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MBK XMAX 2014
Service manual
Yamaha MBK XMAX 2014 Service Manual
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Service manual
(482 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline of the Fi System
Fi System
OUTLINE of the ABS (for YP250RA)
Abs Component Functions
Abs Operation
Abs Warning Light and Operation
Instrument Functions
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Rubber Parts
Quick Fasteners
Basic Service Information
Electrical System
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
General Tightening Torque Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Engine
Lubrication Points and Lubricant Types
Chassis
Cooling System Diagrams
Cable Routing
Periodic Checks and Adjustments
General Maintenance and Lubrication Chart
Introduction
Periodic Maintenance
Periodic Maintenance Chart for the Emission Control System
Adjusting the Valve Clearance
Checking the Fuel Line
Checking the Spark Plug
Checking the Throttle Body Joint and Intake Manifold
Adjusting the Exhaust Gas Volume
Checking the Breather Hose
Checking the Exhaust System
Replacing the Air Filter Element
Checking the Brake Fluid Level
Checking the Brake Operation
Cleaning the V-Belt Case Air Filter Element
BLEEDING the HYDRAULIC BRAKE SYSTEM (for YP250R)
BLEEDING the HYDRAULIC BRAKE SYSTEM (ABS) (for YP250RA)
Checking the Front Brake Hoses
Checking the Front Brake Pads
CHECKING the REAR BRAKE PADS (for YP250R)
CHECKING the REAR BRAKE PADS (for YP250RA)
Checking the Rear Brake Hose
Checking the Tires
Checking the Wheels
Checking and Adjusting the Steering Head
Checking the Wheel Bearings
Checking the Centerstand
Checking the Chassis Fasteners
Checking the Sidestand
Checking the Sidestand Switch
Lubricating the Centerstand
Lubricating the Levers
Lubricating the Sidestand
Adjusting the Rear Shock Absorber Assemblies
Checking the Front Fork
Checking the Rear Suspension
Changing the Engine Oil
Checking the Engine Oil Level
Checking the Coolant Level
Changing the Coolant
Checking the Cooling System
Changing the Final Transmission Oil
Replacing the V-Belt
Checking and Lubricating the Cables
Checking the Brake Light Switches
Lubricating the Rear Suspension
Chassis
General Chassis
Installing the Center Panels
Installing the Storage Box
Removing the Center Panels
Installing the Rear Upper Cover
Removing the Rear Panels
Removing the Rear Upper Cover
Installing the Rear Panels
Installing the Upper Panel and Front Cowling Cover
Removing the Front Cowling Cover and Upper Panel
Installing the Front Upper Panel
Removing the Front Cowling
Removing the Front Upper Panel
Installing the Front Cowling
Removing the Main Switch Cover
Installing the Footrest Board
Installing the Main Switch Cover
Removing the Footrest Board
Disposing of a Seat Hinge Damper
Handling the Seat Hinge Damper
Front Wheel
Checking the Front Wheel
Disassembling the Front Wheel
REMOVING the FRONT WHEEL (for YP250R)
REMOVING the FRONT WHEEL (for YP250RA)
MAINTENANCE of the FRONT WHEEL SENSOR and SENSOR ROTOR (for YP250RA)
Assembling the Front Wheel
Adjusting the Front Wheel Static Balance
INSTALLING the FRONT WHEEL (FRONT BRAKE DISC) (for YP250R)
INSTALLING the FRONT WHEEL (FRONT BRAKE DISCS) (for YP250RA)
Rear Wheel
Adjusting the Rear Wheel Static Balance
Checking the Rear Wheel
Installing the Rear Wheel (Rear Brake Disc)
MAINTENANCE of the REAR WHEEL SENSOR ROTOR (for YP250RA)
REMOVING the REAR WHEEL (DISC) (for YP250R)
REMOVING the REAR WHEEL (DISC) (for YP250RA)
Checking the Front Brake Disc
Front Brake
Introduction
Replacing the Front Brake Pads
Checking the Front Brake Caliper
Disassembling the Front Brake Caliper
Removing the Front Brake Caliper
Assembling the Front Brake Caliper
Installing the Front Brake Caliper
Assembling the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Removing the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Checking the Rear Brake Disc
Introduction
REPLACING the REAR BRAKE PADS (for YP250R)
REPLACING the REAR BRAKE PADS (for YP250RA)
Removing the Rear Brake Caliper
Checking the Rear Brake Caliper
DISASSEMBLING the REAR BRAKE CALIPER (for YP250R)
DISASSEMBLING the REAR BRAKE CALIPER (for YP250RA)
Assembling the Rear Brake Caliper
CHECKING the REAR BRAKE CALIPER (for YP250RA)
INSTALLING the REAR BRAKE CALIPER (for YP250R)
INSTALLING the REAR BRAKE CALIPER (for YP250RA)
Assembling the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Removing the Rear Brake Master Cylinder
ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA)
Checking the Hydraulic Unit Assembly
Installing the Hydraulic Unit Assembly
Removing the Hydraulic Unit Assembly
Hydraulic Unit Operation Tests
Checking the Abs Warning Light
Handlebar
Checking the Handlebar
Installing the Handlebar
Removing the Handlebar
Front Fork
Disassembling the Front Fork Legs
Removing the Front Fork Legs
Assembling the Front Fork Legs
Checking the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Checking the Steering Head
Installing the Steering Head
Removing the Lower Bracket
Rear Shock Absorber Assemblies and Swingarm
(For YP250RA)
Checking the Rear Shock Absorber Assembly
Checking the Swingarm
Maintenance of the Rear Wheel Sensor
Removing the Rear Shock Absorber Assemblies
Removing the Swingarm
Installing the Swingarm
Engine
Engine Inspection
Measuring the Compression Pressure
Engine Removal
Installing the Engine
Cylinder Head
Checking the Cylinder Head
Removing the Cylinder Head
Checking the Camshaft Sprocket
Checking the Timing Chain Tensioner
Installing the Cylinder Head
Camshaft
Checking the Camshaft
Removing the Rocker Arms and Camshaft
Checking the Rocker Arms and Rocker Arm Shafts
Checking the Valves and Valve Guides
Removing the Valves
Valves and Valve Springs
Checking the Valve Seats
Checking the Valve Springs
Installing the Valves
Cylinder and Piston
Checking the Cylinder and Piston
Removing the Piston
Checking the Piston Rings
Checking the Piston Pin
Checking the Timing Chain Guide
Installing the Piston and Cylinder
V-Belt Automatic Transmission
Removing the Primary Sheave
Removing the Secondary Sheave
Checking the Clutch Housing
Checking the Clutch Shoes
Checking the V-Belt
Disassembling the Secondary Sheave
Assembling the Primary Sheave
Checking the Primary Sheave
Checking the Primary Sheave Sliders
Checking the Primary Sheave Weights
Checking the Secondary Sheave
Assembling the Secondary Sheave
Installing the V-Belt
Starter Clutch and Generator
Checking the Starter Clutch
Removing the Generator
Removing the Starter Clutch
Installing the Generator
Installing the Starter Clutch
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Oil Pump
Assembling the Oil Pump
Checking the Oil Pump
Installing the Oil Pump
Transmission
Checking the Transmission
Installing the Transmission
Removing the Transmission
Crankshaft
Disassembling the Crankcase
Removing the Crankshaft Assembly
Checking the Crankshaft and Connecting Rod
Checking the Timing Chain and Timing Chain Guide
Checking the Bearing and Oil Seal
Checking the Crankcase
Checking the Oil Strainers
Installing the Crankshaft
Assembling the Crankcase
Cooling System
Checking the Radiator
Installing the Radiator
Radiator
Thermostat
Checking the Thermostat
Installing the Thermostat
Water Pump
Assembling the Water Pump
Checking the Water Pump
Disassembling the Water Pump
Installing the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Installing the Fuel Pump
Installing the Fuel Tank
Removing the Fuel Pump
Removing the Fuel Tank
Checking the Fuel Pressure
Throttle Body
Checking the Fuel Injector
Checking the Throttle Body
Installing the Fuel Hose
Installing the Intake Manifold
Removing the Fuel Hose
Checking the Isc (Idle Speed Control) Unit
Checking the Throttle Position Sensor
Installing the Throttle Body
Electrical System
Circuit Diagram
Ignition System
Troubleshooting
CIRCUIT DIAGRAM (for YP250R)
Electric Starting System
CIRCUIT DIAGRAM (for YP250RA)
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250R)
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250RA)
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Circuit Diagram
Lighting System
Troubleshooting
CIRCUIT DIAGRAM (for YP250R)
Signaling System
CIRCUIT DIAGRAM (for YP250RA)
Troubleshooting
Circuit Diagram
Cooling System
Troubleshooting
CIRCUIT DIAGRAM (for YP250R)
Fuel Injection System
CIRCUIT DIAGRAM (for YP250RA)
Ecu Self-Diagnostic Function
Diagnostic Mode
Troubleshooting Method
Troubleshooting Details
CIRCUIT DIAGRAM (for YP250R)
Fuel Pump System
CIRCUIT DIAGRAM (for YP250RA)
Troubleshooting
Circuit Diagram
Immobilizer System
General Information
Part Replacement and Key Code Registration Requirements
Self-Diagnosis Fault Code Indication
Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA)
Circuit Diagram
Abs Components Chart
Abs Coupler Location Chart
Abs Troubleshooting Outline
Maintenance of the Abs Ecu
Basic Instructions for Troubleshooting
Basic Process for Troubleshooting
[A-1] Only the Abs Warning Light Fails to Come on
[A-2] the Abs Warning Light and All Other Indicator Lights Fail to Come on
[A-3] the Abs Warning Light Comes on
[A] Checking the Abs Warning Light
[B-1] Malfunction Are Currently Detected
[B-2] Diagnosis Using the Fault Codes
[B-3] Deleting the Fault Codes
Electrical Components
Checking the Switches
Checking the Bulbs and Bulb Sockets
Checking the Fuses
Checking and Charging the Battery
Checking the Relays
Checking the Turn Signal/Hazard Relay
Checking the Diodes
Checking the Ignition Coil
Checking the Spark Plug Cap
Checking the Crankshaft Position Sensor
Checking the Ignition Spark Gap
Checking the Lean Angle Sensor
Checking the Starter Motor Operation
Checking the Fuel Sender
Checking the Rectifier/Regulator
Checking the Stator Coil
Checking the Radiator Fan Motor
CHECKING the SPEED SENSOR (for YP250R)
Checking the Coolant Temperature Sensor
Checking the Throttle Position Sensor
Checking the Intake Air Pressure Sensor
Checking the Intake Air Temperature Sensor
Checking the Air Temperature Sensor
Checking the Fuel Injector
Checking the Isc (Idle Speed Control) Unit
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2014
SERVICE MANUAL
YP250R
YP250RA
2DL-F8197-E0
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Chapters
Table of Contents
7
Specifications
49
Periodic Checks and Adjustments
113
Chassis
141
Engine
233
Cooling System
297
Fuel System
307
Electrical System
315
Troubleshooting
469
Table of Contents
Troubleshooting
TROUBLESHOOTING
320
TROUBLESHOOTING
330
TROUBLESHOOTING
334
TROUBLESHOOTING
338
TROUBLESHOOTING
344
TROUBLESHOOTING
352
TROUBLESHOOTING METHOD
359
TROUBLESHOOTING DETAILS
362
TROUBLESHOOTING
394
TROUBLESHOOTING
402
MAINTENANCE OF THE ABS ECU
412
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
413
BASIC PROCESS FOR TROUBLESHOOTING
414
TROUBLESHOOTING
469
TROUBLESHOOTING
470
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This manual is also suitable for:
Mbk evolis 2014
Yp250r 2014
Yp250ra 2014
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