FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data forthe YP250 (J) ’98. For complete service information procedures it is necessary to use this Sup-plementary Service Manual together with the following manual.

YP250 SERVICE MANUAL: 4UC-AE1

YP250 (J) ’98

SUPPLEMENTARY

SERVICE MANUAL

1997 by Yamaha Motor Co., Ltd.

First Edition, June 1997

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha deal-ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic inone manual, so it is assumed that anyone who uses this book to perform maintenance and re-pairs on Yamaha scooter has a basic understanding of the mechanical ideas and the proceduresof scooter repair. Repairs attempted by anyone without this knowledge are likely to render thescooter unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modificationsand significant changes in specifications or procedures will be forwarded to all authorized Ya-maha dealers and will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury ordeath to the scooter operator, a bystander or a person inspecting or re-pairing the scooter.

A CAUTION indicates special precautions that must be taken to avoiddamage to the scooter.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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YP002000

HOW TO USE THIS MANUALMANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-bols”)

1st title 1 : This is the title of the chapter with its symbol on the upper right corner of eachpage.

2nd title 2 : This title indicates the section of the chapter and only appears on the first page ofeach section. It is located in the upper left corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures ac-companied by corresponding illustrations.

EXPLODED DIAGRAMS

To heps identify parts and clarify procedure steps, there are exploded diagrams at start of eachremoval and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is en-

closed by a circle indicates a disassembly step.3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol

marks 6 . The meanings of the symbol marks are given on the next page.4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.5. For jobs requiring more information, the step-by-step format supplements 8 are given in

addition to the exploded diagram and the job instruction chart.

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EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are designed asthumb tabs to indicate the chapter’s numberand content.

1 General information2 Specifications3 Periodic inspection and adjustment4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting

Illustrated symbols 10 to 17 are used to iden-tify the specifications appearing in the text.

10 Possible to maintain with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening15 Wear limit, clearance16 Engine speed17 Ω, V, A

Illustrated symbols 18 to 23 in the explodeddiagrams indicate the types of lubricantsand lubrication points.

18 Apply engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the explodeddiagrams indicate the where to apply lock-ing agent 24 and when to install new parts25 .

24 Apply locking agent (LOCTITE )25 Use new one

CONTENS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCOOTER IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION AND ADJUSTMENTS 11. . . . . . . . . . . . . . . . . . . COVER AND PANEL 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE PANEL AND SEAT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YP250 ’98 WIRING DIAGRAM (FOR EUROPE)

YP250J WIRING DIAGRAM (FOR OCEANIA)

1

SCOOTER IDENTIFICATIONGENINFO

YP100000

GENERAL INFORMATIONSCOOTER IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (for E)

The vehicle identification number 1 isstamped into the right side of the frame.

MODEL LABEL

The model label 1 is affixed under the seat.This information will be needed to orderspare parts.

2

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Model YP250

Model code: 4UC3 (except for CH, A, AUS)4UD3 (for CH, A)4UC4 (for AUS)

Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A*

front rear

Loading condition B*front

rearHigh-speed riding

front rear

197 kg0 90 kg175 kPa (1.75 kg/cm2, 1.75 bar)200 kPa (2.0 kg/cm2, 2.0 bar)90 197 kg200 kPa (2.0 kg/cm2, 2.0 bar)225 kPa (2.25 kg/cm2, 2.25 bar)

200 kPa (2.0 kg/cm2, 2.0 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

Wheel travel:Front wheel travelRear wheel travel

100 mm90 mm

Bulb wattage quantity:HeadlightMarker lightTail /brake lightFlasher lightMeter lightHigh beam indicator lightOil indicator lightTurn indicator light

License light

12V 60 W/55 W 112V 5 W 112V 5 W/21 W 112V 21W 412V 1.7W 412V 1.7 W 112V 1.7 W 112V 3.4 W 212V 5 W 1

*Load is the total weight of cargo, rider, passenger, and accessories.

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MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

V-belt:V-belt width 23.0 mm 21.0 mm

Carburetor:TypeI.D. markVentuly outside diameterMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Throttle valve size (Th.V)Pilot air jet (P.A.J.1)Needle jet (N.J)Pilot outlet (P.O)Pilot jet (P.J)Bypass (B.P)Pilot screw (P.S)Valve seat size (V.S)Starter jet 1 (G.S.1)Starter jet 2 (G.S.2)Float height (F.H)Engine idle speedIntake vacuum

Oil temperatureCooling water temperature

Y28V-1B-14UC 00 [4UD 00 (CH, A)]ø28#130ø0.95D32-3/511ø1.2#85ø0.8#440.7 31 1/21.4ø0.5ø1.327 mm1,350 1,450 r/min220 260 mmHg65 75C80C

CHASSIS

Item Standard Limit

Steering system:Steering bearing type Ball and angular bearing

Front suspension:Front fork travelFork spring free lengthSpring rate (K1)Stroke (K1)Oil capacityOil levelOil gradeInner tube vend limit

100 mm265.8 mm5.7 N/mm (0.57 kg/mm)0 100 mm0.142 L (142 cm3)80 mmFork oil 15 WT or equivalent

265 mm

0.2 mm

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MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Rear suspension:Shock absorber strokeSpring free lengthFitting lengthSpring rate (K1)

(K2)(K3)

Stroke (K1)(K2)(K3)

106 mm265 mm317 mm7.7 N/mm (0.77 kg/mm)12.6 N/mm (1.26 kg/mm)25.8 N/mm (2.58 kg/mm)0 40 mm40 75 mm75 106 mm

260 mm

ELECTRICAL

Item Standard limit

Spark plug cap:TypeResistance

Resin type10 kΩ

Charging system:TypeModel/manufacturerNormal outputStator coil resistance/color

A.C. magnetoF4T252/MITSUBISHI14 V 16 A at 5,000 r/min0.54 0.66 Ω at 20C/White – White

Rectifire/regulator:Model/manufacturerNo load regulated voltageCapacityWithstand voltage

SH640D-12/SHINDENGEN14.7 V14 A200 V

Battery:Specific gravity 1.320

Electric starter system:TypeStarter motor:Model/manufacturer/ID numberOperation voltageOutputArmature coil resistanceBrush overall lengthBrash quantitySpring forceCommutator diameterMica undercut (depth)

Constant mesh type

SM-13/MITSUBA/SM-1345412 V0.65 kW0.0012 0.0022 Ω at 20C10 mm2 pcs.570 920 g28 mm0.7 mm

4 mm

570 g27 mm

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MAINTENANCE SPECIFICATIONS SPEC

Item Standard limit

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

MS5F-471JIDECO100 A4.2 4.6 Ω at 20C

Horn:Model/manufacturerMaximum amperage

YF-12/NIKKO3 A

Flasher relay:TypeModel/manufacturerFlasher frequency

Full transistor typeFE246BH/DENSO75 95 cycle/min

Starting circuit cut-off relay:Model/manufacturerCoil winding resistance

ACA12115-1/MATSUSHITA72 88 Ω

Thermo unit:Model/manufacturer 11H/NIPPON SEIKI

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CABLE ROUTING SPEC

1 Box light2 Rectifier/regulator3 Fuel sender4 Roll over valve5 Fuse6 Seat lock cable7 Handlebar switch lead (right)8 Front brake switch lead9 Brake hose10 Speedometer cable11 Pipe12 Starter relay13 Battery14 Flasher relay

15 Reservoir tank16 Battery negative (–) lead17 Battery positive (+) lead18 Ignition coil19 Breather hose20 Air filter21 Mudguard22 Seat lock cable23 Down tube24 Wireharness25 Ground lead26 Engine bracket27 AC magnet leads28 Starter motor lead

A Pass the box light lead fromoutside of frame throughinside of protector.

B Clamp the fuel sender lead tothe pipe.

C Clamp the fuel sender leadand auto choke lead to theframe.

D Pass the box switch leadthrough under the fuel tankhinge projection.

E Align the mark on seat lockcable to the protector end.

F Clamp the wireharness(white tape) to frame.

CABLE ROUTING

7

G Install the meter cable withits sheaved side facing to themeter gear.

H Install the brake hose to thebrake caliper with its markingfacing to the tire side.

I Pass the overflow hose formthe reservoir tank throughthe clamp inside the frame.

J Clamp the mainharness,battery (+) lead and (–) leadto clamp of the frame.

K Keep the clamping clearanceover 3 mm.

CABLE ROUTING SPEC

8

B Pass the drain hose throughthe clamp (spring hook).

C Clamp the brake cable 2 to theframe.(Up and down)Align the locating mark of thebrake cable 2 with the underclamp.

D Pass the overflow hose fromthe tank through the clampinside the frame pipe.

1 Throttle cable (pull side)2 Throttle cable (push side)3 Carburetor drain hose4 Carburetor coolant drain hose5 Air vent hose6 Steering head7 Rear brake cable8 Steering head9 Wireharness10 Down tube

CABLE ROUTING SPEC

11 Throttle cables12 Radiator13 Throttle cables14 Wireharness15 Stay

A Pass the air vent hose,coolant drain hose, andfuel drain hose through the“U” clamp on the holder.

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13 Fuel cock14 Fuel tank15 Over flow hose16 Starting circuit cutoff relay17 Auto choke unit lead18 Protector19 Seat lock cable20 Seat lock21 Ground lead22 Starter motor lead23 AC magneto leads

1 Air filter2 Chain tensioner3 Fuel tank breather hose4 Vacuum hose5 Fuel hose6 Fuel hose7 Vacuum hose8 Sidestand switch lead9 Fan motor lead10 Thermo switch lead11 Fuel hose12 Vacuum hose

CABLE ROUTING SPEC

A Install the positive (+) leadbetween the battery and thestarter relay to the starter relayalong the chassis.

B Put the coupler of the A.C.magneto lead and the autochoke lead along the framepipe after connection.

C Clamp the wireharness, A.C.magneto leads, starter motorlead and grand lead to theframe.

D Clamp the AC magneto leads,starter motor lead and groundlead to the engine bracket.

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13 Handlebar switch (right)14 Front brake switch15 Seat lock cable16 Throttle cable17 Brake hose18 Handlebar switch (left)19 Rear brake switch20 Rear brake cable21 Under handlebar cover22 Speedometer cable23 Stay

CABLE ROUTING SPEC

1 Front flasher light (right)2 Front flasher light (left)3 Rear brake cable4 Throttle cable5 Speedometer cable6 Brake hose7 Horn8 Stay9 Mark10 Brake hose stopper11 Grip heater lead12 Ararm terminal

A Install the brake hose with itsmarking facing to the stopperside.

B Pass the speedometer cableand the brake hose throughthe clamps on the frame.(Front: Speedometer cableRear: Brake hose)

C Do not interfere each otherafter installing the handlebarupper cover.

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Install the damper assembly to thebody with its rod side backward andlabels upward.

Reverse the removal procedure forinstallation.

Order Job name/Part name Q’ty Remarks

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Side panel and seat removal

Rear panelSide panel (left)Side panel (right)RivetFront panelClipDamper assembly

Seat

1112121

1

Remove the parts in order.

NOTE:

COVER AND PANELINSPADJ

PERIODIC INSPECTIONS AND ADJUSTMENTS

COVER AND PANELSIDE PANEL AND SEAT

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3 Main switch4 Battery5 Main fuse24 Rear brake switch25 Front brake switch26 Flasher relay27 Horn28 Turn switch29 Horn switch33 Tail /Brake light35 Rear flasher lights36 Front flasher lights

39 Turn indicator lights44 Fuel gauge50 Fuel sender52 Box light53 Box light switch

SIGNAL SYSTEM ELEC

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1. Bulb and bulb socket.

Disconnect the bulb socket connector.Connect the pocket tester (Ω 1) to thebulb socket connector.

2. Box light switch

Disconnect the box light switch coupler.Connect the pocket tester (Ω 1) to thebox light switch.

Check the bulb socket for continuity. Replace the bulb and/or bulb socket.

NO CONTINUITY

NO CONTINUITY

Replace the box light switch.

CONTINUITY

Tester (+) lead Read 1 terminal.

Tester (–) lead Blue/Green 2 terminal.

1

2

Check the box light switch for continuity.

3. Wiring connection

Wiring circuit from the main switch to thebulb socket connector is faulty. Repair.Refer to “SIGNAL SYSTEM WIRING DIA-GRAM”.

CONTINUITY

1 2

SIGNAL SYSTEM ELEC

SIGNAL SYSTEM CHECK

If the box light fails to come on.

1 A.C. magneto2 Rectifier regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Alarm (option)9 Thermo switch (auto choke)10 Auto choke11 Ignitor unit12 Ignition coil13 Spark plug14 Pickup coil15 Sidestand switch16 Starting circuit cut-off relay17 Lights switch18 Starter switch19 Engine stop switch20 Handlebar switches (right)21 Fuse (fan)22 Thermo switch23 Fan motor24 Rear brake switch25 Front brake switch26 Flasher relay27 Horn28 Turn switch29 Horn switch30 Dimmer switch31 Pass switch32 Handlebar switches (left)33 Tail /Brake light34 Licence light35 Rear flasher lights36 Front flasher lights37 Head light38 Auxiliary light39 Turn indicator lights40 High beam indicator light41 Meter lights42 Oil indicator light43 Reset switch44 Fuel gauge45 Read switch46 Clock47 Thermometer48 Speedometer49 Meter assembly50 Fuel sender51 Thermo unit52 Box light53 Box light switch

B/R Black/Red. . . . . . Br/W Brown/White. . . . . G/R Green/Red. . . . . G/Y Green/Yellow. . . . . . L/B Blue/Black. . . . . . L/G Blue/Green. . . . . .

COLOR CODEB Black. . . . . . . . Br Brown. . . . . . . Ch Chocolate. . . . . . Dg Dark green. . . . . . G Green. . . . . . . L Blue. . . . . . . .

O Orange. . . . . . . P Pink. . . . . . . . R Red. . . . . . . . Sb Sky blue. . . . . . . W White. . . . . . . Y Yellow. . . . . . . .

L/R Blue/Red. . . . . . L/W Blue/White. . . . . L/Y Blue/Yellow. . . . . . R/W Red/White. . . . . R/Y Red/Yellow. . . . . . W/G White/Green. . . . .

Y/R Yellow/Red. . . . . .

YP250 ’98 WIRING DIAGRAM (FOR EUROPE)

1 A.C. magneto2 Rectifier regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Alarm (option)9 Thermo switch (auto choke)10 Auto choke11 Ignitor unit12 Ignition coil13 Spark plug14 Pickup coil15 Sidestand switch16 Starting circuit cut-off relay17 Starter switch18 Engine stop switch19 Handlebar switches (right)20 Fuse (fan)21 Thermo switch22 Fan motor23 Rear brake switch24 Front brake switch25 Flasher relay26 Horn27 Turn switch28 Horn switch29 Dimmer switch30 Pass switch31 Handlebar switches (left)32 Tail /Brake light33 Licence light34 Rear flasher lights35 Front flasher lights36 Head light37 Turn indicator lights38 High beam indicator light39 Meter lights40 Oil indicator light41 Reset switch42 Fuel gauge43 Read switch44 Clock45 Thermometer46 Speedometer47 Meter assembly48 Fuel sender49 Thermo unit50 Box light51 Box light switch

B/R Black/Red. . . . . . Br/W Brown/White. . . . . G/R Green/Red. . . . . G/Y Green/Yellow. . . . . . L/B Blue/Black. . . . . . L/G Blue/Green. . . . . .

COLOR CODEB Black. . . . . . . . Br Brown. . . . . . . Ch Chocolate. . . . . . Dg Dark green. . . . . . G Green. . . . . . . L Blue. . . . . . . .

O Orange. . . . . . . P Pink. . . . . . . . R Red. . . . . . . . Sb Sky blue. . . . . . . W White. . . . . . . Y Yellow. . . . . . . .

L/W Blue/White. . . . . L/Y Blue/Yellow. . . . . . R/B Red/Black. . . . . . R/W Red/White. . . . . R/Y Red/Yellow. . . . . . W/G White/Green. . . . .

Y/R Yellow/Red. . . . . .

YP250J WIRING DIAGRAM (FOR OSEANIA)