Yamaha YP250R X-MAX 2005 Service Information
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Yamaha YP250R X-MAX 2005 Service Information

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

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Summary of Contents for Yamaha YP250R X-MAX 2005

  • Page 1 YP250R ’05 1C01-SE0 X-MAX SERVICE INFORMATION...
  • Page 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.
  • Page 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-...
  • Page 4 SYMBOL USE SPEC The symbols from are used to INFO identify the different chapters and to indi- cate their content. CHK/ General information Specifications Inspection and periodic adjustments Engine Cooling system COOL CARB Fuel Chassis Electric system Fault finding. CHAS ELEC The symbols from may be used to...

  • Page 5: Table Of Contents

    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...

  • Page 7: General Information

    GEN/ SCOOTER IDENTIFICATION 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.

  • Page 8: Special Tools

    GEN/ SPECIAL TOOLS 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...
  • Page 9 GEN/ SPECIAL TOOLS 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.
  • Page 10 GEN/ SPECIAL TOOLS 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.
  • Page 11 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).

  • Page 12: Specifications

    SPEC GENERAL SPECIFICATIONS 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) ---- 775 mm (30.51 in) Seat height ---- Wheelbase...

  • Page 13: Engine

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid cooled 4-stroke, SOHC ---- 249.7 cm Displacement (15.24 cu.in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) ---- Compression ratio 10.1 : 1 ----...
  • Page 14 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- 0.10 ~ 0.15 mm Inner-rotor-to-outer-rotor-tip clear- 0.40 mm (0.003 ~ 0.013 in) ance (0.0015 in) Outer-rotor-to-oil-pump-housing 0.013 ~ 0.036 mm 0.15 mm clearance (0.005 ~ 0.001 in) (0.005 in) Oil-pump-housing-to-inner-and-outer 0.04 ~ 0.09 mm...
  • Page 15 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions 36.545 ~ 36.645 mm (1.4387 ~ 1.4427 in) 36.450 mm Measurement A (1.4350 in) 30.021 ~ 30.121 mm (1.1819 ~ 1.1858 in) 29.920 mm Measurement B (1.1779 in) Exhaust camshaft lobe dimensions...
  • Page 16 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arms/rocker arm shafts 12.000 ~ 12.0.18 mm (0.4724 ~ 0.4731 in) 12.030 mm Rocker arm inside diameter (0.4736 in) 11.981 ~ 11.991 mm (0.4717 ~ 0.4720 in) 11.950 mm Rocker arm shaft outside diameter (0.4704 in) Rocker-arm-to-rocker-arm-shaft 0.009 ~ 0.037 mm (0.0004 ~ 0.0014 in)
  • Page 17 SPEC ENGINE SPECIFICATIONS Item Standard Limit 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...
  • Page 18 SPEC ENGINE SPECIFICATIONS Item Standard Limit Winding direction (top view) Counterclockwise Inner ---- Outer Clockwise ---- Cylinder Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) ---- Compression ratio 10.1 : 1 ---- 69.000 ~ 69.005 mm (2.7165 ~ 2.7167 in) 69.100 mm Bore...
  • Page 19 SPEC ENGINE SPECIFICATIONS Item Standard Limit 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 (0.0047 in) 2nd ring Ring type Taper ---- Dimensions (B ×...
  • Page 20 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2,250 ~ 2,850 r/min Clutch-in revolution ---- 3,700 ~ 4,700 r/min Clutch-stall revolution ---- V-belt 20.3 mm V-belt width 22.6 mm (0.89 in) (0.79 in) Transmission Primary reduction system Helical gear ---- 40 × 15 (2.666) Primary reduction ratio ---- Secondary reduction system...
  • Page 21 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Steel tube underbone ---- Caster angle 28° ---- Trail 100.0 mm (3.94 in) ---- Front wheel Wheel type Cast wheel ---- 15 × MT3.5 Size ---- Material Aluminum ---- Wheel travel 94.0 mm (3.70 in) ----...
  • Page 22 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 140/70-14M/C 68P or 68S ---- Model (manufacturer) GOLD STANDARD (MICHELIN) ---- GTS 24 (PIRELLI) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 220 kPa (2.20 kgf/cm , 31 psi) ---- 90 ~ 189 kg (198 ~ 417 lb)
  • Page 23 ---- 0.2 mm (0.008 in) Optional spring available ---- Fork oil Recommended oil Yamaha fork oil 15WT ---- Quantity (each front fork leg) 195.0 cm (6.86 Imp oz, 6.59 US oz) ---- Level (from the top of the inner 105.0 mm (4.13 in)
  • Page 24 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Spring preload adjusting positions Standard ---- Minimum ---- Maximum ---- 2 - 13...
  • Page 25 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system DC.C.D.I. Ignition system type ---- 10° BTDC at 1,700 r/min Ignition timing ---- Advancer type Digital ---- Engine control unit model (manufac- 1C00-00 (MORIC) ---- turer) Ignition coil 4719 (MITSUBA)
  • Page 26 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage/wattage × quantity) 12 V 35/35.0 W × 2 Headlight ---- 12 V 5.0 W × 2 Auxiliary light ---- 12 V 21.0/5.0 W × 2 Tail/brake light ---- 12 V 10.0 W × 2 Front turn signal light ---- 12 V 10.0 W ×...
  • Page 27 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Turn signal/hazard relay Relay type Full transistor ---- Model (manufacturer) 01 8610 (GUILERA) ---- Self-cancelling device built-in ---- Turn signal blinking frequency 70.0 ~ 100.0 cycles/minute ---- 10 W × 2 + 1.2 W Wattage ---- Fuses (amperage ×...
  • Page 28 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Speed sensor Output voltage When sensor is on DC 4.8 V or more ---- When sensor is off DC 0.6 V or less ---- 2 - 17...
  • Page 29 CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
  • Page 30 SPEC TIGHTENING TORQUES Crankcase tightening sequence: Cylinder head tightening sequence: 2-19...

  • Page 31: Tightening Torques (Engine)

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Element Screw threrad Tightening size torque Notes N·m m·kg Oil level verification bolt Exhaust tube double end stud 12.5 1.25 Air induction system tube stud Spark plug 17.5 1.75 Camshaft pinion cover Cylinder and cylinder head (nut) Cylinder and cylinder head (Pin) (distribution chain side) Generator rotor...
  • Page 32 SPEC CHASSIS TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Element Screw thread Tightening size torque Notes N·m m·kg Radiator bolts 9.75 Exhaust manifold nuts Exhaust / silencer joining flange nut Rocker silencer nuts Large / small exhaust protection sealant Exhaust end trim sealant Engine bracket rod shaft (nut) 31.5...
  • Page 33 Shaft 1 Intermediate gear 2 support surfaces Intermediate gear 2 interior surfaces Primary shaft support surfaces Engine shaft and primary shaft grooves Sump contact surfaces Yamaha sealant, No. 1215 Sump ventilator plug Stator grommet Yamaha sealant, No. 1215 Suction tube ®...
  • Page 34 SPEC LURICATION AND GREASE CHASSIS LUBRICATION AND GREASE CHASSIS Lubrication application points Symbol The front wheel seal lips (left and right) Steering bearings (upper and lower) Steering dust guard lips (upper and lower) Seat bracket pin Seat lock Throttle cable guide interior surface Engine bracket shaft Front / rear brake cylinder Front support friction surface...
  • Page 35 SPEC CABLE ROUTES Handlebars Inserted temperature probe cable all the way into the steering shaft. Rear brake cylinder Connect and fit the rubber cap to the Rear brake lever speedometer cabling. Rear brake switch cable Rear brake conduit Left-hand side indicator cable Left-hand side handlebar switches cable Right-hand side handle bar switches cable Right-hand side indicator cable...
  • Page 36 SPEC CABLE ROUTES Rear brake Connect to the main installation Throttle cable see detail B Front brake Starter relay Starter motor cable Neutral terminal Battery housing Regulator Horn Trip distance sensor cable Seat lock cable Main switch Relay Indicator relay Fuse box Main installation 2-25...
  • Page 37 SPEC CABLE ROUTES Fuse box Allow sufficient clearance to turn the handle bars. Take by the flange: Main switch cable, Front light terminal flasher relay cable, fuse box, cable antenna Trip sensor terminal cable, trip counter cable Antenna terminal Flasher relay Main switch terminal 2-26...
  • Page 38 SPEC CABLE ROUTES Light relay Fuel tank line to pump Ventilator relay Fuel tank line to carburettor ECU relay Coolant expansion tank Stand relay Spark plug hood Speedometer sensor cable Coil Brake hose Earth terminal Thermal contact Fuel probe terminal Ventilator terminal Rear brake Fuel pump terminal...
  • Page 39 SPEC CABLE ROUTES Take the main installation by the flange Take by the flange: Main installation, rear brake, starter motor cable, coil cables, Join the speed sensor and hose. Distribute starter cables, thermal contact cabling, the flanges evenly. generator cabling. A regulator and horn Take by the flange: Main installation, rear Pass the ventilator cable behind the...

  • Page 40: Cable Routes

    SPEC CABLE ROUTES Registration light Take by the flange: The main installation, rear light cables, registration light Take the main installation by the welded flange Pass the brake hose by the guide Pass the registration light according to the illustration 2-29...
  • Page 41 SPEC CABLE ROUTES Front light terminal Pass the starter motor cable by the window in the battery housing Battery assembly Take in the back: Seat lock cable, throttle Radiator filler cap cable. Centre stand Take by the flange: Seat lock cable, stand Side stand cable, throttle cable.
  • Page 42 SPEC CABLE ROUTES Fuel pump Connect and cover the generator cables with hood and position according to the Fuel tank line from carburettor illustration. Fuel tank tube to pump Take by the welded flange: motor cables Stand terminal (coincide with mark), starter motor cable Fuel tank Pass seat lock cable through the frame.
  • Page 43 SPEC CABLE ROUTES Rear left-hand side light terminal Take the rear left-hand side light connection cable by the flanges. Seat lock Rear right-hand side light terminal Seat lock cable 2-32...
  • Page 44 • From 50,000 km , repeat maintenance intervals every 10,000 km. • The operations marked with an asterisk should be made by Yamaha dealer, given that the required tools and specific data as well as the technical qualifications will be requi- red.

  • Page 45: Inspections And Periodic Adjustments

    INSPECTIONS AND PERIODIC CHK/ ADJUSTMENTS KILOMETER COUNTER READING ( x 1.000 km) ANNUAL VERIFICATION AND MAINTENANCE REVISION Nº ELEMENT OPERATION Front and rear √ √ √ √ √ √ • Check operation. brake switches Mobile elements √ √ √ √ √...
  • Page 46 ELECTRIC DIAGRAM YP250R X-MAX...
  • Page 47 ELECTRIC DIAGRAM YP250R X-MAX COLOUR CODE COMPONENTS 1 Main switch B ....black 2 generator Br.....Brown 3 rectifier / regulator Ch ....Chocolate 4 battery Dg ....Dark green G .....Green 6 battery cable Gy ....Grey 7 starter relay L .....Blue 8 starter motor O....Orange P ....Pink 10 speed sensor...
  • Page 48 Aiguaders, 10-16 • Pol. Ind. Riera de Caldes 08184 Palau-Solità i Plegamans • Barcelona • Spain IMPRESO EN ESPAÑA OPTEL, S.L. 05.2005 (E)

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