YP250 Service Manual
Transcript of 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.
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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.
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19 2018
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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
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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.
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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.
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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
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GENERAL SPECIFICATIONS SPEC
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
GENERAL SPECIFICATIONS SPEC
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
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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
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MAINTENANCE SPECIFICATIONS SPEC
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
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MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
MAINTENANCE SPECIFICATIONS SPEC
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
COVER AND PANELINSPADJ
Order Job name/Part name Q’ty Remarks
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
COVER AND PANELINSPADJ
Order Job name/Part name Q’ty Remarks
1011
1213
BracketCoupler (Main box light read)
Seat lockMain box
11
21
Disconnect the couplers.
Reverse the removal procedure forinstallation.
NOTE:
13 Nm (1.3 mkg)
16 Nm (1.6 mkg)
7 Nm (0.7 mkg)
RIDER SEAT AND MAIN BOX
31
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
Reverse the removal procedure forinstallation.
7 Nm (0.7 mkg)
COVER AND PANELINSPADJ
SIDE COVER MOLE AND FOOTREST BOARD
32
COVER AND PANELINSPADJ
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
Disconnect the couplers.
Reverse the removal procedure forinstallation.
NOTE:
Disconnect the couplers.NOTE:
7 Nm (0.7 mkg)
COWLING, HANDLE COVER, METER ASSEMBLY
33
Order Job name/Part name Q’ty Remarks
123456789
Legshield and fuel tank removalLegshieldInner fenderFront under braketFuel tank braketFuel hoseCoupler (fuel sensor lead)Fuel tankRivetCover
111111111
Remove the parts in order.
Disconnect the couplers.
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)
COVER AND PANELINSPADJ
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
COOLANT REPLACEMENTINSPADJ
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
COOLANT REPLACEMENTINSPADJ
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
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
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
Order Job name/Part name Q’ty Remarks
678
Caliper assemblyBrake hose 1Air induction system hose
111
Reverse the removal procedure forinstallation.
10 Nm (1.0 mkg)40 Nm (4.0 mkg)
43
ENGINE REMOVAL ENG
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
(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
Order Job name/Part name Q’ty Remarks
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
Order Job name/Part name Q’ty Remarks
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
Reverse the removal procedure for installation.
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
Order Job name/Part name Q’ty Remarks
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.
Reverse the removal procedure forinstallation.
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
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
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 ANDSECONDARY/PRIMARY SHEAVE ENG
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)
Order Job name/Part name Q’ty Remarks
1213141516
CamWeightSliderSpacerOil seal
18441
Reverse the removal procedure for installation.
Refer to “PRIMARY SHEAVE ASSEMBLY” section.
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE ENG
*Shell BT grease No. 3 (90890-69927)
49
TRANSMISSION ENG
Order Job name/Part name Q’ty Remarks
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
Order Job name/Part name Q’ty Remarks
89
10111213
Conical spring washerDrive axleMain axleConical spring washerPrimary driven gearPlain washer
111111
Reverse the removal procedure for installation.
16 Nm (1.6 mkg)
51
Order Job name/Part name Q’ty Remarks
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
Order Job name/Part name Q’ty Remarks
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.
Reverse the removal procedure for installation.
Refer to “COVER AND PANEL” section.
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
YP500000
COOLING SYSTEMRADIATOR
55
Order Job name/Part name Q’ty Remarks
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
Remove the parts in order.
Refer to “COOLANT REPLACEMENT”section.
Do not bend the air filter joint clampwhen installing the carburetor.
Reverse the removal procedure for installation.
Refer to “COVER AND PANEL” section.
CAUTION:
10 Nm (1.0 mkg)
CARBURETOR CARB
EB600000
CARBURETORCARBURETOR
56
Order Job name/Part name Q’ty Remarks
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
Order Job name/Part name Q’ty Remarks
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
Order Job name/Part name Q’ty Remarks
12345678
Speed sensor and sensor rotorremovalCowling bodySpeed sensorBrake caliperAxle nutWheel axleFront wheelSensor housingCollarFront wheel sensor lead connector
11111111
Remove the parts in order.
Refer to “COVER AND PANEL” section.
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
Order Job name/Part name Q’ty Remarks
1234
Rear wheel and brake disc removalSwingarm
PlateO-ringCollarRear wheel
1111
Refer to “REAR SHOCK ABSORBERAND SWINGARM” section.
Reverse the removal procedure forinstallation.
REAR WHEEL
65
REAR SHOCK ABSORBER AND SWINGARM CHAS
Order Job name/Part name Q’ty Remarks
12
3456789
10
Rear shock absorber and swingarmremovalSide panels
NutMuffler assembly
Axle nutRear shock absorberRear caliper assemblySwingarmCollarOil sealBearingOil seal
21
12111111
Remove the parts in order.
Refer to “COVER AND PANEL” section.
Loosen.
Remove with the rear brake applied.
Reverse the removal procedure forinstallation.
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
LIGHTING SYSTEM ELEC
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
LIGHTING SYSTEM ELEC
1. Bulb and bulb socket
Refer to “CHECKING SWITCHES” section.
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
LIGHTING SYSTEM ELEC
YP805021
1. Bulb and bulb socket
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
This circuit is not faulty.
The wiring circuit from main switch to bulbsocket is faulty. Repair.
OUT OF SPECIFICATION
77
LIGHTING SYSTEM ELEC
1. Bulb and bulb socket
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 connector.
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) on the bulb socketconnector.
CONTINUITY
1
2
MEETSSPECIFICATION
This circuit is not faulty.
The wiring circuit from main switch to bulbconnector is faulty. Repair.
OUT OF SPECIFICATION
YP805022
3. The taillight fails to come on.
78
LIGHTING SYSTEM ELEC
1. Bulb and bulb socket
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 connector.
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) on the bulb socketconnector.
CONTINUITY
1
2
MEETSSPECIFICATION
This circuit is not faulty.
The wiring circuit from main switch to bulbconnector is faulty. Repair.
OUT OF SPECIFICATION
YP805022
3. The license plate light fails to come on.
79
LIGHTING SYSTEM ELEC
1. Bulb and bulb socket
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 connector.
Tester (+) lead Blue/Red terminalTester (–) lead Black terminal
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
12
MEETSSPECIFICATION
This circuit is not faulty.
The wiring circuit from main switch to bulbconnector is faulty. Repair.
OUT OF SPECIFICATION
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
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
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
Refer to “CHECKING SWITCHES” section.
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.
OUT OF SPECIFICATION
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
1. Bulb and bulb socket
Refer to “CHECKING SWITCHES” section.Replace the bulb and/or bulb socket.
NO CONTINUITY
3. Voltage
Connect the pocket tester (DC20 V) to thebulb socket connector.
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
This circuit is not faulty.
OUT OF SPECIFICATION
2. Brake switch (Front/Rear)
Refer to “CHECKING SWITCHES” section.Replace brake switch.
NO CONTINUITY
CONTINUITY
4. Wiring connection
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
1. Bulb and bulb socket
Refer to “CHECKING SWITCHES” section.
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.
OUT OF SPECIFICATION
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.
OUT OF SPECIFICATION
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
6. Wiring connection
Wiring circuit from the turn switch to bulbsocket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.
5. Voltage
Connect the pocket tester (DC20 V) to thebulb socket connector.
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
This circuit is not faulty.
OUT OF SPECIFICATION
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.
OUT OF SPECIFICATION
Turn the main switch to “ON”.Check for voltage (12 V) of the “Brown” leadon the fuel sender lead.
OUT OF SPECIFICATION
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
This circuit is not faulty.
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
FUEL PUMP SYSTEM ELEC
EB808010
FUEL PUMP CIRCUIT OPERATIONThe ignitor unit includes the control unit for the fuel pump.
91
FUEL PUMP SYSTEM ELEC
5. Relay unit (fuel pump relay)6. Fuel pump7. Wiring connection
(engine fuel pump 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. Engine stop switch
Refer to “CHECKING SWITCHES” section.
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
7. Wiring connection
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
OUT OF SPECIFICATION
Replace the fuel pump
Replace the ignition unit
FUEL PUMP SYSTEM ELEC
93
FUEL PUMP SYSTEM ELEC
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