Yamaha YP250 98 Supplementary Service Manual Download

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FOREWORD

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

YP250 SERVICE MANUAL: 4UC-AE1

YP250 (J) ’98

SUPPLEMENTARY

SERVICE MANUAL



1997 by Yamaha Motor Co., Ltd.

First Edition, June 1997

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Summary of Contents for YP250 98

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Page 3: ...tion procedures it is necessary to use this Sup plementary Service Manual together with the following manual YP250 SERVICE MANUAL 4UC AE1 YP250 J 98 SUPPLEMENTARY SERVICE MANUAL 1997 by Yamaha Motor Co Ltd First Edition June 1997 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ll its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Ya maha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert ...

Page 5: ... To heps identify parts and clarify procedure steps there are exploded diagrams at start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for disassembly and assembly jobs 2 Numbers 5 are given in the order of jobs in the exploded diagram A number that is en closed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an ...

Page 6: ...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 diagrams indicate the types of lubricants and lubrication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight lithi...

Page 7: ...NERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 3 ENGINE 3 CHASSIS 3 ELECTRICAL 4 CABLE ROUTING 6 PERIODIC INSPECTION AND ADJUSTMENTS 11 COVER AND PANEL 11 SIDE PANEL AND SEAT 11 ELECTRICAL 12 SIGNAL SYSTEM 12 CIRCUIT DIAGRAM 12 SIGNAL SYSTEM CHECK 13 YP250 98 WIRING DIAGRAM FOR EUROPE YP250J WIRING DIAGRAM FOR OCEANIA ...

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Page 9: ...ORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER for E The vehicle identification number 1 is stamped into the right side of the frame MODEL LABEL The model label 1 is affixed under the seat This information will be needed to order spare parts ...

Page 10: ... 0 kg cm2 2 0 bar 90 197 kg 200 kPa 2 0 kg cm2 2 0 bar 225 kPa 2 25 kg cm2 2 25 bar 200 kPa 2 0 kg cm2 2 0 bar 250 kPa 2 5 kg cm2 2 5 bar Wheel travel Front wheel travel Rear wheel travel 100 mm 90 mm Bulb wattage quantity Headlight Marker light Tail brake light Flasher light Meter light High beam indicator light Oil indicator light Turn indicator light License light 12V 60 W 55 W 1 12V 5 W 1 12V ...

Page 11: ... jet 2 G S 2 Float height F H Engine idle speed Intake vacuum Oil temperature Cooling water temperature Y28V 1B 1 4UC 00 4UD 00 CH A ø28 130 ø0 9 5D32 3 5 11 ø1 2 85 ø0 8 44 0 7 3 1 1 2 1 4 ø0 5 ø1 3 27 mm 1 350 1 450 r min 220 260 mmHg 65 75 C 80 C CHASSIS Item Standard Limit Steering system Steering bearing type Ball and angular bearing Front suspension Front fork travel Fork spring free length ...

Page 12: ...ator coil resistance color A C magneto F4T252 MITSUBISHI 14 V 16 A at 5 000 r min 0 54 0 66 Ω at 20 C White White Rectifire regulator Model manufacturer No load regulated voltage Capacity Withstand voltage SH640D 12 SHINDENGEN 14 7 V 14 A 200 V Battery Specific gravity 1 320 Electric starter system Type Starter motor Model manufacturer ID number Operation voltage Output Armature coil resistance Br...

Page 13: ...O 100 A 4 2 4 6 Ω at 20 C Horn Model manufacturer Maximum amperage YF 12 NIKKO 3 A Flasher relay Type Model manufacturer Flasher frequency Full transistor type FE246BH DENSO 75 95 cycle min Starting circuit cut off relay Model manufacturer Coil winding resistance ACA12115 1 MATSUSHITA 72 88 Ω Thermo unit Model manufacturer 11H NIPPON SEIKI ...

Page 14: ... coil 19 Breather hose 20 Air filter 21 Mudguard 22 Seat lock cable 23 Down tube 24 Wireharness 25 Ground lead 26 Engine bracket 27 AC magnet leads 28 Starter motor lead A Pass the box light lead from outside of frame through inside of protector B Clamp the fuel sender lead to the pipe C Clamp the fuel sender lead and auto choke lead to the frame D Pass the box switch lead through under the fuel t...

Page 15: ...the brake hose to the brake caliper with its marking facing to the tire side I Pass the overflow hose form the reservoir tank through the clamp inside the frame J Clamp the mainharness battery lead and lead to clamp of the frame K Keep the clamping clearance over 3 mm CABLE ROUTING SPEC ...

Page 16: ... clamp inside the frame pipe 1 Throttle cable pull side 2 Throttle cable push side 3 Carburetor drain hose 4 Carburetor coolant drain hose 5 Air vent hose 6 Steering head 7 Rear brake cable 8 Steering head 9 Wireharness 10 Down tube CABLE ROUTING SPEC 11 Throttle cables 12 Radiator 13 Throttle cables 14 Wireharness 15 Stay A Pass the air vent hose coolant drain hose and fuel drain hose through the...

Page 17: ...uum hose 8 Sidestand switch lead 9 Fan motor lead 10 Thermo switch lead 11 Fuel hose 12 Vacuum hose CABLE ROUTING SPEC A Install the positive lead between the battery and the starter relay to the starter relay along the chassis B Put the coupler of the A C magneto lead and the auto choke lead along the frame pipe after connection C Clamp the wireharness A C magneto leads starter motor lead and gra...

Page 18: ...her light right 2 Front flasher light left 3 Rear brake cable 4 Throttle cable 5 Speedometer cable 6 Brake hose 7 Horn 8 Stay 9 Mark 10 Brake hose stopper 11 Grip heater lead 12 Ararm terminal A Install the brake hose with its marking facing to the stopper side B Pass the speedometer cable and the brake hose through the clamps on the frame Front Speedometer cable Rear Brake hose C Do not interfere...

Page 19: ...stallation Order Job name Part name Q ty Remarks 1 2 3 4 5 6 7 8 Side panel and seat removal Rear panel Side panel left Side panel right Rivet Front panel Clip Damper assembly Seat 1 1 1 2 1 2 1 1 Remove the parts in order NOTE COVER AND PANEL INSP ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS COVER AND PANEL SIDE PANEL AND SEAT ...

Page 20: ...witch 25 Front brake switch 26 Flasher relay 27 Horn 28 Turn switch 29 Horn switch 33 Tail Brake light 35 Rear flasher lights 36 Front flasher lights 39 Turn indicator lights 44 Fuel gauge 50 Fuel sender 52 Box light 53 Box light switch SIGNAL SYSTEM ELEC ...

Page 21: ...t for continuity Replace the bulb and or bulb socket NO CONTINUITY NO CONTINUITY Replace the box light switch CONTINUITY Tester lead Read 1 terminal Tester lead Blue Green 2 terminal 1 2 Check the box light switch for continuity 3 Wiring connection Wiring circuit from the main switch to the bulb socket connector is faulty Repair Refer to SIGNAL SYSTEM WIRING DIA GRAM CONTINUITY 1 2 SIGNAL SYSTEM E...

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Page 23: ...bar switches left 33 Tail Brake light 34 Licence light 35 Rear flasher lights 36 Front flasher lights 37 Head light 38 Auxiliary light 39 Turn indicator lights 40 High beam indicator light 41 Meter lights 42 Oil indicator light 43 Reset switch 44 Fuel gauge 45 Read switch 46 Clock 47 Thermometer 48 Speedometer 49 Meter assembly 50 Fuel sender 51 Thermo unit 52 Box light 53 Box light switch B R Bla...

Page 24: ...ebar switches left 32 Tail Brake light 33 Licence light 34 Rear flasher lights 35 Front flasher lights 36 Head light 37 Turn indicator lights 38 High beam indicator light 39 Meter lights 40 Oil indicator light 41 Reset switch 42 Fuel gauge 43 Read switch 44 Clock 45 Thermometer 46 Speedometer 47 Meter assembly 48 Fuel sender 49 Thermo unit 50 Box light 51 Box light switch B R Black Red Br W Brown ...

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