Yamaha MBK XMAX 2014 User manual

2014
SERVICE MANUAL
YP250R
YP250RA
2DL-F8197-E0

EAS20040
YP250R/YP250RA 2014
SERVICE MANUAL
©2013 by MBK Industrie
First edition, November 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.

EAS5WWL025
IMPORTANT
This manual was produced by MBK Industrie. primarily for use by Yamaha and MBK dealers and their
qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There-
fore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. and MBK Industrie are continually striving to improve all of its models.
Modifications and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha and MBK dealers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
• Sub-section titles appear in smaller print than the section title “2”.
• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly
step “4”.
• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc “6”.
• Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
1
7
3
5
4
6
2

EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

EAS20110 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE ABS (for YP250RA) ....................................................1-4
ABS COMPONENT FUNCTIONS .............................................................1-8
ABS OPERATION ...................................................................................1-14
ABS WARNING LIGHT AND OPERATION.............................................1-17
INSTRUMENT FUNCTIONS..........................................................................1-18
IMPORTANT INFORMATION .......................................................................1-24
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-24
REPLACEMENT PARTS.........................................................................1-24
GASKETS, OIL SEALS AND O-RINGS ..................................................1-24
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-24
BEARINGS AND OIL SEALS ..................................................................1-25
CIRCLIPS ................................................................................................1-25
RUBBER PARTS.....................................................................................1-25
BASIC SERVICE INFORMATION.................................................................1-26
QUICK FASTENERS...............................................................................1-26
ELECTRICAL SYSTEM...........................................................................1-27
SPECIAL TOOLS ..........................................................................................1-31

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the location
shown. This information will be needed to order
spare parts.
1
1