yp250 service manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for theYP250. For complete service information procedures it is necessary to use this Supplementary Ser-vice Manual together with the following manual.

YP250 SERVICE MANUAL: 4UC-AE1YP250 (K) ’98 SUPPLEMENTARY SERVICE MANUAL: 4UC-AE2YP250D ’98 SUPPLEMENTARY SERVICE MANUAL: 5DF-AE1

YP250 2000SUPPLEMENTARYSERVICE MANUAL

1999 by Yamaha Motor Co., Ltd. 1999 by MBK Industrie

First Edition, November 1999Any reproduction or unauthorized use

without the written permission ofYamaha Motor Co., Ltd.is expressly prohibited.

NOTE:

WARNING

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha/MBK dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yama-ha/MBK scooter has a basic understanding of the mechanical ideas and the procedures of scooterrepair. Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe andunfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK dealersand 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 or death tothe scooter operator, a bystander or a person inspecting or repairing the scoot-er.

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

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

12 4 3

5

6

7

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8

YP002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

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

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of eachsection. 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 accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo heps identify parts and clarify procedure steps, there are exploded diagrams at start of each remov-al 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 enclosed 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.

22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELECCHAS

COOL

INSPADJ

TRBLSHTG

EB003000

ILLUSTRATED SYMBOLSIllustrated 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 identifythe 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 exploded dia-grams indicate the types of lubricants and lu-brication 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 exploded dia-grams indicate the where to apply locking agent24 and when to install new parts 25 .

24 Apply locking agent (LOCTITE )25 Use new one

CONTENTS

GENERAL INFORMATIONSCOOTER IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER (for E) 1. . . . . . . . . . . . . . . FRAME SERIAL NUMBER (except for E) 1. . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONSGENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTNING TORQUES 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTNING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND GRADE OF LUBRICANT 15. . . . . . . . . ENGINE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE/LUBRICATION INTERVALS 26. . . . . . . . COVER AND PANEL 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE COVER, SIDE COVER MOLE PASSENGER SEAT 28. . . . . RIDER SEAT AND MAIN BOX 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE COVER MOLE AND FOOTREST BOARD 31. . . . . . . . . . . . . COWLING, HANDLE COVER, METER ASSEMBLY 32. . . . . . . . . . LEGSHIELD AND FUEL TANK 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE FILTER CLEANING 35. . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM INSPECTION 36. . . . . . . . . . . . . . . . . . . COOLANT REPLACEMENT 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT 40. . . . . . . . . . . . . . . . . . . . . . . .

ENGIVE OVERHAULENGINE REMOVAL 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIREHARNESS, CABLE AND REAR BRAKE 41. . . . . . . . . . . . . . . HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND

ENGINE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 46. . . . . . CRANKCASE FILTER COVER AND CRANKCASE COVER

(LEFT) 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 47. . . .

TRANSMISSION 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE AND CRANKSHAFT 52. . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE REMOVAL 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT REMOVAL 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSTALLATION 52. . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEMRADIATOR 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETORCARBURETOR 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR DISASSEMBLY 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE POSITION SENSOR ADJUSTMENT 58. . . . . . . . . . . .

CHASSISFRONT WHEEL 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEED SENSOR AND SENSOR ROTOR 59. . . . . . . . . . . . . . . . . . SPEED SENSOR AND THE SENSOR ROTOR 60. . . . . . . . . . . . . . SPEED SENSOR REMOVAL 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED SENSOR AND SENSOR ROTOR INSPECTION 60. . . . . SPEED SENSOR ASSEMBLY 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND SWINGARM 65. . . . . . . . . . . . . . . . .

ELECTRICALELECTRICAL COMPONENTS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCHES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH POSITION AND TERMINAL CONNECTION 69. . . . . . . . CHECKING STEPS 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH CONNECTION AS SHOWN IN THIS MANUAL 70. . . . . .

IGNITION SYSTEM 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUT DIAGRAM 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION 90. . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 93. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM

1

SCOOTER IDENTIFICATIONGENINFO

NOTE:

NOTE:

YP100000

GENERAL INFORMATIONSCOOTER IDENTIFICATION

YP100010

VEHICLE IDENTIFICATION NUMBER (for E)The vehicle identification number 1 is stampedinto the right side of the frame.

The vehicle identification number is used toidentify your scooter and may be used to regis-ter your scooter with the licensing authority inyour country.

YP100020

FRAME SERIAL NUMBER (except for E)The frame serial number 1 is stamped into theright side of the frame.

EB100030

ENGINE SERIAL NUMBERThe engine serial number is stamped into thecrankcase.

Designs and specifications are subject tochange without notice.

MODEL LABELThe model label is affixed under the seat.This information will be needed to order spareparts.

2

SPECIAL TOOLSGENINFO

EB102000

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly.Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri-ate tools or improvised techniques.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Usage Illustration

90890-01135

Crankcase separating tool

90890-01135

This tool is used to remove the crankshaft.

Installer pot90890-01274

Bolt90890-01275

Adaptor

Crankshaft installer pot/bolt/adapter/spacer

90890-0128090890-01478

Spacer90890-0101690890-01288 These tools are used to install the crankshaft.

3

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Model YP250

Model code: 5GM2, 5GM3

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,140 mm,780 mm

1,350 mm,730 mm

1,535 mm,120 mm

2,700 mm

Basic weight:With oil and full fuel tank 168 kg

Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting systemLubrication system:

Liquid-cooled 4-stroke, SOHCForward-inclined single cylinder0.249L (249 cm3)69.0 66.8 mm10 : 11,400 kPa (14 kg/cm2, 14 bar) at 500 r/minElectric starterWet sump

Oil type or grade:

Engine oilAPI STANDERD:SE or higher grade

Periodic oil changeTotal amount

Transmission oilTotal amount

1.2 L1.4 L

0.25 L

Radiator capacity:Total amount (including all routes) 1.4 L

Air filter:Carburetor sideCrankcase side

Wet type elementDry type element

Fuel:TypeFuel tank capacity

Regular unleaded gasoline12 L

4


Model YP250

Carburetor:Type/quantityManufacturer

Y28V-1E/1TEIKEI

Spark plug:TypeManufacturerSpark plug gap

DR8EANGK0.6 0.7 mm

Clutch type: Dry, centrifugal automatic

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationSingle speed automatic

Helical gear40/15 (2.666)Helical gear38/15 (2.533)Single speed automatic (V-belt type)Centrifugal automatic type2.44 0.83:1

Chassis:Frame typeCaster angleTrail

Steel tube underbone28103 mm

Tire:TypeSize front

rearManufacturer front

rearType front

rear

Tubeless110/90-12 64L130/70-12 62LIRC/MICHELNIRC/MICHELNMB67/BOPPERMB67/BOPPER

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

front rear

Loading condition B*front

rearHigh-speed riding

front rear

187 kg0 90 kg175 kPa (1.75 kg/cm2, 1.75 bar)200 kPa (2.0 kg/cm2, 2.0 bar)90 205 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)225 kPa (2.25 kg/cm2, 2.25 bar)

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

5


Model YP250

Brake:Front brake type

operationRear brake type

operation

Single disc brakeRight hand operationSingle disc brakeLeft hand operation

Suspension:Front suspensionRear suspension

Telescopic forkUnit swing

Shock absorber:Front shock absorberRear shock absorber

Coil spring/Oil damperCoil spring/Oil damper

Wheel travel:Front wheel travelRear wheel travel

100 mm90 mm

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

T.C.I. (Digital)A.C. magnetoGT7B-412 V 6.5 AH

Headlight type: Quartz bulb (Halogen)

Bulb wattage quantity:Headlight (High)Headlight (Low)Auxiliary lightTail /brake lightFlasher light (Front)Flasher light (Rear)Meter lightHigh beam indicator lightOil indicator lightTurn indicator light

License light

12 V 60 W/55 W 112 V 55 W 112 V 5 W 112 V 5 W/21 W 212 V 21 W 212 V 16 W 212 V 1.7 W 312 V 1.7 W 112 V 1.7 W 112 V 3.4 W 212 V 5 W 1

6

MAINTENANCE SPECIFICATIONS SPEC

12

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Cylinder head:Warp limit 0.05 mm

Cam chain:Cam chain type/No. of linksCam chain adjustment method

DID SCA-0404A SDH/104Automatic

Automatic centrifugal clutch:Clutch shoe thicknessClutch housing inside diameterClutch shoe spring free lengthWeight outside diameterClutch – in revolutionClutch – stall revolution

3.3 mm135 mm28.1 mm20 mm2,250 2,850 r/min3,700 4,700 r/min

2.0 mm135.5 mm

19.5 mm

V-belt:V-belt width 22.6 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-1E/15GM 10ø28#128ø0.95D9B-3/511ø1.2#85ø0.8#430.7 321.4ø0.5ø0.526.5 27.5 mm1,300 1,500 r/min29.3 36.0 kPa (220 270 mmHg)65 75C80C

Fuel pump:TypeModel/manufacturer

Electrical2GV/MITSUBISHI

7


Item Standard Limit

Radiator:TypeWidth/height/ thicknessRadiator cap opening pressure

Radiator capacityReservoir tank capacity

Cooling fin with electric fan140/238/24 mm110 140 kPa (1.1 1.4 kg/cm2,1.1 1.4 bar)1.4 L0.4 L

8


TIGHTENING TORQUESENGINE

Part to be tightened Part nameThread

size Q’tyTightening

torque Remarksg size yNm mkg

Oil check boltExhaust pipe stud boltAir induction system pipe stud boltSpark plugCam sprocket coverCylinder head and cylinderCylinder head and cylinder(Cam chain side)Valve coverRotorValve adjuster locknutCam shaft bearing stopperCam sprocketCam chain tensioner(Body)(Plug)Guide stopper 2Water pump housing coverHose jointThermostatic valve coverFiller neck supportingOil pumpOil pump coverOil strainer coverCarburetor jointCarburetor joint and carburetorAir filter assemblyAir filter coverExhaust pipe assemblyMufflerMuffler and exhaust pipeProtector (Exhaust pipe)Protector (Muffler end cap)Air induction system pipeAir induction system assemblyAir induction system air filter assemblyCrankcase (left and right)Drain bolt (Engine oil)Drain bolt (Transmission oil)Oil fillerTransmission case coverCrankcase cover (left)Crankcase filter coverCrankcase cover protectorCrankcase cover protectorMagnet cover

————

BoltNutBolt

BoltNutNutBoltBolt

BoltBoltBoltBolt—

BoltBolt

ScrewBoltBoltBoltNutBolt

ScrewNutBoltBolt

ScrewScrew

NutBoltBoltBoltBoltBoltBoltBoltBolt—

BoltScrew

—

M6M8M6M12M6M8M6

M6M16M6M6M10

M6M8M6M6M6M6M5M6M3M35M6M6M6M5M8M10M8M6M6M6M6M6M6M12M8M14M8M6M5M6M6M6

1221242

51221

2113221211222723123222911168313

10

7131018102210

1080148

60

108

10107

10571

32101071

205314101012107

1020223

16101.277

10

0.71.31.01.81.02.21.0

1.08.01.40.86.0

1.00.81.01.00.71.00.50.70.13.21.01.00.70.12.05.31.41.01.01.21.00.71.02.02.20.31.61.0

0.120.70.71.0

9


Part to be tightened Part nameThread

size Q’tyTightening

torque Remarksg size yNm mkg

Cover (oil pump)Timing check plugOne way clutchClutch housingGrease stopper (Primary sheave)Primary fixed sheaveClutch carrier assemblyStatorPick up coilStarter motorThermo switchThermo unit

BoltPlug—

Bolt—————

Bolt——

M6M16M8M14M4M14M36M6M5M6M18

Pt 1/8

213141132221

128

30603

8090107

10238

1.20.83.06.00.38.09.01.00.71.02.30.8

10


CHASSIS

Item Standard Limit

Front suspension:Front fork travelFork spring free lengthSpring rate (K1)Spring rate (K2)Stroke (K1)Stroke (K2)Oil capacityOil levelOil gradeInner tube vend limit

100 mm268 mm4.82 N/mm (0.49 kg/mm)8.84 N/mm (0.9 kg/mm)0 40 mm40 100 mm0.142 L (142 cm3)80 mmFork oil 15 WT or equivalent

263 mm

0.2 mm

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

(K2)(K3)

Stroke (K1)(K2)(K3)

106 mm262 mm7.57 N/mm (0.77 kg/mm)14 N/mm (1.43 kg/mm)26.39 N/mm (2.69 kg/mm)0 40 mm40 70 mm70 106 mm

257 mm

Rear disk brake:TypeDisc outside diameter thicknessPad thicknessMaster cylinder inside diameterCaliper cylinder outside diameterBrake fluid type

Single230 5 mm5.3 mm11 mm22.2 mm 2DOT #4

0.8 mm

Brake lever:Brake lever free play (front at leverside)Brake lever free play (rear)Throttle cable free play

2 5 mm

2 5 mm3 5 mm

11


TIGHTENING TORQUESCHASSIS

Part to be tightened Thread sizeTightening

torque RemarksgNm mkg

Frame and engine bracketEngine bracket, compression rod and engineCompression rod and frameSidestand (bolt and frame)Sidestand (bolt and nut)Rear footrest bracketSwingarmRear shock absorber and frameRear shock absorber and engineSteering ring nutHandle holder and steering shaftHandle upper holder and lower holderBrake hose and master cylinderFuel tank

(font)(rear)

Fuel senderFilterRoll over valveBoxBox (Bracket)Standing handleSheet lock assemblyPlastic parts & coverCowling stayCowling bodyFootrest boardHeadlight assemblyTail light assemblyFront wheel axle and nutRear wheel axle and nutFront brake caliper and front forkBrake disc and hubBrake hose and caliperBrake caliper and bleed screwRear brake caliper and swingarmSpeed sensor and sensor housingWindscreen

M12 1.25M10 1.25M10 1.25M10 1.25M10 1.25M 6 1.0M 8 1.25M10 1.25M 8 1.25M25 1.0M20 1.5M 8 1.25M10 1.25

M 6 1.0M 6 1.0M 5 0.8M 6 1.0M 5 0.8M 6 1.0M 8 1.25M 8 1.0M 6 1.0M 5 1.0M 8 1.25M 6 1.0M 6 1.0M 6 1.0M 6 1.0M14 1.5M14 1.5M10 1.25M 8 1.25M10 1.25M 7 1.0M10 1.25M 8 1.25M 5 1.0

59326440407

35402022

1552330

107374

101616102

167777

701355023306

40230.4

5.93.26.44.04.00.73.54.02.02.2

15.52.33.0

1.00.70.30.70.41.01.61.61.00.21.60.70.70.70.77.0

13.55.02.33.00.64.02.3

0.04

See “NOTE”

12


NOTE:1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 mkg) by using the torque wrench, then

loosen the ring nut 1/4 turn.2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 mkg) by using the torque wrench,

then finger tighten the ring nut (center). Align the slots both ring nut and install the lock washer.3. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 75 Nm (7.5 mkg) by

using the torque wrench.

13


ELECTRICAL

Item Standard limit

Ignition timing:Ignition timing (B.T.D.C.)Advanced timing (B.T.D.C.)Advanced type

10 at 1,400 r/min32 at 5,000 r/minElectrical type

T.C.I.:Pickup coil resistance/color

T.C.I. unit model/manufacturer

189 231 Ω at 20C/Yellow – BlueJ4T117/MITSUBISHI

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

F6T507/MITSUBISHI6 mm3.6 4.8 Ω at 20C10.7 14.5 kΩ at 20C

Spark plug cap:TypeResistance

Resin type10 kΩ

Charging system:TypeModel/manufacturerNormal outputStator coil resistance/color

A.C. magnetoF4T370/MITSUBISHI14 V 19.5 A at 5,000 r/min0.37 0.45 Ω at 20C/White – White

Rectifire/regulator:Model/manufacturerNo load regulated voltageCapacityWithstand voltage

SH640A-12/SHINDENGEN14.1 14.9 V18 A200 V

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 kW0.0017 0.0027 Ω at 20C10 mm2 pcs.8.82 N (899 g)28 mm0.7 mm

4 mm

570 g27 mm

14


Item Standard limit

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

MS5F-421/JIDECO180 A4.2 4.6 Ω at 20C

Horn:Model/manufacturerMaximum amperage

YF-12/NIKKO3 A

Flasher/hazard relayTypeModel/manufacturerFlasher frequency

Full transistor typeFE246BH/DENSO75 95 cycle/min

Fuel gage:Model/manufacturerSender unit resistance – fullSender unit resistance – empty

5GM/NIPPON SEIKI4 10 Ω90 100 Ω

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

ACA12115-1/MATSUSHITA72 88 Ω

Electric fan motor:Model/manufacturer 5GM/MITSUBA

Thermo switch (electric fan):Model/manufacturer 5GH/NIHON THERMOSTAT

Thermo switch (auto choke):Model/manufacturer 5GM/NIHON THERMOSTAT

Thermo unit:Model/manufacturer 46X/NIPPON SEIKI

Circuit breaker:TypeMAINHEAD LIGHTSIGNALING SYSTEMIGNITIONRADIATORBACK UPReserveReserveReserveReserve

Fuse30 A 1 pc.15 A 1 pc.15 A 1 pc.7.5 A 1 pc.4 A 1 pc.10 A 1 pc.30 A 1 pc.15 A 1 pc.10 A 1 pc.7.5 A 1 pc.

15

LUBRICATION POINTS AND GRADE OF LUBRICANT SPEC

LUBRICATION POINTS AND GRADE OF LUBRICANTENGINE

Lubrication Point Symbol

Oil seal lips

O-ring (Except V-belt drive unit)

Cylinder head tightening nut mounting surface

Crankshaft pin outside

Connecting rod big end thrust surface

Rotary filter inner surface

Drive gear inner surface

Cam chain outside sprocket inner surface

Piston pin

Piston outside and ring groove

Camshaft cam profile

Valve stem (IN, EX)

Valve stem end (lN, EX)

Rocker shaft

Valve rocker arm inner surface

Shaft

Shaft (Oil pump assembly)

Gasket (Oil pump assembly)

Holder

Idle gear 1 thrust surfaces

Shaft 1

Idle gear 2 thrust surfaces

Idle gear 2 inner surface

Main axle thrust surfaces

Crankcase mating surfaces Yamaha bond No. 1215

Crankcase breather plug

Stator grommet Yamaha bond No. 1215

Suction pipe

16

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

CHASSIS

Lubrication Point Symbol

Front wheel oil seal lips (left /right)

Swingarm oil seal lips (left /right)

Steering head pipe bearing (upper/ lower)

Steering head pipe dust seal lips (upper/ lower)

Tube guide (throttle grip) inner surface

Brake lever and lever holder bolt sliding surface

Sidestand sliding surface

Centerstand sliding surface and mounting bolt

Centerstand stopper pivot shaft

17

1 Speed sensor2 Front brake hose3 Throttle cable4 Relay5 Brake hose assembly6 Thermo switch lead7 Fan motor lead8 Switch assembly9 Carburetor fuel drain hose10 Carburetor coolant drain hose11 Carburetor air ventilation hose12 Coolant pipe13 Sidestand switch14 Ignitor unit

15 Frame16 Seat lock cable17 Footrest board18 Handlebar19 Handlebar under cover20 Handlebar upper cover21 Right handlebar switch lead22 Front brake switch lead23 Left handlebar switch lead24 Rear brake switch lead

A Route the brake hose assemblythrough the guide on the handle-bar.

B Fasten the front brake hose,brake hose assembly throttlecable to the frame with a plasticband.

C Fasten the brake hose assembly,throttle cable to the frame with aband and the end of band isbackward.

CABLE ROUTING SPEC

CABLE ROUTING

18

P Fasten the wire harness to theframe with a band and the end ofband inside.

Q Roll the tape because of fix theprotection tube to the fuel pumlead.

R Clamp the fuel pump lead andsidestand switch lead.

S Fasten the throttle cable and theend of band backward.

T Lubricate the silicone greasebefor fasten the cable andhoses.

I Throttle cable pull side. (Whitenut)

J Throttle cable push side. (Blackand white nut)

K Clamp the fuel hose.L Route the carburetor coolant

drain hose, carburetor fuel drainhose through the clamp.

M Route the carburetor drain hosethrough the centerstand springhook.

N Clamp the sidestand switchlead.

O Touch the protection tube on thefuel pump.

D Clamp the brake hose assembly.E Fasten the seat lock cable

throttle cable and wireharness tothe frame with a band, and theend of band is downward.

F Clamp the switch assembly leadwith a band and cut the end ofband. It’s downward.

G Fasten the throttle cable with aband and more than 10 mmbetween throttle cable and box.

H Don’t scrub each other when fixthe throttle cables.

CABLE ROUTING SPEC

19

A’ Fasten the left handlebar switchlead and rear brake switch leadto the handlebar with a plasticlocking tie, cut the end of lockingtie at 5 mm or less.

B’ Don’t catch the seat lock cablebetween footrest board and box.

U More than 10 mm.V Route the seat lock cable

through the footrest board.W Route the left handlebar switch

lead through front side of thehandlebar under cover.

X Route the right handlebar switchlead through the clamp.

Y Route the front brake hosethrough the right hole of handle-bar under cover.

Z Route the brake hose assemblythrough the left hole of the han-dlebar under cover.

CABLE ROUTING SPEC

20

1 Box light2 Rectifire/regulator3 Air induction system air filter4 Wireharness5 Battery negative lead6 Battery positive lead7 Seat lock cable assembly8 Battery9 Rodiator reservoir tank10 Ignition coil11 Air induction system12 Engine ground

13 Engine bracket14 Rear brake hose15 A. C. magneto lead16 Starter motor lead

A Fasten the wireharness to theframe with a plastic locking tie.

B Route the brake hose assemblythrough the clamp of enginebracket.

C Fix the seat lock to the box.

D Fasten the wireharness to theframe with a plastic locking tie.

E Clamp the rear brake hose.F Clamp the wireharness to the

frame with a plastic locking tie.G Fasten the seat lock cable and

wireharness with a band andband of the end on inside of theframe.

CABLE ROUTING SPEC

21

H Fasten the wireharness to theframe with a band and the bandof end on inside of the frame.

I Clamp the radiator reservoirhose.

J Fasten the wireharness to thestay with a band and the end ofband on rearside.

K Fasten the speed sensor lead tothe stay.

L Route the front speed sensorlead and front brake hosethrough the clamp on the frame.(front side: speed sensor leadrear side: front brake hose)

M Clamp the speed sensor lead tothe front brake hose. Position theclamp (locatio of the speed sen-sor) to front of the upper clampand another clamps to outside.

N Through the speed sensor leadbetween front brake caliper andbolt.

O Route the speed sensor leadthrough the guide.

P When pull the speed sensorlead. Don’t loose.

Q Clamp the speed sensor leadand that caliper tightning boltand clamp in parallel with frontfork.

R Fix the starter relay to the foot-rest board.

S Clamp the radiator reservoirhose and starter motor lead tothe frame with a plastic clamp.

T Fix the fuse box to the footrestboard.

U Fasten the rodiator reservoirhose and starter motor lead onthe frame with a plastic clamp.

CABLE ROUTING SPEC

22

V Fix the turn signal relay on thefootboard.

W Fasten the starter motor leadand engine ground lead on theframe with the plastic clamp.

X Route the parking cable and rearbrake hose through the guide.

Y Clamp the A. C. magneto.

CABLE ROUTING SPEC

23

1 Air filter case2 Seat lock3 Tensioner4 Crankcase breather hose5 Fuel sender6 Throttle cable7 Seat lock cable assembly8 Panel9 Footrest board10 Radiator resorvoir tank breather

hose11 Vacuum hose12 Throttle position sensor lead13 Seat lock

14 Auto choke lead15 Brake hose assembly16 A. C. magneto lead17 Starter motor lead18 Engine ground lead19 Wireharness

A Don’t turn the idle adjust screw,when fix the hose.

B Route the gray seat lock outercable through the left side offrame.

C Set the fuel tank sender lead andsub lead.

D Fasten the wireharness on thefrome with a band and the end ofband match the tank rail pipeangle.

E Fix the seat lock cable along theguide of panel.

F Fasten the wireharness on theframe with a plastic clamp.

G Fasten the starter motor lead onthe fuel tank brocket with a plas-tic locking tie.

H Route the starter relay lead to-ward inside.

I Route the battery negative leadtoward inside.

CABLE ROUTING SPEC

24

J Route the thermo unit leadthrough the shortest distanceand dont roll another lead butloose the thermounit lead.

K Route the black seat lock cableouter through right side of frame.

L Fasten the A. C. magneto leadstarter motor lead and engineground lead to the clamp on theengine bracket.

M Route the crankcase breatherhose into the hole of air filtercase.

CABLE ROUTING SPEC

25

1 Front right turn signal light2 Relay3 Front left turn signal light4 Front brake hose assembly5 Horn lead (Hi)6 Horn (Hi)7 Throttle cable8 Speed sensor lead9 Front brake hose10 Horn (Lo)11 Stay12 Seat lock cable13 Leg sealed14 Seat lock cable assembly15 Inner fender

16 Panel17 Auxiliary light lead

A Don’t loosen the break hosewhen fix the break hose.

B Route the speed sensor leadthrough the brake hose holder.

C Fix the front brake hose on thefront brake hose holder.

D Align the white mark H of head-light assembly with the whitetape of coupler lead

E Install in stay 1F To the headlight assemblyG Clamp near the caupler side root

of auxiliary light lead.

CABLE ROUTING SPEC

26

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSPADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.YP301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

No ITEM CHECKS AND MAINTENANCE JOBInitial EVERY ANNUAL

No. ITEM CHECKS AND MAINTENANCE JOB(1,000 km) 10,000 km 20,000 km CHECK

1 * Fuel line Check fuel hoses and vacuum hose for cracks or damage. Replace if necessary.

2 Fuel filter Check condition. Replace if necessary.

3 Spark plug Check condition. Clean, regap or replace if necessary.

4 * Valves Check valve clearance. Adjust if necessary.

5 Air filter Clean or replace if necessary.

6 V-belt case air filter Clean or replace if necessary.

7 * Front brake Check operation, fluid level and vehicle for fluid leakage. Correct accordingly. Replace brake pads if necessary.

8 * Rear brake Check operation, fluid level and vehicle for fluid leakage. Correct accordingly. Replace brake pads if necessary.

9 * Brake hoses Check for cracks or damage. Replace if necessary.

10 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary.

11 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

12 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.

13 * Steerin g bearin gs Check bearing play and steering for roughness. Correct accordingly.

3 S ee g bea gs Lubricate with lithium soap base grease.

14 * Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.

15 Sidestand / centers-tand

Check operation. Lubricate and repair if necessary.

16 * Sidestand switch Check operation. Replace if necessary.

17 * Front fork Check operation and for oil leakage. Correct accordingly.

18 * Rear shock absorb-er assemblies

Check operation and shock absorbers for oil leakage. Replace shock absorber assembly if necessary.

19 * Carburetor Check engine idling speed and starter operation. Adjust if necessary.

20 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

Replace every 3,000 km

21 * Engine oil strainer Clean or replace if necessary. Clean or replace every

6,000 km

22 * Coolin g system Check coolant level and vehicle for coolant leakage. Correct if necessary.

Coo g sys e Change coolant.

23 Final gear oil Check oil level and vehicle for oil leakage. Change oil.

24 * V-belt Replace.

27

PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ

NOTE:

No ITEM CHECKS AND MAINTENANCE JOBInitial EVERY ANNUAL

No. ITEM CHECKS AND MAINTENANCE JOB(1,000 km) 10,000 km 20,000 km CHECK

25 *Front /Rear brakeswitch

Check operation. Adjust or replace if necessary.

26Moving parts andcables

Lubricate if necessary.

27 *Electrical compo-nents

Check all lights, signals and switches function. Correct if necessary. Adjust headlight beam if necessary.

*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU02970

The annual checks must be performed once a year unless a 10,000 km or 20,000 km maintenance wasperformed in the same year.The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake systemWhen disassembling the master cylinder or caliper, always replace the brake fluid. Check the brakefluid level regularly and fill as required.

Replace the oil seals on the inner parts of the master cylinder and caliper every two years.Replace the brake hoses every four years or if cracked or damaged.

28

COVER AND PANELINSPADJ

Order Job name/Part name Q’ty Remarks

1234567

Side cover, Side cover panel andpassenger seat removalPassenger seatStanding handleSide cover mole 3Cap 1Cap 2Side cover 1Side cover 2

1111111

Remove the parts in order.

Reverse the removal procedure forinstallation.

16 Nm (1.6 mkg)

8 Nm (0.8 mkg)

COVER AND PANELSIDE COVER, SIDE COVER MOLE, PASSENGER SEAT

29



123456

7

89

Rider seat and main box removalFuel tank capCoverRider seatSide cover 3ClipDamper assembly

Coupler (Seat switch lead)

PinBottom plate

111111

1

11

Remove the parts in order

Install the damper assembly to the bodywith its rod side backward and labels upward.

NOTE:

Disconnect the couplers.NOTE:

7 Nm (0.7 mkg)

13 Nm (1.3 mkg)

16 Nm (1.6 mkg)

RIDER SEAT AND MAIN BOX

30



1011

1213

BracketCoupler (Main box light read)

Seat lockMain box

11

21

Disconnect the couplers.


NOTE:

13 Nm (1.3 mkg)

16 Nm (1.6 mkg)

7 Nm (0.7 mkg)

RIDER SEAT AND MAIN BOX

31


123456789

101112

Side panel and footrest board removalMat (footrest board) (left /right)Cover (footrest board) (left /right)Cover 2Battery negative (–) leadBattery positive (+) leadBatteryFlasher relayFuse boxStarter relaySide cover mole 1Side cover mole 2Footrest board

1/11/11111111111



7 Nm (0.7 mkg)


SIDE COVER MOLE AND FOOTREST BOARD

32



123456789

10

Cowling, handle cover, meterassembly removalUpper coverWind screenInner panelMeter assemblyCoupler (Meter lead)Cowling bodyHandle coverCoupler (headlight lead)Coupler (front flasher light lead (left))Coupler (front flasher light lead (right))

1111111211




NOTE:

Disconnect the couplers.NOTE:

7 Nm (0.7 mkg)

COWLING, HANDLE COVER, METER ASSEMBLY

33


123456789

Legshield and fuel tank removalLegshieldInner fenderFront under braketFuel tank braketFuel hoseCoupler (fuel sensor lead)Fuel tankRivetCover

111111111



Revers the removal procedure forinstallation.

NOTE:

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

16 Nm (1.6 mkg)


LEGSHIELD AND FUEL TANK

34

ENGINE OIL REPLACEMENTINSPADJ

20 Nm (2.0 mkg)

NOTE:

ENGINEENGINE OIL REPLACEMENT1. Start the engine and let it warm up for several

minutes.2. Turn off the engine and place an oil pan un-

der the engine.3. Remove:Drain plug 1GasketDrain the crankcase of its oil.

4. Install:Gasket NewDrain plug 1

5. Fill:Crankcase

Oil quantity:1.4 L

6. Check:Engine oil levelRefer to “ENGINE OIL LEVEL INSPEC-TION” section.

7. Reset:Engine oil indicator circuit

Resetting steps:Turn the main switch to on.Push and hold in the reset button for 2 to 5 se-conds.

Release the reset button 1 and the oil indica-tor light will go off.

If the oil is changed before the oil indicator lightcomes on (i.e. before the 3,000 km oil changeinterval is reached), be sure to reset the oil indi-cator light after changing the oil, so that it willcome on at the correct time to indicate the next3,000 km oil replacement.To reset the oil indicator light before it comes on:Release the reset button and the oil indicatorlight will come on for 1.4 seconds.

35

CRANKCASE FILTER CLEANINGINSPADJ

NOTE:

CAUTION:

7 Nm (0.7 mkg)

CRANKCASE FILTER CLEANING1. Remove:Crankcase filter cover 1Crankcase filter cover sealCrankcase filter element

When installing the element in its case, besureits sealing surface matches the sealing surfaceof the case so there is no air leak.

2. Inspect:Crankcase filter elementDamaged Replace.

This element is a dry type.Be careful not to stain with grease or water.

3. Clean:Crankcase filter element 1Blow out the dust in the element from the out-er surface using compressed air.

4. Install:Crankcase filter elementCrankcase filter cover sealCrankcase filter cover

36

AIR INDUCTION SYSTEM INSPECTIONINSPADJ

AIR INDUCTION SYSTEM INSPECTION1. Remove:Side cover mole 3Passenger seatStanding handleSide cover 2Refer to “COVER AND PANEL” section.

2. Inspect:Hose 3 1Air filter case 2Hose 2 3Air induction system assembly 4Vacuum hose 5Pipe 1 6Hose 1 7Cracks/damage Replace.

3. Install:Side cover 2Standing handlePassenger seatSide cover mole 3

37

COOLANT REPLACEMENTINSPADJ

WARNING

NOTE:

YP303180

COOLANT REPLACEMENT1. Remove:Side cover moleRefer to the “COVERS AND PANEL” section.

2. Remove:Hose 1 (reservoir tank)Drain the reservoir tank of its coolant.

3. Remove:Drain bolt 1Rivet 2Cover 3Radiator capOpen the front trunk, remove the cover, slow-ly loosen to remove the radiator cap anddrain the coolant.

Do not remove the radiator cap when the en-gine and radiator are hot. Scalding hot fluidand steam may be blown out under pres-sure, which could cause serious injury.When the engine has cooled, open the radia-tor cap as follows:Place a thick rag or a towel over the radiatorcap. Slowly rotate the cap counterclockwisetoward the detent. This allows any residualpressure to escape. When the hissing soundhas stopped, press down on the cap whileturning counterclockwise and remove it.

Remove the radiator cap after removing thedrain bolt.

Place the scooter upright on a level surfacewhen draining the coolant completely.

4. Clean:RadiatorFill soft water into the filler neck support 1(reservoir tank).

38


10 Nm (1.0 mkg)

5. Install:Gasket 1 NewDrain bolt 2

6. Loosen:Screw 1 (carburetor bleed)

7. Connect:Hose (reservoir tank)

8. Fill:Radiator(to specified level 1 )Fill the coolant slowly, until the coolantcomes out from the carburetor drain pipe.

Reservoir tank(to maximum level a )

Recommended coolant:High quality ethylene glycolanti-freeze containingcorrosion inhibitors foraluminium engine.

Coolant 2 and water 3 (softwater):

Mixed ratio: 50%/50%Total amount:

1.4 LReservoir tank capacity:

0.4 L

Handling notes for coolant:Coolant is potentially harmful and should behandled with special care.

39


WARNING

CAUTION:

NOTE:

If coolant splashes in your eyes:thoroughly wash your eyes with water andconsult a doctor.

If coolant splashes on your clothes:quickly wash it away with water and thenwith soap and water.

If coolant is swallowed:quickly make the person who has swal-lowed it vomit and then take him to a doc-tor.

Hard water or salt water is harmful to en-gine parts. Use only distilled water if softwater is not available.

If you use tap water, make sure it is soft wa-ter.

Do not use water containing impurities oroil.

Take care that no coolant splashes ontopainted surfaces. If it does, wash themstraightaway with water.

Do not mix different types of ethylene gly-col antifreeze containing corrosion inhibi-tors for aluminum engines.

9. Tighten:Screw (carburetor bleed)Fill the coolant slowly to the specified level.

10. Install:Radiator cap

11. Start the engine and let it warm up for sever-al minutes.

12. Stop the engine and inspect the level.Refer to “COOLANT LEVEL INSPECTION”section.

Wait a few minutes until the coolant settles be-fore inspecting the coolant level.

13. Install:Side cover moleRefer to “COVER AND PANEL” section.

40

HEADLIGHT BEAM ADJUSTMENTINSPADJ

ELECTRICALHEADLIGHT BEAM ADJUSTMENT1. AdjustHeadlight beam (vertical)Turn the adjuster 1 in or out.

Turning in Headlight beam moveslower.

Turning out Headlight beam moves higher.

2. AdjustHeadlight beam (horizontal)Turn the adjuster 1 in or out.

Left headlight

Turning in Headlight beam movesleft.

Turning out Headlight beam movesright.

Right head light

Turning in Headlight beam movesright.

Turning out Headlight beam movesleft.

41


12345

Wireharness, cables and rear brakeremovalSide coverMain boxFootrest boardDrain the coolant.

CarburetorSpark plug capThermo unit leadStartor coil /Pick up coil leadStarting motor leadEarth lead

11

1/111


Refer to “COOLANT REPLACEMENT”section.Refer to “CARBURETOR” section.

Refer to “COVER AND PANEL” section.

7 Nm (0.7 mkg)10 Nm (1.0 mkg)

ENGINE REMOVAL ENG

EB400000

ENGINE OVERHAULENGINE REMOVALWIREHARNESS, CABLE, REAR BRAKE

42

ENGINE REMOVAL ENG


678

Caliper assemblyBrake hose 1Air induction system hose

111


10 Nm (1.0 mkg)40 Nm (4.0 mkg)

43

ENGINE REMOVAL ENG


123456789

Hoses, air filter case, engine mountingbolt and engine removalCrankcase breather hoseInlet hose (water pump)Outlet hose (cylinder head)Air filter case assemblyBoltSelf locknut/Plane washerBoltBolt /Plane washer/Rod assemblyEngine

11112

1/11

1/2/11


(Rear shock absorber – lower)

Reverse the removal procedure for installation.

Refer to “ENGINE REMOUNTING”section.

32 Nm (3.2 mkg)

64 Nm (6.4 mkg)

20 Nm ( 2.0 mkg)

HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE

44

CYLINDER HEAD ENG


123456789

Cylinder head removalDrain the coolant.Side coverMain boxFootrest boardCarburetorThermo unit leadPlug capHoseOutlet hose (cylinder head)Vacuum hoseBreather hose (crankcase)Carburetor jointJointO-ring

112111112

Remove the parts in the order.

Refer to “CARBURETOR” section.

Refer to the “COVER AND PANELS” section.

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

22 Nm (2.2 mkg)

10 Nm (1.0 mkg)

8 Nm (0.8 mkg)

10 Nm (1.0 mkg)

CYLINDER HEAD

45

CYLINDER HEAD ENG


1011121314151617181920212223

Crankcase filter coverPipe 1GasketPlug/O-ringCam sprocket cover/O-ringValve cover (intake side)/O-ringValve cover (exhaust side)/O-ringTiming chain tensioner assemblyTiming chain tensioner gasketBreather plateCam sprocket/Timing chainCylinder headCylinder head gasketDowel pin

111

1/11/11/11/1111

1/1112


Refer to “CYLINDER HEAD REMOVALAND INSTALLATION” section.

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

22 Nm (2.2 mkg)

10 Nm (1.0 mkg)

8 Nm (0.8 mkg)

10 Nm (1.0 mkg)

46


1234

Crankcase filter cover and crankcasecover (left) removalSide cover panelCrankcase filter coverCrankcase cover protectorCrankcase cover (left)Crankcase cover gasket

1111

Remove the parts in order

Refer “COVER AND PANEL” section.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE ENG

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVECRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT)

47


123456789

1011

V-belt, clutch and secondary/primary sheave removalNut/Plain washerPrimary fixed sheaveBracketNutSpacer/O-ringClutch housingClutch assemblyV-beltPrimary sliding sheaveCollarPrimary sheave cap

1/1111

1/1111111


Refer to “PRIMARY SHEAVE ASSEMBLY” section.

Refer to “SECONDARY SHEAVE ANDV-BELT REMOVAL” section.Refer to “SECONDARY SHEAVE INSTALLATION” section.

Refer to “PRIMARY SHEAVE REMOVAL” section.

22 Nm (2.2 mkg)

60 Nm (6.0 mkg)60 Nm (6.0 mkg)

3 Nm (0.3 mkg)


V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

*Shell BT grease No. 3 (90890-69927)

48

22 Nm (2.2 mkg)

60 Nm (6.0 mkg)60 Nm (6.0 mkg)

3 Nm (0.3 mkg)


1213141516

CamWeightSliderSpacerOil seal

18441


Refer to “PRIMARY SHEAVE ASSEMBLY” section.


*Shell BT grease No. 3 (90890-69927)

49

TRANSMISSION ENG


1234567

Transmission removalRear wheel

Crankcase cover (left)

Drain the transmission oil.

Transmission case coverGasket (transmission case cover)Dowel pinPrimary drive gearPlain washerPlain washer1st wheel gear

1121111

Remove the parts in order.Refer to “REAR WHEEL/REAR BRAKE”section.Refer to “V-BELT, CLUTCH, SECONDARY/PRIMARY SHEAVE” section.Refer to “TRANSMISSION OIL REPLACEMENT” section.

16 Nm (1.6 mkg)

TRANSMISSION

50

TRANSMISSION ENG


89

10111213

Conical spring washerDrive axleMain axleConical spring washerPrimary driven gearPlain washer

111111


16 Nm (1.6 mkg)

51


1234567

Air induction system removalClipHose 2ClipVacuum hoseClipHose 1Air induction system assembly

1111111

Remove the parts in the order

Reverse the removal procedure for installation

AIR INDUCTION SYSTEM ENG

AIR INDUCTION SYSTEM

52

CRANKCASE AND CRANKSHAFT ENG

NOTE:

NOTE:

CAUTION:

NOTE:

CRANKCASE AND CRANKSHAFTCRANKCASE REMOVAL1. RemoveCrankcase 2 1

Remove the crankshaft assembly with thecrankcase separating tool 2 .

Make sure that the crankcase separating toolis centered over the crankshaft assembly.

Crankshaft separating tool90890-01135

CRANKSHAFT REMOVAL1. Remove:Timing chain 1

Before removing the crankshaft assembly, re-move the timing chain from the crankshaftsprocket.

If the timing chain hooks to the crankshaftsprocket, the crankshaft cannot be removed.

crankshaft 1Remove the crankshaft assembly with thecrankcase separating tool 2

Do not tap on the crankshaft.

Crankshaft separating tool90890-01135

CRANKSHAFT INSTALLATION1. Install:Crankshaft 1Crankcase 2Install the crankshaft assembly with thecrankshaft installer pot 3 , crankshaft install-er bolt 4 , adapter 5 , spacer 6 .

Hold the connecting rod at top dead center(TDC) with one hand while turning the nut of thecrankshaft installing tool with the other.Turn the crankshaft installing tool until thecrankshaft assembly bottoms against the bear-ing.Do not tap on the crankshaft.

53

CRANKCASE AND CRANKSHAFT ENG

Yamaha bond No.1215

NOTE:

Crankshaft installer pot 390890-01274

Crankshaft installer bolt 490890-01275

Adapter 590890-01478

Spacer 690890-01016

2. Clean all the gascket mating surface andcrankcase surface thoroughly.

3. Apply:sealant(onto the left crankcase mating surface)

4. Install:Timing chain 1

Install the timing chain not to be seen through thecrankshaft hole a on the crankcase (left) 2 .

5. Install:Crankcase 2 1

Install the crankshaft assembly with the crank-shaft installer pot 2 , crankshaft installer bolt 3 ,adapter 4 , spacer 5 .

Crankshaft installer pot 290890-01274

Crankshaft installer bolt 390890-01275

Adapter 490890-01280

Spacer 590890-01288

54

RADIATOR COOL


123456

Radiator removalDrain the coolant

Fuel tankFootrest board, under coverCowling body, leg shieldFan motor leadsThermo switch leadsFiller hose (radiator)Outlet hose (radiator)Inlet hose (radiator)Radiator

121111

Remove the parts in order.Refer to “COOLANT REPLACEMENT”section.



23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

YP500000

COOLING SYSTEMRADIATOR

55


123456

78

Carburetor removalSide panelMain boxDrain the coolant

Auto choke lead couplerThrottle position sensor leadInlet/Outlet hose (carburetor)Fuel hoseThrottle cableAir filter joint

NutCarburetor assembly

11

1/1121

21


Refer to “COOLANT REPLACEMENT”section.

Do not bend the air filter joint clampwhen installing the carburetor.



CAUTION:

10 Nm (1.0 mkg)

CARBURETOR CARB

EB600000

CARBURETORCARBURETOR

56


Carburetor disassemblyAuto choke unitThrottle stop screw setPilot screw setCover/Diaphragm springPiston valveJet needle assemblyCoasting enricherAccererating pump

Float chamberFloat pin

111

1/11111

11

Disassemble the parts in order.

Refer to “CARBURETOR ASSEMBLY” section.

Refer to “CARBURETOR ASSEMBLY” section.

12345678

910

CARBURETOR CARB

CARBURETOR DISASSEMBLY

57


FloatNeedle valveMain jetPilot jetMain nozzleThrottle position sensor

111111

Reverse the disassembly procedure for assembly.

Refer to “CARBURETOR ASSEMBLY”section.

111213141516

CARBURETOR CARB

58

CARBURETOR CARB

NOTE:

NOTE:

THROTTLE POSITION SENSOR ADJUST-MENT

Before adjusting the throttle position sensorthe engine idling speed should be properly ad-justed.

When installing the throttle position sensor,adjust its angle according to the RPM which isdisplayed on the tachometer, Refer to the ad-justment procedure below.

1. Turn the main switch to “ON”2. Loosen:Throttle position sensor screws 1

3. Inspect:Throttle position sensor input voltage.

tester (+) lead blue 1tester (–) lead black 2

Throttle position sensor in putvoltage

5 V

Out of specification Check the wireharnessbetween battery and igniter or igniter andthrottle position sensor.Throttle position sensor output voltage

tester (+) lead yellow 3tester (–) lead black 2

Throttle position sensor outputvoltage.

0.73 0.63 V

Out of specification Adjust or replace.

When check the throttle position sensor must beconnect the throttle sensor coupler to the wire-harness.

4. Tighten:Throttle position sensor screws

59

FRONT WHEEL CHAS


12345678

Speed sensor and sensor rotorremovalCowling bodySpeed sensorBrake caliperAxle nutWheel axleFront wheelSensor housingCollarFront wheel sensor lead connector

11111111



Disconnect the connecter.Reverse the removal procedure forinstallation.

70 Nm (7.0 mkg)

23 Nm (2.3 mkg)

CHASSISFRONT WHEELSPEED SENSOR AND SENSOR ROTOR

60

FRONT WHEEL CHAS

CAUTION:

NOTE:

CAUTION:

SPEED SENSOR AND THE SENSOR ROTOR

Speed sensor cannot be disassembled.Never disassemble it. If failed, replace witha new one.

SPEED SENSOR REMOVAL1. Remove:Clamp 1

Clamp can be easily removed by moving theclamp tip of brake hose and speed sensor leadsup and down.

2. Remove:caliper 1Speed sensor 2

Care should be taken not to allow the sen-sor electrode to contact the metal partswhen removing the speed sensor from thewheel hub.

To remove the wheel, do not operate thebrake lever.

SPEED SENSOR AND SENSOR ROTOR IN-SPECTION1. Check:Speed sensor 1Cracks, bending and distortion ReplaceIron powder and dust Clean

61

FRONT WHEEL CHAS

NOTE:

2. Measure:Speed sensor resistanceConnect the pocket tester (Ω 1) to the ter-minal of speed sensor connector.Tester’s positive (+) lead Terminal 1Tester’s negative (–) lead Terminal 2

Regulated resistance:1.19 to 2.21 k Ω at 20C

Out of specification Replace

3. Check:Sensor rotor 1Cracks and damage Replace the wheelassembly

Sensor rotor of YP250 is inserted under pres-sure by the special process and cannot be re-placed as a single unit. To replace the sensor ro-tor, replace it as a wheel assembly.

SPEED SENSOR ASSEMBLYProceed in the reverse order of disassemblingpaying attention to the following items.1. Apply:Litium soap base grease

1 Wheel axle

62

FRONT WHEEL CHAS

70 Nm (7.0 mkg)

NOTE:

CAUTION:

23 Nm (2.3 mkg)

50 Nm (5.0 mkg)

NOTE:

CAUTION:

2. Install:Sensor housing

3. Install:Front wheelWheel axleAxle nut

Align the slot of sensor housing with the projec-tion part of front fork, then assemble them.

Install after checking if foreign materials aremixed in the wheel hub. If foreign materialsare mixed, it causes to damage the sensorrotor and speed sensor.

4. Install:Speed sensor 1Brake caliper 2Clamp 3

When installing the speed sensor, check if thespeed sensor lead is twisted or foreign mattersattached to the electrode.

To route the speed sensor lead, refer to theCABLE ROUTING.

63

FRONT WHEEL CHAS

5. Install:Speed sensor lead 1

64

REAR WHEEL CHAS


1234

Rear wheel and brake disc removalSwingarm

PlateO-ringCollarRear wheel

1111

Refer to “REAR SHOCK ABSORBERAND SWINGARM” section.


REAR WHEEL

65

REAR SHOCK ABSORBER AND SWINGARM CHAS


12

3456789

10

Rear shock absorber and swingarmremovalSide panels

NutMuffler assembly

Axle nutRear shock absorberRear caliper assemblySwingarmCollarOil sealBearingOil seal

21

12111111



Loosen.

Remove with the rear brake applied.


NOTE:

NOTE:

40 Nm (4.0 mkg)

53 Nm (5.3 mkg)

35 Nm (3.5 mkg)

40 Nm (4.0 mkg)

135 Nm (13.5 mkg)

20 Nm (2.0 mkg)

REAR SHOCK ABSORBER AND SWINGARM

66

ELECTRICAL COMPONENTS ELEC

EB800000

ELECTRICALELECTRICAL COMPONENTS1 Main switch2 Ignition coil3 Spark plug cap4 Fuel sender5 Rectifier /Regulator6 Wireharness7 Thermo unit8 Ignitor unit

9 Fuel pump10 Sidestand switch11 Flasher relay12 Battery13 Starter relay14 Starting circuit cut-off relay15 Horn16 Fuel pump relay

67

CIRCUIT DIAGRAM ELEC

CIRCUIT DIAGRAM

68

32 Thermo switch (Fan)33 Fan motor34 Brake light switch35 Flasher relay36 Horn37 Turn switch38 Horn switch39 Dimmer switch40 Pass switch41 Left handlebar switch42 License plate light43 Tail /brake light44 Rear flasher light45 Front flasher light46 Head light (LO)47 Head light (HI)48 Auxiliary light49 Trun signal indicator light50 High beam indicator light51 Meter light52 Oil indicator light53 Fuel gauge54 Thermometer55 Clock56 Speedometer57 Meter assembly58 Fuel sender59 Thermo unit60 Alarm61 Grip warmer switch (OPUTION)62 Grip warmer (OPUTION)63 Ground

1 A.C. magneto2 Pickup coil3 Rectifier regulator4 Main switch5 Backup fuse6 Battery7 Main fuse8 Starter relay9 Starter motor10 Diode11 Starting circuit cut-off relay12 Thermo switch (Auto choke)13 Auto choke14 Ignitor unit15 Ignition coil16 Spark pulg17 Throttle position sensor18 Speed sensor19 Fuel pump20 Fuel pump relay21 Sidestand switch22 Light switch23 Start switch24 Engine stop switch25 Right handlebar switch26 Ignition fuse27 Seat switch28 Box light29 Head light fuse30 Fan fuse31 Signal fuse

CIRCUIT DIAGRAM ELEC

NOTE:Starter switch is closed while the button (switch) is pushed.Sidestand switch is closed while the side stand is upped.Brake switch is closed while the brake is applied.

COLOR CODE

B Black W White L/Y Blue/Yellow

Br Brown B/R Black/Red L/W Blue/White

Ch Chocolate B/W Black/White R/G Red/Green

Dg Dark green Br/L Brown/Blue R/Y Red/Yellow

G Green Br/W Brown/White R/W Red/White

L Blue G/R Green/Red Y/R Yellow/Red

O Orange G/Y Green/Yellow Y/L Yellow/Blue

P Pink L/B Blue/Black W/G White/Green

R Red L/G Blue/Green

Y Yellow L/R Blue/Red

69

CHECKING SWITCHES ELEC

Before checking a switch refer to the checkingswitches as shown in the left page and check forthe correct terminal connections (closed circuit)according to the color combinations shown inthe chart.Poor connection, fault Repair or replace.

YP*****

CHECKING SWITCHESSWITCH POSITION AND TERMINAL CONNECTION

70

CHECKING SWITCHES ELEC

NOTE:

YP-N

CHECKING SWITCHESCHECKING STEPSUsing pocket tester, check switches for continu-ity between their terminals to determine wheth-er they are correctly connected.Replace the switch component if any of thecombinations does not produce the correctreading.

Pocket tester:90890-03112

Turn the switch to the “ON”, “OFF” positionsseveral times.

Adjust the pocket tester to correct “0” positionbefore checking switches.

Set the pocket tester selector to “ 1” Ω.

SWITCH CONNECTION AS SHOWN IN THIS MANUALThis manual contains connection charts, likethe one shown on the left, showing the terminalconnections of switches (e.g. the main switch,handlebar switch, brake switch, lighting switchetc.)

The column on the extreme left indicates the dif-ferent switch positions, the top line indicates thecolors of the leads connected to the terminalson the switch.

“ ” indicates terminals between whichthere is continuity, i.e. a closed circuit, in the giv-en switch position.

In this chart:“Br and R” have continuity with the switch in the“ON” position.

71

2 Pickup coil 4 Main switch6 Battery7 Main fuse14 Ignitor unit15 Ignition coil16 Spark plug21 Sidestand switch24 Engine stop switch60 Alarm

EB802000

IGNITION SYSTEMCIRCUIT DIAGRAM

IGNITION SYSTEM ELEC

72

4 Main switch 6 Battery7 Main fuse8 Starter relay9 Starter motor11 Starting circuit cut-off relay21 Sidestand switch23 Starter switch24 Engine stop switch26 Ignition fuse31 Signal fuse34 Brake light switch60 Alarm

EB80300

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

ELECTRIC STARTING ELEC

73

4 Main switch5 Backup Fuse6 Battery7 Main fuse22 Lights switch27 Seat switch28 Box light29 Head light fuse39 Dimmer switch

40 Pass switch42 License plate light45 Tail/Brake light46 Head light (Lo)47 Head light (HI)48 Auxiliary light50 High beam indicator light51 Meter lights

LIGHTING SYSTEM ELEC

EB804000

LIGHTING SYSTEMCIRCUIT DIAGRAM

74


5. Dimmer switch and pass switch6. Seat switch7. Wiring connection (entire lighting system)

NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section.Replace the fuse.

NO CONTINUITY

CONTINUITY

YP******

2. Battery

Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.

Clean battery terminals.Recharge or replace battery.

INCORRECT

CORRECTYP******

3. Main switch

Refer to “CHECKING SWITCHES” section.Replace the main switch.

NO CONTINUITY

CONTINUITYYP******

4. Lights switch

Refer to “CHECKING SWITCHES” section.

Replace the right handlebar switch.

NO CONTINUITY

CONTINUITY

YP805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAMINDICATOR LIGHT, TAILLIGHT,

BOX LIGHT, LICENSE PLATE LIGHT AND/OR METER LIGHT FAIL TO COME ON.

ProcedureCheck:1. Fuse (Main, Backup)2. Battery3. Main switch4. Lights switch

Remove the following parts before trouble-shooting.1) Rider seat2) Passenger seat3) Box4) Legshield5) Cowling body

Use the special tools specified in the trouble-shooting section.

Pocket tester90890-03112

75

YP******

5. Dimmer switch/Pass switch

Refer to “CHECKING SWITCHES” section.Replace the left handlebar switch.

NO CONTINUITY

YP******

7. Wiring connection

Check the connections of the entire lightingsystem.Refer to “WIRING DIAGRAM”. Correct.

POOR CONNECTIONS

Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”

YP******

6. Seat switch

Refer to “CHECKING SWITCHES” section.Replace the handlebar switch.

NO CONTINUITY


1. Bulb and bulb socket


Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to theheadlight and high beam indicator light cou-plers.

When the dimmer switch is on low beam.When dimmer switch is on high beam orthe Pass switch is pushed.

Headlight:Tester (+) lead Green or YellowleadTester negative (–) lead Blacklead

High beam indicator light:Tester (+) lead Yellow leadTester (–) lead Black lead

4

CONTINUITY

A

B

1

3

2

5

YP805020

LIGHTING SYSTEM CHECK1. If the headlight and the high beam indicator light fail to come on.

76


YP805021


Refer to “CHECKING SWITCHES” section.Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thebulb socket coupler.

Tester (+) lead Blue terminal

Tester (–) lead Black terminal

Turn the main switch to on.Turn the lights switch to on or pilot position.Check the voltage (12 V) of the leads on thebulb socket connector.

CONTINUITY

1

Turn the main switch to on.Turn the light switch to on position.Turn the dimmer switch to low beam or highbeam.

Pass switch to push in.Check for voltage (12 V) on the lead at bulbsocket connectors.

This circuit is not faulty.

MEETSSPECIFICATION

The wiring circuit from the main switch tobulb socket connector is faulty. Repair.

OUT OF SPECIFICATION

2. If the meter light fails to come on.

2

MEETSSPECIFICATION


The wiring circuit from main switch to bulbsocket is faulty. Repair.


77




NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thebulb socket connector.



Turn the main switch to on.Turn the lights switch to on or pilot position.Check the voltage (12 V) on the bulb socketconnector.

CONTINUITY

1

2

MEETSSPECIFICATION


The wiring circuit from main switch to bulbconnector is faulty. Repair.


YP805022

3. The taillight fails to come on.

78




NO CONTINUITY

2. Voltage





CONTINUITY

1

2

MEETSSPECIFICATION




YP805022

3. The license plate light fails to come on.

79




NO CONTINUITY

2. Voltage


Tester (+) lead Blue/Red terminalTester (–) lead Black terminal


CONTINUITY

12

MEETSSPECIFICATION




YP805023

4. If the auxiliary light fails to come on.

80

4 Main switch6 Battery7 Main fuse31 Signal fuse34 Brak light switch35 Flasher relay36 Horn37 Turn switch

38 Horn switch43 Tail /Brake light44 Rear flasher lights45 Front flasher lights49 Turn indicator lights53 Fuel gauge58 Fuel sender

EB806000

SIGNAL SYSTEMCIRCUIT DIAGRAM

SIGNAL SYSTEM ELEC

81

SIGNAL SYSTEM ELEC

3. Main switch4. Wiring connection (entire signal system)

NOTE:

YP******

1. Fuse


NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRECT

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITY

YP806010

TROUBLESHOOTING

IF THE FLASHER LIGHT, BRAKELIGHT AND/OR INDICATOR LIGHT

FAIL TO COME ON.IF THE HORN FAILS TO SOUND.

ProcedureCheck:1. Fuse (Main, signal)2. Battery

Remove the following parts before trouble-shooting.1) Cowling body2) Side panels

Use the special tools in the troubleshootingsection.

Pocket tester:90890-03112

82

SIGNAL SYSTEM ELEC

YP******

4. Wireharness

Check the connections of the entire signalsystem.Refer to “CIRCUIT SYSTEM WIRING DIA-GRAM” section. Correct.

POOR CONNECTION

Check condition of each of the signal sys-tem’s circuits.Refer to “SIGNAL SYSTEM CHECK” section.

CONTINUITY

83

SIGNAL SYSTEM ELEC

1. HORN switch


CONTINUITY

Replace the left handlebar switch.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thehorn lead.

Tester (+) lead Brown terminalTester (–) lead Frame ground

1

MEETSSPECIFICATION

Turn the main switch to on.Check for voltage (12 V) on the “Brown” leadat the horn terminal.

The wiring circuit from the main switch to thehorn is faulty. Repair.


3. Horn

Connect the pocket tester (DC20 V) to thehorn at the “Pink” terminal.

Tester (+) lead Pink terminalTester (–) lead Frame ground

1

Turn the main switch to on.Check for voltage on the “Pink” lead to frameground.

Replace the horn.

NO CONTINUITY

CONTINUITY

Adjust or replace horn.

YP806020

SIGNAL SYSTEM CHECK1. If the horn fails to sound.

84



NO CONTINUITY

3. Voltage


Tester (+) lead Yellow terminalTester (–) lead Black terminal

Turn the main switch to on.The brake lever is pulled in.Check for voltage (12 V) of the “Yellow” leadon the bulb socket connector.

CONTINUITY

12

MEETSSPECIFICATION



2. Brake switch (Front/Rear)

Refer to “CHECKING SWITCHES” section.Replace brake switch.

NO CONTINUITY

CONTINUITY


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

SIGNAL SYSTEM ELEC

YP806022

2. If the brake light fails to come on:

85



MEETSSPECIFICATION

Replace the bulb and/or bulb socket.

NO CONTINUITY

3. Voltage

Connect the pocket tester (DC20 V) to theflasher relay coupler.

Tester (+) lead Brown terminalTester (–) lead Frame ground

1

MEETS SPECIFICATION

Turn the main switch to on.Check for voltage (12 V) of the “Brown”

lead at the flasher relay terminal.

The wiring circuit from main switch to flasherrelay connector is faulty. Repair.


4. Voltage

Connect the pocket tester (DC20 V) to theflasher relay coupler.

Tester (+) lead Brown/White terminal

Tester (–) lead Frame ground1

Turn the main switch to on.Check for voltage (12 V) on the “Brown/White” lead at the flasher relay terminal.

The flasher relay is faulty. Replace.


CONTINUITY

2. Turn switch

Refer to “CHECKING SWITCHES” section.Replace the left handlebar switch.

NO CONTINUITY

CONTINUITY

1

SIGNAL SYSTEM ELEC

YP806023

3. If the flasher light and/or turn indicator light fails to blink.

86


Wiring circuit from the turn switch to bulbsocket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.

5. Voltage


At flasher light (left)Tester (+) lead Chocolate leadTester (–) lead Black terminal

Turn the main switch to on.Turn the turn switch to left or right.Check for voltage (12 V) on the “Chocolate”lead and “Dark green” at the flasher light ter-minal.

13

MEETSSPECIFICATION



At flasher light (right)Tester (+) lead Dark green leadTester (–) lead Black terminal

23

SIGNAL SYSTEM ELEC

87

SIGNAL SYSTEM ELEC

Float positionSpecificatedresistance

UP 4 10 Ω90 100 ΩDOWN

1. Fuel sender

Remove the fuel sender from the fuel tank.Disconnect the fuel sender coupler from thewireharness.Connect the pocket tester (Ω 10) to thefuel sender coupler lead.

2. Voltage

Connect the pocket tester (DC20 V) to thefuel gauge coupler.

Tester (+) lead Green terminalTester (–) lead Black terminal

1

3

Check the fuel sender for specificated resis-tance.

Replace the fuel sender.


Turn the main switch to “ON”.Check for voltage (12 V) of the “Brown” leadon the fuel sender lead.


Check the connection of the entire signalsystem.Refer to “CHECKING OF CONNECTIONS”.Refer to “CIRCUIT DIAGRAM”.

MEETSSPECIFICATION

4

BOTH MEETSPECIFICATION

Tester (+) lead Brown terminal

Tester (–) lead Frame ground

1

2

YP806027

4. If the fuel gauge fails to operate.

88

Float “UP” “F”“E”Float “DOWN”

3. Fuel gauge

Connect the fuel sender to wireharness.Move the float to “UP” or “DOWN” .

1

Turn the main switch to “ON”.Check the fuel gauge needle moves “F” or“E”.

Replace the fuel gauge.

DOES NOT MOVE

2

MOVES

Float position Needle moves


NOTE:Before reading the meter, stay put the float formore than three minutes respectively at “UP”or “DOWN”.

1 2

SIGNAL SYSTEM ELEC

89

4 Main switch6 Battery7 Main fuse14 Ignitor unit19 Fuel pump20 Fuel pump relay24 Engine stop switch26 Ignition fuse

EB808000

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

FUEL PUMP SYSTEM ELEC

90

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pump


EB808010

FUEL PUMP CIRCUIT OPERATIONThe ignitor unit includes the control unit for the fuel pump.

91


5. Relay unit (fuel pump relay)6. Fuel pump7. Wiring connection

(engine fuel pump system)

NOTE:

YP******

1. Fuse


NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRECT

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITYYP******

4. Engine stop switch


Replace the right handlebar switch.

NO CONTINUITY

CONTINUITY

EB808020

TROUBLESHOOTING

The fuel pump fails to operate.

ProcedureCheck:1. Fuse (Main and Ignition)2. Battery3. Main switch4. Engine stop switch

Remove the following parts before trouble-shooting.1) Rider seat2) Passenger seat3) Box4) Legshield

Use the special tools specified in the trouble-shooting section.

Pocket tester90890-03112

92

Tester positive probe red/whiteTester negative probe blue/black

12

NO CONTINUITY

5. Relay unit (fuel pump relay)

Disconnect the relay unit from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit terminals asshown.

Battery positive terminal red/white Battery negative terminal blue/red

34

Turn the main switch to on.Check the starter relay for continuity.

CONTINUITY

6. Fuel pump resistance

Disconnect the fuel pump coupler from thewire harness.

Connect the pocket tester (Ω 1) to the fuelpump coupler (fuel pump side) as shown.

CORRECT


Check the entire fuel pump system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Correct.

POOR CONNECTION

CORRECT

Replace the starter relay

12

Tester positive probe black/blue Tester negative probe black

Measure the fuel pump resistance.

Fuel pump resistance11 13 Ω at 20C


Replace the fuel pump

Replace the ignition unit


93


WARNING

EB808410

CHECKING THE FUEL PUMP

Gasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosion or fire. Be extremely carefuland note the following points:Stop the engine before refuelling.Do not smoke and keep away from openflames, sparks or any other source of fire.

If you do accidentally spill gasoline, wipe itup immediately with dry rags.

If gasoline touches the engine when it ishot, a fire may occur. Therefore, make surethat the engine is completely cool beforeperforming the following test.

1. Check:Fuel pump operation

a. Fill the fuel tank.b. Put the end of the fuel hose into an open con-

tainer.c. Turn the fuel cock to “ON” or “RES”.d. Connect the battery (12 V) to the fuel pump

coupler as shown.

Battery positive lead black/blue 1Battery negative lead black 2

e. If fuel flows out of the fuel hose, the fuel pumpis OK. If fuel does not flow, replace the fuelpump.

1 A. C. magneto2 Pickup coil3 Rectifier regulator4 Main switch5 Backup fuse6 Battery7 Main fuse8 Starter relay9 Starter motor10 Diode11 Starting circuit cut-off relay12 Thermo switch (Auto choke)13 Auto choke14 Ignitor unit15 Ignition coil16 Spark pulg17 Throttle position sensor18 Speed sensor19 Fuel pump20 Fuel pump relay21 Sidestand switch22 Light switch23 Start switch24 Engine stop switch25 Right handlebar switch26 Ignition fuse27 Seat switch28 Box light29 Head light fuse30 Fan fuse31 Signal fuse32 Thermo switch (Fan)33 Fan motor34 Brake light switch35 Flasher relay36 Horn37 Turn switch38 Horn switch39 Dimmer switch40 Pass switch

COLOR CODEB Black. . . . . . . . Br Brown. . . . . . . Ch Chocolate. . . . . . Dg Dark green. . . . . . G Green. . . . . . . L Blue. . . . . . . . O Orange. . . . . . . P Pink. . . . . . . . R Red. . . . . . . . Y Yellow. . . . . . . . W White. . . . . . . B /R Black /Red. . . . . . B /W Black /White. . . . . Br /L Brown/Blue. . . . .

41 Left handlebar switch42 License plate light43 Tail /brake light44 Rear flasher light45 Front flasher light46 Head light (LO)47 Head light (HI)48 Auxiliary light49 Trun signal indicator light50 High beam indicator light51 Meter light52 Oil indicator light53 Fuel gauge54 Thermometer55 Clock56 Speedometer57 Meter assembly58 Fuel sender59 Thermo unit60 Alarm61 Grip warmer switch (OPTION)62 Grip warmer (OPTION)63 Ground

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

YP250 2000 WIRING DIAGRAM

yp250 service manual

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