Yamaha YP250 5GM2-AE1 2000 Service Manual Download

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A’ Fasten the left handlebar switch

lead and rear brake switch lead
to the handlebar with a plastic
locking tie, cut the end of locking
tie at 5 mm or less.

B’ Don’t catch the seat lock cable

between 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 the
handlebar under cover.

X Route the right handlebar switch

lead through the clamp.

Y Route the front brake hose

through the right hole of handle-
bar under cover.

Z Route the brake hose assembly

through the left hole of the han-
dlebar under cover.

CABLE ROUTING

SPEC

Summary of Contents for YP250 5GM2-AE1 2000

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Page 3: ...ice Manual together with the following manual YP250 SERVICE MANUAL 4UC AE1 YP250 K 98 SUPPLEMENTARY SERVICE MANUAL 4UC AE2 YP250D 98 SUPPLEMENTARY SERVICE MANUAL 5DF AE1 YP250 2000 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd 1999 by MBK Industrie First Edition November 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibit...

Page 4: ...rove all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha MBK dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Saf...

Page 5: ... To 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 ...

Page 6: ...pecifications appearing in the text 10 Possible to maintain with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit clearance 16 Engine speed 17 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 oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grea...

Page 7: ...17 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION 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 COO...

Page 8: ... 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 ELECTRICAL ELECTRICAL 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 I...

Page 9: ...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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Page 11: ...tify your scooter and may be used to regis ter your scooter with the licensing authority in your country YP100020 FRAME SERIAL NUMBER except for E The frame serial number 1 is stamped into the right side of the frame EB100030 ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase Designs and specifications are subject to change without notice MODEL LABEL The model label is aff...

Page 12: ...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 pot 90890 01274 Bolt 90890 01275 Adaptor Crankshaft installer pot bolt adapter spacer 90890 01280 90890 01478 Spacer 90890 01016 90890 01288 These t...

Page 13: ...Bore stroke Compression ratio Compression pressure STD Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 0 249L 249 cm3 69 0 66 8 mm 10 1 1 400 kPa 14 kg cm2 14 bar at 500 r min Electric starter Wet sump Oil type or grade Engine oil API STANDERD SE or higher grade Periodic oil change Total amount Transmission oil Total amount 1 2 L 1 4 L 0 25 L Radiato...

Page 14: ...ugal automatic type 2 44 X 0 83 1 Chassis Frame type Caster angle Trail Steel tube underbone 28 103 mm Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 110 90 12 64L 130 70 12 62L IRC MICHELN IRC MICHELN MB67 BOPPER MB67 BOPPER Tire pressure cold tire Maximum load except motorcycle Loading condition A front rear Loading condition B front rear High speed riding front rear ...

Page 15: ...l Front wheel travel Rear wheel travel 100 mm 90 mm Electrical Ignition system Generator system Battery type Battery capacity T C I Digital A C magneto GT7B 4 12 V 6 5 AH Headlight type Quartz bulb Halogen Bulb wattage quantity Headlight High Headlight Low Auxiliary light Tail brake light Flasher light Front Flasher light Rear Meter light High beam indicator light Oil indicator light Turn indicato...

Page 16: ...700 4 700 r min 2 0 mm 135 5 mm 19 5 mm V belt V belt width 22 6 mm 21 0 mm Carburetor Type I D mark Ventuly outside diameter Main 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 speed Intake vacuu...

Page 17: ... SPEC Item Standard Limit Radiator Type Width height thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 140 238 24 mm 110 140 kPa 1 1 1 4 kg cm2 1 1 1 4 bar 1 4 L 0 4 L ...

Page 18: ...r induction system assembly Air induction system air filter assembly Crankcase left and right Drain bolt Engine oil Drain bolt Transmission oil Oil filler Transmission case cover Crankcase cover left Crankcase filter cover Crankcase cover protector Crankcase cover protector Magnet cover Bolt Nut Bolt Bolt Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Nut Bolt Screw Nut Bolt ...

Page 19: ...g check plug One way clutch Clutch housing Grease stopper Primary sheave Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit Bolt Plug Bolt Bolt M6 M16 M8 M14 M4 M14 M36 M6 M5 M6 M18 Pt 1 8 2 1 3 1 4 1 1 3 2 2 2 1 12 8 30 60 3 80 90 10 7 10 23 8 1 2 0 8 3 0 6 0 0 3 8 0 9 0 1 0 0 7 1 0 2 3 0 8 ...

Page 20: ...nt 263 mm 0 2 mm Rear suspension Shock absorber stroke Spring free length Spring rate K1 K2 K3 Stroke K1 K2 K3 106 mm 262 mm 7 57 N mm 0 77 kg mm 14 N mm 1 43 kg mm 26 39 N mm 2 69 kg mm 0 40 mm 40 70 mm 70 106 mm 257 mm Rear disk brake Type Disc outside diameter thickness Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Single 230 5 mm 5 3 mm 11 mm ...

Page 21: ...ard Headlight assembly Tail light assembly Front wheel axle and nut Rear wheel axle and nut Front brake caliper and front fork Brake disc and hub Brake hose and caliper Brake caliper and bleed screw Rear brake caliper and swingarm Speed sensor and sensor housing Windscreen M12 1 25 M10 1 25 M10 1 25 M10 1 25 M10 1 25 M 6 1 0 M 8 1 25 M10 1 25 M 8 1 25 M25 1 0 M20 1 5 M 8 1 25 M10 1 25 M 6 1 0 M 6 ...

Page 22: ... loosen the ring nut 1 4 turn 2 Second tighten the ring nut lower approximately 22 Nm 2 2 m kg 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 m kg by using the torque wrench ...

Page 23: ...g cap Type Resistance Resin type 10 kΩ Charging system Type Model manufacturer Normal output Stator coil resistance color A C magneto F4T370 MITSUBISHI 14 V 19 5 A at 5 000 r min 0 37 0 45 Ω at 20_C White White Rectifire regulator Model manufacturer No load regulated voltage Capacity Withstand voltage SH640A 12 SHINDENGEN 14 1 14 9 V 18 A 200 V Electric starter system Type Starter motor Model manu...

Page 24: ...it resistance empty 5GM NIPPON SEIKI 4 X 10 Ω 90 X 100 Ω Starting circuit cut off relay Model manufacturer Coil winding resistance ACA12115 1 MATSUSHITA 72 X 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...

Page 25: ...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 m...

Page 26: ...ight 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 ...

Page 27: ...ock cable 17 Footrest board 18 Handlebar 19 Handlebar under cover 20 Handlebar upper cover 21 Right handlebar switch lead 22 Front brake switch lead 23 Left handlebar switch lead 24 Rear brake switch lead A Route the brake hose assembly through the guide on the handle bar B Fasten the front brake hose brake hose assembly throttle cable to the frame with a plastic band C Fasten the brake hose assem...

Page 28: ...e L Route the carburetor coolant drain hose carburetor fuel drain hose through the clamp M Route the carburetor drain hose through the centerstand spring hook N Clamp the sidestand switch lead O Touch the protection tube on the fuel pump D Clamp the brake hose assembly E Fasten the seat lock cable throttle cable and wireharness to the frame with a band and the end of band is downward F Clamp the s...

Page 29: ...oard 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 the handlebar under cover X Route the right handlebar switch lead through the clamp Y Route the front brake hose through the right hole of handle bar under cover Z Route the brake hose assembly through the left hole of the han dlebar under cover CABLE R...

Page 30: ... hose 15 A C magneto lead 16 Starter motor lead A Fasten the wireharness to the frame with a plastic locking tie B Route the brake hose assembly through the clamp of engine bracket C Fix the seat lock to the box D Fasten the wireharness to the frame 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 an...

Page 31: ...ition the clamp locatio of the speed sen sor to front of the upper clamp and another clamps to outside N Through the speed sensor lead between front brake caliper and bolt O Route the speed sensor lead through the guide P When pull the speed sensor lead Don t loose Q Clamp the speed sensor lead and that caliper tightning bolt and clamp in parallel with front fork R Fix the starter relay to the foo...

Page 32: ...al relay on the footboard W Fasten the starter motor lead and engine ground lead on the frame with the plastic clamp X Route the parking cable and rear brake hose through the guide Y Clamp the A C magneto CABLE ROUTING SPEC ...

Page 33: ... A Don t turn the idle adjust screw when fix the hose B Route the gray seat lock outer cable through the left side of frame C Set the fuel tank sender lead and sub lead D Fasten the wireharness on the frome with a band and the end of band match the tank rail pipe angle E Fix the seat lock cable along the guide of panel F Fasten the wireharness on the frame with a plastic clamp G Fasten the starter...

Page 34: ...ut loose the thermounit lead K Route the black seat lock cable outer through right side of frame L Fasten the A C magneto lead starter motor lead and engine ground lead to the clamp on the engine bracket M Route the crankcase breather hose into the hole of air filter case CABLE ROUTING SPEC ...

Page 35: ...k cable assembly 15 Inner fender 16 Panel 17 Auxiliary light lead A Don t loosen the break hose when fix the break hose B Route the speed sensor lead through the brake hose holder C Fix the front brake hose on the front brake hose holder D Align the white mark H of head light assembly with the white tape of coupler lead E Install in stay 1 F To the headlight assembly G Clamp near the caupler side ...

Page 36: ...ehicle 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 1...

Page 37: ...hese 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 was performed in the same year The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system When disassembling the master cylinder or caliper ...

Page 38: ...over panel and passenger seat removal Passenger seat Standing handle Side cover mole 3 Cap 1 Cap 2 Side cover 1 Side cover 2 1 1 1 1 1 1 1 Remove the parts in order Reverse the removal procedure for installation 16 Nm 1 6 m kg 8 Nm 0 8 m kg COVER AND PANEL SIDE COVER SIDE COVER MOLE PASSENGER SEAT ...

Page 39: ...cap Cover Rider seat Side cover 3 Clip Damper assembly Coupler Seat switch lead Pin Bottom plate 1 1 1 1 1 1 1 1 1 Remove the parts in order Install the damper assembly to the body with its rod side backward and labels up ward NOTE Disconnect the couplers NOTE 7 Nm 0 7 m kg 13 Nm 1 3 m kg 16 Nm 1 6 m kg RIDER SEAT AND MAIN BOX ...

Page 40: ...e Part name Q ty Remarks 10 11 12 13 Bracket Coupler Main box light read Seat lock Main box 1 1 2 1 Disconnect the couplers Reverse the removal procedure for installation NOTE 13 Nm 1 3 m kg 16 Nm 1 6 m kg 7 Nm 0 7 m kg RIDER SEAT AND MAIN BOX ...

Page 41: ...otrest board left right Cover 2 Battery negative lead Battery positive lead Battery Flasher relay Fuse box Starter relay Side cover mole 1 Side cover mole 2 Footrest board 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order Reverse the removal procedure for installation 7 Nm 0 7 m kg COVER AND PANEL INSP ADJ SIDE COVER MOLE AND FOOTREST BOARD ...

Page 42: ...nel Meter assembly Coupler Meter lead Cowling body Handle cover Coupler headlight lead Coupler front flasher light lead left Coupler front flasher light lead right 1 1 1 1 1 1 1 2 1 1 Remove the parts in order Disconnect the couplers Reverse the removal procedure for installation NOTE Disconnect the couplers NOTE 7 Nm 0 7 m kg COWLING HANDLE COVER METER ASSEMBLY ...

Page 43: ...ront under braket Fuel tank braket Fuel hose Coupler fuel sensor lead Fuel tank Rivet Cover 1 1 1 1 1 1 1 1 1 Remove the parts in order Disconnect the couplers Revers the removal procedure for installation NOTE 7 Nm 0 7 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg 16 Nm 1 6 m kg COVER AND PANEL INSP ADJ LEGSHIELD AND FUEL TANK ...

Page 44: ...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 light comes on i e before the 3 000 km oil change interval is reached be sure to reset the oil indi cator light after changing the oil so that it will ...

Page 45: ...ase besure its sealing surface matches the sealing surface of the case so there is no air leak 2 Inspect Crankcase filter element Damaged Replace This element is a dry type Be careful not to stain with grease or water 3 Clean Crankcase filter element 1 Blow out the dust in the element from the out er surface using compressed air 4 Install Crankcase filter element Crankcase filter cover seal Crankc...

Page 46: ...over mole 3 Passenger seat Standing handle Side cover 2 Refer to COVER AND PANEL section 2 Inspect Hose 3 1 Air filter case 2 Hose 2 3 Air induction system assembly 4 Vacuum hose 5 Pipe 1 6 Hose 1 7 Cracks damage Replace 3 Install Side cover 2 Standing handle Passenger seat Side cover mole 3 ...

Page 47: ...hot Scalding hot fluid and 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 radiator cap Slowly rotate the cap counterclockwise toward the detent This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise ...

Page 48: ...ly until the coolant comes out from the carburetor drain pipe Reservoir tank to maximum level a Recommended coolant High quality ethylene glycol anti freeze containing corrosion inhibitors for aluminium engine Coolant 2 and water 3 soft water Mixed ratio 50 50 Total amount 1 4 L Reservoir tank capacity 0 4 L Handling notes for coolant Coolant is potentially harmful and should be handled with speci...

Page 49: ...r make sure it is soft wa ter Do not use water containing impurities or oil Take care that no coolant splashes onto painted surfaces If it does wash them straightaway 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 Sta...

Page 50: ...or out Turning in Headlight beam moves lower Turning out Headlight beam moves higher 2 Adjust Headlight beam horizontal Turn the adjuster 1 in or out Left headlight Turning in Headlight beam moves left Turning out Headlight beam moves right Right head light Turning in Headlight beam moves right Turning out Headlight beam moves left ...

Page 51: ...retor Spark plug cap Thermo unit lead Startor coil Pick up coil lead Starting motor lead Earth lead 1 1 1 1 1 1 Remove the parts in order Refer to COOLANT REPLACEMENT section Refer to CARBURETOR section Refer to COVER AND PANEL section 7 Nm 0 7 m kg 10 Nm 1 0 m kg ENGINE REMOVAL ENG EB400000 ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS CABLE REAR BRAKE ...

Page 52: ...2 ENGINE REMOVAL ENG Order Job name Part name Q ty Remarks 6 7 8 Caliper assembly Brake hose 1 Air induction system hose 1 1 1 Reverse the removal procedure for installation 10 Nm 1 0 m kg 40 Nm 4 0 m kg ...

Page 53: ...mp Outlet hose cylinder head Air filter case assembly Bolt Self locknut Plane washer Bolt Bolt Plane washer Rod assembly Engine 1 1 1 1 2 1 1 1 1 2 1 1 Remove the parts in order Rear shock absorber lower Reverse the removal procedure for installation Refer to ENGINE REMOUNTING section 32 Nm 3 2 m kg 64 Nm 6 4 m kg 20 Nm 2 0 m kg HOSES AIR FILTER CASE ENGINE MOUNTING BOLT AND ENGINE ...

Page 54: ...d Carburetor Thermo unit lead Plug cap Hose Outlet hose cylinder head Vacuum hose Breather hose crankcase Carburetor joint Joint O ring 1 1 2 1 1 1 1 1 2 Remove the parts in the order Refer to CARBURETOR section Refer to the COVER AND PANELS section 10 Nm 1 0 m kg 12 Nm 1 2 m kg 22 Nm 2 2 m kg 10 Nm 1 0 m kg 8 Nm 0 8 m kg 10 Nm 1 0 m kg CYLINDER HEAD ...

Page 55: ...Valve cover exhaust side O ring Timing chain tensioner assembly Timing chain tensioner gasket Breather plate Cam sprocket Timing chain Cylinder head Cylinder head gasket Dowel pin 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Reverse the removal procedure for installation Refer to CYLINDER HEAD REMOVAL AND INSTALLATION section 10 Nm 1 0 m kg 12 Nm 1 2 m kg 22 Nm 2 2 m kg 10 Nm 1 0 m kg 8 Nm 0 8 m kg 10 Nm...

Page 56: ...rankcase cover protector Crankcase cover left Crankcase cover gasket 1 1 1 1 Remove the parts in order Refer COVER AND PANEL section Reverse the removal procedure for installation 10 Nm 1 0 m kg 10 Nm 1 0 m kg V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ENG V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER LEFT ...

Page 57: ... Collar Primary sheave cap 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to PRIMARY SHEAVE ASSEMBLY section Refer to SECONDARY SHEAVE AND V BELT REMOVAL section Refer to SECONDARY SHEAVE INSTALLATION section Refer to PRIMARY SHEAVE REMOVAL section 22 Nm 2 2 m kg 60 Nm 6 0 m kg 60 Nm 6 0 m kg 3 Nm 0 3 m kg V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ENG V BELT CLUTCH AND SECONDARY PRIMAR...

Page 58: ...Order Job name Part name Q ty Remarks 12 13 14 15 16 Cam Weight Slider Spacer Oil seal 1 8 4 4 1 Reverse the removal procedure for installation Refer to PRIMARY SHEAVE ASSEMBLY section V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ENG Shell BT grease No 3 90890 69927 ...

Page 59: ...ssion oil Transmission case cover Gasket transmission case cover Dowel pin Primary drive gear Plain washer Plain washer 1st wheel gear 1 1 2 1 1 1 1 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 m kg TRANSMISSION ...

Page 60: ...der Job name Part name Q ty Remarks 8 9 10 11 12 13 Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Plain washer 1 1 1 1 1 1 Reverse the removal procedure for installation 16 Nm 1 6 m kg ...

Page 61: ...3 4 5 6 7 Air induction system removal Clip Hose 2 Clip Vacuum hose Clip Hose 1 Air induction system assembly 1 1 1 1 1 1 1 Remove the parts in the order Reverse the removal procedure for installation AIR INDUCTION SYSTEM ENG AIR INDUCTION SYSTEM ...

Page 62: ... timing chain hooks to the crankshaft sprocket the crankshaft cannot be removed crankshaft 1 Remove the crankshaft assembly with the crankcase separating tool 2 Do not tap on the crankshaft Crankshaft separating tool 90890 01135 CRANKSHAFT INSTALLATION 1 Install Crankshaft 1 Crankcase 2 Install the crankshaft assembly with the crankshaft installer pot 3 crankshaft install er bolt 4 adapter 5 space...

Page 63: ...oroughly 3 Apply sealant onto the left crankcase mating surface 4 Install Timing chain 1 Install the timing chain not to be seen through the crankshaft 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 2 90890 01274 Crankshaft installer bolt 3 90890 0127...

Page 64: ...ing body leg shield Fan motor leads Thermo switch leads Filler hose radiator Outlet hose radiator Inlet hose radiator Radiator 1 2 1 1 1 1 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 m kg 23 Nm 2 3 m kg YP500000 COOLING SYSTEM RADIATOR ...

Page 65: ...hose carburetor Fuel hose Throttle cable Air filter joint Nut Carburetor assembly 1 1 1 1 1 2 1 2 1 Remove the parts in order Refer to COOLANT REPLACEMENT section Do not bend the air filter joint clamp when installing the carburetor Reverse the removal procedure for installation Refer to COVER AND PANEL section CAUTION 10 Nm 1 0 m kg CARBURETOR CARB EB600000 CARBURETOR CARBURETOR ...

Page 66: ...screw set Cover Diaphragm spring Piston valve Jet needle assembly Coasting enricher Accererating pump Float chamber Float pin 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in order Refer to CARBURETOR ASSEMBLY section Refer to CARBURETOR ASSEMBLY section 1 2 3 4 5 6 7 8 9 10 CARBURETOR CARB CARBURETOR DISASSEMBLY ...

Page 67: ... name Q ty Remarks Float Needle valve Main jet Pilot jet Main nozzle Throttle position sensor 1 1 1 1 1 1 Reverse the disassembly procedure for assembly Refer to CARBURETOR ASSEMBLY section 11 12 13 14 15 16 CARBURETOR CARB ...

Page 68: ...ion sensor screws 1 3 Inspect Throttle position sensor input voltage tester lead blue 1 tester lead black 2 Throttle position sensor in put voltage 5 V Out of specification Check the wireharness between battery and igniter or igniter and throttle position sensor Throttle position sensor output voltage tester lead yellow 3 tester lead black 2 Throttle position sensor output voltage 0 73 0 63 V Out ...

Page 69: ...ensor Brake caliper Axle nut Wheel axle Front wheel Sensor housing Collar Front wheel sensor lead connector 1 1 1 1 1 1 1 1 Remove the parts in order Refer to COVER AND PANEL section Disconnect the connecter Reverse the removal procedure for installation 70 Nm 7 0 m kg 23 Nm 2 3 m kg CHASSIS FRONT WHEEL SPEED SENSOR AND SENSOR ROTOR ...

Page 70: ...moved by moving the clamp tip of brake hose and speed sensor leads up and down 2 Remove caliper 1 Speed sensor 2 Care should be taken not to allow the sen sor electrode to contact the metal parts when removing the speed sensor from the wheel hub To remove the wheel do not operate the brake lever SPEED SENSOR AND SENSOR ROTOR IN SPECTION 1 Check Speed sensor 1 Cracks bending and distortion Replace ...

Page 71: ... kΩ at 20_C Out of specification Replace 3 Check Sensor rotor 1 Cracks and damage Replace the wheel assembly 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 ASSEMBLY Proceed in the reverse order of disassembling paying attention to the following items 1 Apply L...

Page 72: ...t of front fork then assemble them Install after checking if foreign materials are mixed in the wheel hub If foreign materials are mixed it causes to damage the sensor rotor and speed sensor 4 Install Speed sensor 1 Brake caliper 2 Clamp 3 When installing the speed sensor check if the speed sensor lead is twisted or foreign matters attached to the electrode To route the speed sensor lead refer to ...

Page 73: ...63 FRONT WHEEL CHAS 5 Install Speed sensor lead 1 ...

Page 74: ...ob name Part name Q ty Remarks 1 2 3 4 Rear wheel and brake disc removal Swingarm Plate O ring Collar Rear wheel 1 1 1 1 Refer to REAR SHOCK ABSORBER AND SWINGARM section Reverse the removal procedure for installation REAR WHEEL ...

Page 75: ...ear shock absorber Rear caliper assembly Swingarm Collar Oil seal Bearing Oil seal 2 1 1 2 1 1 1 1 1 1 Remove the parts in order Refer to COVER AND PANEL section Loosen Remove with the rear brake applied Reverse the removal procedure for installation NOTE NOTE 40 Nm 4 0 m kg 53 Nm 5 3 m kg 35 Nm 3 5 m kg 40 Nm 4 0 m kg 135 Nm 13 5 m kg 20 Nm 2 0 m kg REAR SHOCK ABSORBER AND SWINGARM ...

Page 76: ...ENTS 1 Main switch 2 Ignition coil 3 Spark plug cap 4 Fuel sender 5 Rectifier Regulator 6 Wireharness 7 Thermo unit 8 Ignitor unit 9 Fuel pump 10 Sidestand switch 11 Flasher relay 12 Battery 13 Starter relay 14 Starting circuit cut off relay 15 Horn 16 Fuel pump relay ...

Page 77: ...67 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM ...

Page 78: ... circuit cut off relay 12 Thermo switch Auto choke 13 Auto choke 14 Ignitor unit 15 Ignition coil 16 Spark pulg 17 Throttle position sensor 18 Speed sensor 19 Fuel pump 20 Fuel pump relay 21 Sidestand switch 22 Light switch 23 Start switch 24 Engine stop switch 25 Right handlebar switch 26 Ignition fuse 27 Seat switch 28 Box light 29 Head light fuse 30 Fan fuse 31 Signal fuse CIRCUIT DIAGRAM ELEC ...

Page 79: ...e checking switches as shown in the left page and check for the correct terminal connections closed circuit according to the color combinations shown in the chart Poor connection fault Repair or replace YP CHECKING SWITCHES SWITCH POSITION AND TERMINAL CONNECTION ...

Page 80: ... checking switches Set the pocket tester selector to 1 Ω SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts like the one shown on the left showing the terminal connections of switches e g the main switch handlebar switch brake switch lighting switch etc The column on the extreme left indicates the dif ferent switch positions the top line indicates the colors of the le...

Page 81: ...Pickup coil 4 Main switch 6 Battery 7 Main fuse 14 Ignitor unit 15 Ignition coil 16 Spark plug 21 Sidestand switch 24 Engine stop switch 60 Alarm EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM ELEC ...

Page 82: ...relay 9 Starter motor 11 Starting circuit cut off relay 21 Sidestand switch 23 Starter switch 24 Engine stop switch 26 Ignition fuse 31 Signal fuse 34 Brake light switch 60 Alarm EB80300 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ELECTRIC STARTING ELEC ...

Page 83: ...at switch 28 Box light 29 Head light fuse 39 Dimmer switch 40 Pass switch 42 License plate light 45 Tail Brake light 46 Head light Lo 47 Head light HI 48 Auxiliary light 50 High beam indicator light 51 Meter lights LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 84: ...SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP 4 Lights switch Refer to CHECKING SWITCHES section Replace the right handlebar switch NO CONTINUITY CONTINUITY YP805010 TROUBLESHOOTING IF THE HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT BOX LIGHT LICENSE PLATE LIGHT AND OR METER LIGHT FAIL TO COME ON Procedure Check 1 Fuse Main Backup 2 Battery 3 Main switch 4 Lights switch Re...

Page 85: ...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 the headlight and high beam indicator light cou plers When the dimmer switch is on low beam When dimmer switch is on high beam or the Pass switch is pushed Headlight Tester lead Green or Yellow lead Tester negat...

Page 86: ...leads on the bulb 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 high beam Pass switch to push in Check for voltage 12 V on the lead at bulb socket connectors This circuit is not faulty MEETS SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty Repair OUT OF SPECIFICATION 2 If t...

Page 87: ...ocket 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 socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from main switch to bulb connector is faulty Repair OUT OF SPECIFICATION YP805022 3 The taillight fails to come on ...

Page 88: ... 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 socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from main switch to bulb connector is faulty Repair OUT OF SPECIFICATION YP805022 3 The license plate light fails to come on ...

Page 89: ...onnector Tester lead Blue Red 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 socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from main switch to bulb connector is faulty Repair OUT OF SPECIFICATION YP805023 4 If the auxiliary light fails to come on ...

Page 90: ... 34 Brak light switch 35 Flasher relay 36 Horn 37 Turn switch 38 Horn switch 43 Tail Brake light 44 Rear flasher lights 45 Front flasher lights 49 Turn indicator lights 53 Fuel gauge 58 Fuel sender EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM SIGNAL SYSTEM ELEC ...

Page 91: ...nals Recharge or replace battery INCORRECT CORRECT YP 3 Main switch Refer to CHECKING SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT BRAKE LIGHT AND OR INDICATOR LIGHT FAIL TO COME ON IF THE HORN FAILS TO SOUND Procedure Check 1 Fuse Main signal 2 Battery Remove the following parts before trouble shooting 1 Cowling body 2 Side panels...

Page 92: ...arness Check the connections of the entire signal system 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 ...

Page 93: ... to on Check for voltage 12 V on the Brown lead at the horn terminal The wiring circuit from the main switch to the horn is faulty Repair OUT OF SPECIFICATION 3 Horn Connect the pocket tester DC20 V to the horn at the Pink terminal Tester lead Pink terminal Tester lead Frame ground 1 Turn the main switch to on Check for voltage on the Pink lead to frame ground Replace the horn NO CONTINUITY CONTIN...

Page 94: ... is pulled in Check for voltage 12 V of the Yellow lead on the bulb socket connector CONTINUITY 1 2 MEETS SPECIFICATION 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 the bulb socket connector is faulty Repair Refer to SIGNAL SYSTEM ...

Page 95: ...it from main switch to flasher relay connector is faulty Repair OUT OF SPECIFICATION 4 Voltage Connect the pocket tester DC20 V to the flasher relay coupler Tester lead Brown White terminal Tester lead Frame ground 1 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 swit...

Page 96: ...flasher light left Tester lead Chocolate lead Tester 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 1 3 MEETS SPECIFICATION This circuit is not faulty OUT OF SPECIFICATION At flasher light right Tester lead Dark green lead Tester lead Black terminal 2 3 SIGNAL SYSTEM ELE...

Page 97: ...pler Tester lead Green terminal Tester 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 lead on the fuel sender lead OUT OF SPECIFICATION Check the connection of the entire signal system Refer to CHECKING OF CONNECTIONS Refer to CIRCUIT DIAGRAM MEETS SPECIFICATION 4...

Page 98: ...r 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 for more than three minutes respectively at UP or DOWN 1 2 SIGNAL SYSTEM ELEC ...

Page 99: ...89 4 Main switch 6 Battery 7 Main fuse 14 Ignitor unit 19 Fuel pump 20 Fuel pump relay 24 Engine stop switch 26 Ignition fuse EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM FUEL PUMP SYSTEM ELEC ...

Page 100: ... fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump FUEL PUMP SYSTEM ELEC EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump ...

Page 101: ...ORRECT YP 3 Main switch Refer to CHECKING SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP 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 Procedure Check 1 Fuse Main and Ignition 2 Battery 3 Main switch 4 Engine stop switch Remove the following parts befo...

Page 102: ...lay for continuity CONTINUITY 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump 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 1 2 Tester positive probe black blue Tester negative probe ...

Page 103: ...l gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is completely cool before performing 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 show...

Page 104: ......

Page 105: ...r switch 40 Pass switch COLOR CODE B 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 switch 42 License plate light 43 Tail brake light 44 Rear flasher light 45 Front flasher light 46 Head light LO 47 Head light HI 48 Auxiliary light 49 Trun signal indicator light 50 High beam indicator l...

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Yamaha YP250 5GM2-AE1 2000, Service Manual

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