90.0mm
(3.54 in)
Weight outside diameter 20.0 mm (0.79 in) 19.5 mm
(0.77 in)
Item Standard Limit
B
T
B
T
C
C
D
A
E

2 - 9
SPEC
ENGINE SPECIFICATIONS
Clutch-in revolution 2,250 ~ 2,850 r/min ----
Clutch-stall revolution 3,700 ~ 4,700 r/min ----
V-belt
V-belt width 22.6mm (0.89in) 20.3mm
(0.79in)
Transmission
Primary reduction system Helical gear ----
Primary reduction ratio 40×15(2.666)----
Secondary reduction system Helical gear ----
Secondary reduction ratio 38 ×15(2.533)----
Clutch type Dry, centrifugal automatic ----
Transmission type V-belt automatic ----
Operation Centrifugal automatic type ----
Single speed automatic 2.440 ~ 0.830:1 ----
Air filter
Air filter element Wet element ----
Fuel pump
Pump type Electrical ----
Model (manufacturer) 2GV (MITSUBISHII) ----
Output pressure 12.5 kPa (0.13 kg/cm2, 1.85 psi) ----
Ca rburettor
Model x qty. CVEK30 x 1 ----
Manufacturer KEIHIN ----
Needle jet #2.6 ----
Main jet #122 ----
Main air jet 90 ----
Jet needle JPBL ----
ID mark 1C0C00 ----
Guide air jet 1 #35 ----
Guide bolt rotations outwards 1- 7/8 ----
Valve seat size 1.6 ----
Starter jet 1 38 ----
Co % 4% ----
Throttle cable free play (at the flange
of the throttle grip)
3~ 5mm (0.12~ 0.20 in) ----
Item Standard Limit