Yamaha 4XEF Supplementary Service Manual Download Page 1 | Manualshive

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YFM250X

(

P

)

4XE3-AE3

SUPPLEMENTARY

SERVICE MANUAL

2002

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Summary of Contents for 4XEF

Page 1: ...YFM250X P 4XE3 AE3 SUPPLEMENTARY SERVICEMANUAL 2002 ...

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Page 3: ...se this Supplementary Service Manual together with the following manual YFM250XL 99 SERVICE MANUAL 4XE3 AE1 YFM250XN 2001 SUPPLEMENTARY SERVICE MANUAL 4XE3 AE2 YFM250X P 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co Ltd First Edition June 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...fications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 5: ...nic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of asterisks with each proce dure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encir...

Page 6: ...clearance E Engine speed F Ω V A Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease Illustrated symbols N to O in the exploded diagrams indic...

Page 7: ...JUSTMENTS 12 INTRODUCTION 12 PERIODIC MAINTENANCE LUBRICATION INTERVALS 12 CHASSIS 14 ADJUSTING THE FRONT BRAKE 14 ADJUSTING THE REAR BRAKE LIGHT SWITH 14 ELECTRICAL 15 CHECKING THE SWITCH 15 CHECKING THE SWITCH 15 CHECKING A SWITCH SHOWN IN THE MANUAL 15 SIGNAL SYSTEM 16 CIRCUIT DIAGRAM 16 CHECKING THE SIGNAL SYSTEM 17 YFM250X P 2002 WIRING DIAGRAM ...

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Page 9: ...imum ground clearance 150 mm 5 9 in Minimum turning radius 2 900 mm 114 2 in Brake Front brake type Dual disc brake operation Right hand operation Rear brake type Drum brake fully sealed operation Left hand and right foot operation Electrical Ignition system DC C D I Generator system A C magneto Battery type YB14A A2 Battery capacity 12 V 14 AH Bulb wattage quantity Headlight 12 V 25 W 25 W 2 Tail...

Page 10: ...d 71 5 mm 2 81 in Oversize 4th 72 mm 2 83 in Piston off set 0 5 mm 0 02 in Piston off set direction Intake side Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in Piston pin outside diameter 15 991 16 000 mm 0 6296 0 6299 in Lubrication system Oil filter type Wire mesh Oil pump type Trochoid type Tip clearance A or B 0 15 mm 0 006 in 0 20 mm 0 008 in Side clearance 0 04 0 09 mm 0 00...

Page 11: ... 69 lb in 0 85 mm 0 3 35 in Optional spring No Part to be tightened Parts name Thread size Q ty Tightening torque Remarks Nm m kg ft lb Master cylinder and brake hose Bolt M10 1 25 1 23 2 3 17 Steering shaft and upper handle bar holder Bolt M8 1 25 4 23 2 3 14 Item Standard Limit Charging system Model manufacturer F4T259 MITSUBISHI Type A C magneto Nominal output 14 V 16 A at 5 000 r min Stator co...

Page 12: ...itch lead to the handlebar with the plastic band Ê Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar below the handlebar not over it Then pass the hose through the cable guide Ë Fasten the handlebar switch assembly lead and rear brake lever switch lead to the handle bar with the plastic bands Ì Fasten the handlebar switch assembly lead...

Page 13: ... vent hose rear brake breather hose and final gear case breather hose into the air duct after routing them through the fuel tank grommet Ê Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm Make sure that the hose is not pinched Ë Fasten the starter motor lead to the frame with the plastic clamp Route the starter motor lead ov...

Page 14: ...at the starter motor lead has no slack É Fasten the starter motor lead and wire harness to the frame with the plastic band Ê Fasten the starter motor lead and wire harness to the frame with the plastic clamp Ë Route the starter motor lead wire harness and battery lead through the hole in the rear fender Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp CABLE ROUTING ...

Page 15: ... Route the rear brake cable and rear brake breather hose through the cable guide Ð Route the rear brake breather hose through the cable guide Ñ Route the final gear case breather hose through the cable guide Ò Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips Ó 10 mm 0 4 in Ô 40 50 mm 1 6 2 0 in Õ 100 mm 4 0 in CABLE ROUTING ...

Page 16: ... switch 8 Rear brake breather hose È Make sure that the battery breather hose is not kinked or bent É Route the rear brake cable through the cable guide on the cylinder Ê Fasten the starter motor lead to the frame with the plastic clamps Ë Fasten the battery breather hose to the frame with the plastic clamps Ì 50 60 mm 2 0 2 4 in CABLE ROUTING ...

Page 17: ...lead and starter motor lead to the rear fender with the plastic clamps É Install the starter circuit cut off relay onto the tab with its terminal side facing down Ê Fasten the wire harness and starter motor lead to the frame with the plastic locking tie Ë Install the starter relay onto the tabs with its ter minal side facing up Ì Fasten the battery breather hose to the rear fender with the plastic...

Page 18: ... 10 SPEC Í Make sure that the grommet is installed with the mark facing forward Î 5 mm 0 2 in CABLE ROUTING ...

Page 19: ...to the inside of the rear brake cable É Fasten the wire harness to the frame with the plastic clamps Ê Make sure the starter motor lead and wire har ness do not contact the ignition coil Ë Fasten the wire harness starter motor lead and ignition coil lead to the frame with the plastic locking tie Ì Route the taillight lead through the lead holders on the lid and the bottom of the storage box Í 50 m...

Page 20: ...heck condition Adjust gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Fuel line Ch...

Page 21: ...ed 2 On the inner parts of the master cylinder and caliper replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Battery Check specific gra...

Page 22: ... of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts Brake lever free play at brake lever end 0 mm 0 in 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in...

Page 23: ...e switch on and off a few times when checking it Pocket tester P N YU 03112 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position ...

Page 24: ... Y L L G Y B Y G B B Y G G Y B Y G B B Y G OFF LO HI OFF ON OFF PUSH Br R B L B L R B L B Br R B L Br R W Br G Y Y B G Y Br B Y G Y B Y G B B Y L G H J J I G F B D E C BLACK BLACK BLACK B R W W W R R L W L B G Y L W Sb R B BLACK BLACK GRAY GRAY Br Y BLACK Y Br BLACK B B BLACK Br Y K B B BLACK Br Y M Br Y G Y B N 2 9 3 Main switch 4 Battery 5 Fuse B Neutral indicator light C Reverse indicator light...

Page 25: ...es Refer to CHECKING THE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main...

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Page 27: ... GRAY Br Y BLACK Y Br BLACK B B BLACK Br Y K B B BLACK Br Y M Br Y G Y B N 2 9 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Reverse indicator light D Neutral switch E Reverse switch F Start switch G Engine stop switch H Lights switch I Handlebar...

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