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.