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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the YP250. For complete service information procedures it is necessary to use this Supplementary Service 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 prohibited.

Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use. a bystander or a person inspecting or repairing the scooter. Yamaha Motor Company. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the scooter operator. Ltd. A NOTE provides key information to make procedures easier or clearer. Modifications and significant 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. NOTE: Designs and specifications are subject to change without notice.EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha/MBK dealers and their qualified mechanics. A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. CAUTION: NOTE: . is continually striving to improve all its models. so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. It is not possible to include all the knowledge of a mechanic in one manual.

there are exploded diagrams at start of each removal and disassembly section. 3. 4. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . notes in jobs. EXPLODED DIAGRAMS To heps identify parts and clarify procedure steps. 1. For jobs requiring more information. This title indicates the section of the chapter and only appears on the first page of each section. A number that is enclosed by a circle indicates a disassembly step. the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. names of parts. etc. The meanings of the symbol marks are given on the next page. 2. Numbers 5 are given in the order of jobs in the exploded diagram.YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs. 2 1 4 3 5 8 6 6 7 . (See “Illustrated symbols”) 1st title 1 : 2nd title 2 : 3rd title 3 : This is the title of the chapter with its symbol on the upper right corner of each page. providing the order of jobs. A job instruction chart 7 accompanies the exploded diagram. 5. It is located in the upper left corner of the page.

18 19 20 18 19 20 21 22 23 21 22 23 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease Illustrated symbols 24 to 25 in the exploded diagrams indicate the where to apply locking agent 24 and when to install new parts 25 .EB003000 1 2 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. clearance Engine speed Ω. A 15 16 17 Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 24 25 24 Apply locking agent (LOCTITE®) 25 Use new one . 1 2 3 4 5 6 7 8 9 General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting GEN INFO 3 SPEC 4 INSP ADJ 5 6 ENG COOL 7 CARB 8 CHAS 9 ELEC 10 Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 11 12 13 14 15 16 17 TRBL SHTG 11 12 13 14 Possible to maintain with engine mounted Filling fluid Lubricant Special tool Tightening Wear limit. V.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIREHARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT . . ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE COVER. . . . . . . . . . . . . . . . HOSES. . . . . . . . . . . . . . TIGHTNING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER (for E) . . . . . . . . . . . . . . . . . . . . CRANKCASE FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CONTENTS GENERAL INFORMATION SCOOTER IDENTIFICATION . . . . . . . . . . . . . . . PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . COOLANT REPLACEMENT . . CABLE AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . 26 26 28 28 29 31 32 33 34 34 35 36 37 40 40 ENGIVE OVERHAUL ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . SIDE COVER MOLE PASSENGER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . AIR INDUCTION SYSTEM INSPECTION . . . . . . . . . . . . . . . ENGINE . . . . . . . . LEGSHIELD AND FUEL TANK . . . . . . 3 6 6 8 10 11 13 15 15 16 17 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION . . AIR FILTER CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTNING TORQUES . . . . . . . . . LUBRICATION POINTS AND GRADE OF LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER AND PANEL . . . . . . . . 1 1 1 1 1 2 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE COVER. . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS . . . . 41 41 43 44 . . . . . . . . . . . . . . . . . . . . . . . RIDER SEAT AND MAIN BOX . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COWLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE MOUNTING BOLT AND ENGINE . . . . . . . . . . . . . . . . . METER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE COVER MOLE AND FOOTREST BOARD . . . . . . . . . FRAME SERIAL NUMBER (except for E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . REAR WHEEL . . . . . CHECKING SWITCHES . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . .V BELT. . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED SENSOR ASSEMBLY . . SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH POSITION AND TERMINAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 CHASSIS FRONT WHEEL . REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . SPEED SENSOR AND SENSOR ROTOR INSPECTION . . . . . . . . . CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 59 60 60 60 61 64 65 ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . SPEED SENSOR REMOVAL . . 66 67 69 69 70 70 71 71 72 72 73 73 74 80 80 81 83 . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE REMOVAL . . . . . . . . . . . . . . . . . . 54 CARBURETOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . 56 THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE AND CRANKSHAFT . . . . . . . . . . ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 46 47 49 51 52 52 52 52 COOLING SYSTEM RADIATOR . . AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . CLUTCH AND SECONDARY/PRIMARY SHEAVE . . . . . . CRANKSHAFT INSTALLATION . . LIGHTING SYSTEM . . SPEED SENSOR AND SENSOR ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH AND SECONDARY/PRIMARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED SENSOR AND THE SENSOR ROTOR . . . . . . . . . . . . . . . . . .

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

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1 . This information will be needed to order spare parts.SCOOTER IDENTIFICATION YP100000 GEN INFO GENERAL INFORMATION SCOOTER IDENTIFICATION YP100010 VEHICLE IDENTIFICATION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame. MODEL LABEL The model label is affixed under the seat. EB100030 ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your country. NOTE: Designs and specifications are subject to change without notice. YP100020 FRAME SERIAL NUMBER (except for E) The frame serial number 1 is stamped into the right side of the frame.

Tool No. refer to the list provided below to avoid any mistakes. Use only the appropriate special tools. When placing an order. Installer pot 90890-01274 Bolt 90890-01275 Adaptor 90890-01280 90890-01478 Spacer 90890-01016 90890-01288 Crankshaft installer pot/bolt/adapter/spacer Illustration These tools are used to install the crankshaft. 2 .SPECIAL TOOLS EB102000 GEN INFO SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Tool name/Usage Crankcase separating tool 90890-01135 This tool is used to remove the crankshaft. this will help prevent damage caused by the use of inappropriate tools or improvised techniques.

249L (249 cm3) 69.25 L 1.700 mm 168 kg Liquid-cooled 4-stroke.120 mm 2.140 mm .400 kPa (14 kg/cm2.730 mm 1.4 L 0. 5GM3 2.GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Oil type or grade: Engine oil API STANDERD: SE or higher grade 5GM2.8 mm 10 : 1 1.535 mm .350 mm .780 mm 1. SOHC Forward-inclined single cylinder 0. 14 bar) at 500 r/min Electric starter Wet sump YP250 Periodic oil change Total amount Transmission oil Total amount Radiator capacity: Total amount (including all routes) Air filter: Carburetor side Crankcase side Fuel: Type Fuel tank capacity 1.2 L 1.0 66.4 L Wet type element Dry type element Regular unleaded gasoline 12 L 3 .

and accessories.0 kg/cm2. centrifugal automatic YP250 SPEC Helical gear 40/15 (2.0 kg/cm2.GENERAL SPECIFICATIONS Model Carburetor: Type/quantity Manufacturer Spark plug: Type Manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Chassis: Frame type Caster angle Trail Tire: Type Size Manufacturer Type Y28V-1E/1 TEIKEI DR8EA NGK 0.7 mm Dry. rider. passenger. 4 .533) Single speed automatic (V-belt type) Centrifugal automatic type 2.6 X 0.0 kg/cm2.666) Helical gear 38/15 (2. 2.0 bar) 225 kPa (2. 2.75 kg/cm2.0 bar) 90 X 205 kg 200 kPa (2.83:1 Steel tube underbone 28: 103 mm Tubeless 110/90-12 64L 130/70-12 62L IRC/MICHELN IRC/MICHELN MB67/BOPPER MB67/BOPPER 187 kg 0 X 90 kg 175 kPa (1.25 bar) 200 kPa (2.25 kg/cm2.75 bar) 200 kPa (2. 2. 2.25 bar) front rear front rear front rear Tire pressure (cold tire): Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear High-speed riding front rear *Load is the total weight of cargo. 1. 2.0 bar) 225 kPa (2.25 kg/cm2.44 X 0.

5 AH Quartz bulb (Halogen) 12 V 60 W/55 W 12 V 55 W 1 12 V 5 W 1 12 V 5 W/21 W 12 V 21 W 2 12 V 16 W 2 12 V 1.C. (Digital) A.7 W 3 12 V 1.I.7 W 1 12 V 3.C.7 W 1 12 V 1. magneto GT7B-4 12 V 6.4 W 2 12 V 5 W 1 1 SPEC Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: 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 indicator light License light 2 5 .GENERAL SPECIFICATIONS Model Brake: Front brake Rear brake type operation type operation YP250 Single disc brake Right hand operation Single disc brake Left hand operation Telescopic fork Unit swing Coil spring/Oil damper Coil spring/Oil damper 100 mm 90 mm T.

V) (P.9 5D9B-3/5 11 ø1.2 #85 ø0.5 26.850 r/min 3.H) 270 mmHg) 6 .5 mm ::: 19.250 2.J) (P.6 mm Y28V-1E/1 5GM 10 ø28 #128 ø0.3 mm 135 mm 28.7 3 1 2 2 1.1) (G.1 mm 20 mm 2.O) (P.S) (G.5 mm 1.S.J) (M.J) (B.500 r/min 29. mark Ventuly outside diameter Main jet Main air jet Jet needle Throttle valve size Pilot air jet Needle jet Pilot outlet Pilot jet Bypass Pilot screw Valve seat size Starter jet 1 Starter jet 2 Float height Engine idle speed Intake vacuum Oil temperature Cooling water temperature Fuel pump: Type Model/manufacturer Standard ::: DID SC:A-0404A SDH/104 Automatic 3.N) (Th.J) (J.J.300 1.8 #43 0.3 36.700 4.A.5 27.S) (V.MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head: Warp limit Cam chain: Cam chain type/No. of links Cam chain adjustment method Automatic centrifugal clutch: Clutch shoe thickness Clutch housing inside diameter Clutch shoe spring free length Weight outside diameter Clutch – in revolution Clutch – stall revolution V-belt: V-belt width Carburetor: Type I.05 mm ::: ::: 2.700 r/min 22.4 ø0.0 mm 135.5 mm ::: ::: 21.D.S.5 ø0.P) (P.2) (F.A.1) (N.0 kPa (220 65 75 C 80 C Electrical 2GV/MITSUBISHI Limit 0.0 mm ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: (M.

MAINTENANCE SPECIFICATIONS Item Radiator: Type Width/height/thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Standard Cooling fin with electric fan 140/238/24 mm 110 X 140 kPa (1.1 X 1. 1.4 bar) 1.4 kg/cm2.1 X 1.4 L SPEC Limit ::: ::: ::: ::: ::: 7 .4 L 0.

1 3.0 1.7 1.5 0.0 1.0 0.7 0.0 1.0 1.1 2.8 6.0 0.3 1.7 1.0 0.0 8.6 1.0 2.7 0.0 0.8 1.2 0.8 1.0 0.2 1.3 1.7 1.3 1.4 0.2 1.7 1.7 0.0 1.0 1.0 5.0 0.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Part to be tightened g Oil check bolt Exhaust pipe stud bolt Air induction system pipe stud bolt Spark plug Cam sprocket cover Cylinder head and cylinder Cylinder head and cylinder (Cam chain side) Valve cover Rotor Valve adjuster locknut Cam shaft bearing stopper Cam sprocket Cam chain tensioner (Body) (Plug) Guide stopper 2 Water pump housing cover Hose joint Thermostatic valve cover Filler neck supporting Oil pump Oil pump cover Oil strainer cover Carburetor joint Carburetor joint and carburetor Air filter assembly Air filter cover Exhaust pipe assembly Muffler Muffler and exhaust pipe Protector (Exhaust pipe) Protector (Muffler end cap) Air induction system pipe Air 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 Part name — — — — Bolt Nut Bolt Bolt Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt — Bolt Bolt Screw Bolt Bolt Bolt Nut Bolt Screw Nut Bolt Bolt Screw Screw Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt — Bolt Screw — Thread size M6 M8 M6 M12 M6 M8 M6 M6 M16 M6 M6 M10 M6 M8 M6 M6 M6 M6 M5 M6 M3 M35 M6 M6 M6 M5 M8 M10 M8 M6 M6 M6 M6 M6 M6 M12 M8 M14 M8 M6 M5 M6 M6 M6 Q’ty y 1 2 2 1 2 4 2 5 1 2 2 1 2 1 1 3 2 2 1 2 1 1 2 2 2 7 2 3 1 2 3 2 2 2 9 1 1 1 6 8 3 1 3 10 SPEC Tightening torque Nm 7 13 10 18 10 22 10 10 80 14 8 60 10 8 10 10 7 10 5 7 1 32 10 10 7 1 20 53 14 10 10 12 10 7 10 20 22 3 16 10 1.0 2.4 1.2 7 7 10 m:kg 0.0 2.0 1.0 1.12 0.2 1.0 Remarks 8 .

3 0.0 6.8 9 .MAINTENANCE SPECIFICATIONS Thread size M6 M16 M8 M14 M4 M14 M36 M6 M5 M6 M18 Pt 1/8 SPEC Remarks Part to be tightened g Cover (oil pump) Timing 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 Part name Bolt Plug — Bolt — — — — — Bolt — — Q’ty y 2 1 3 1 4 1 1 3 2 2 2 1 Tightening torque Nm 12 8 30 60 3 80 90 10 7 10 23 8 m:kg 1.0 2.0 0.7 1.0 9.0 0.8 3.3 8.0 1.2 0.

43 kg/mm) 26.2 mm 2 DOT #4 2 2 3 5 mm 5 mm 5 mm SPEC Limit ::: 263 mm ::: ::: ::: ::: ::: ::: ::: 0.39 N/mm (2.8 mm ::: ::: ::: ::: ::: ::: 10 .84 N/mm (0.MAINTENANCE SPECIFICATIONS CHASSIS Item Front suspension: Front fork travel Fork spring free length Spring rate (K1) Spring rate (K2) Stroke (K1) Stroke (K2) Oil capacity Oil level Oil grade Inner tube vend limit Rear suspension: Shock absorber stroke Spring free length Spring rate (K1) (K2) (K3) Stroke (K1) (K2) (K3) Rear disk brake: Type Disc outside diameter thickness Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Brake lever: Brake lever free play (front at lever side) Brake lever free play (rear) Throttle cable free play Standard 100 mm 268 mm 4.82 N/mm (0.3 mm 11 mm 22.57 N/mm (0.49 kg/mm) 8.9 kg/mm) 0 40 mm 40 100 mm 0.69 kg/mm) 0 40 mm 40 70 mm 70 106 mm Single 230 5 mm 5.142 L (142 cm3) 80 mm Fork oil 15 WT or equivalent ::: 106 mm 262 mm 7.2 mm ::: 257 mm ::: ::: ::: ::: ::: ::: ::: ::: 0.77 kg/mm) 14 N/mm (1.

0 SPEC Tightening torque Nm 59 32 64 40 40 7 35 40 20 22 155 23 30 10 7 3 7 4 10 16 16 10 2 16 7 7 7 7 70 135 50 23 30 6 40 23 0.0 1.25 1.9 3.4 m:kg 5.0 0.25 1.7 0.5 1.3 3.25 1.0 1.0 1.6 4.25 1.0 1.5 4.6 1.25 1.0 1.7 0.5 5.7 7.25 1.0 1.0 13.0 1.0 2.5 2.0 0.0 1.25 1.25 1.04 Remarks See “NOTE” 11 .7 3.6 0.25 1.8 1.25 1.0 1.7 0.7 0.3 0.8 1.7 0.25 1.2 6.0 4.25 1.0 1.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Part to be tightened g Frame and engine bracket Engine bracket.25 1.0 0.5 1.4 1.25 1.0 2.4 4.0 2.3 3.0 1.0 1.2 1.5 1.6 1. compression rod and engine Compression rod and frame Sidestand (bolt and frame) Sidestand (bolt and nut) Rear footrest bracket Swingarm Rear shock absorber and frame Rear shock absorber and engine Steering ring nut Handle holder and steering shaft Handle upper holder and lower holder Brake hose and master cylinder Fuel tank (font) (rear) Fuel sender Filter Roll over valve Box Box (Bracket) Standing handle Sheet lock assembly Plastic parts & cover Cowling stay Cowling body Footrest board 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 Thread size M12 M10 M10 M10 M10 M 6 M 8 M10 M 8 M25 M20 M 8 M10 M 6 M 6 M 5 M 6 M 5 M 6 M 8 M 8 M 6 M 5 M 8 M 6 M 6 M 6 M 6 M14 M14 M10 M 8 M10 M 7 M10 M 8 M 5 1.0 2.3 0.0 0.0 0.0 1.2 15.25 1.0 1.0 0.25 1.25 1.

then finger tighten the ring nut (center). hold the ring nuts (lower and center) and tighten the ring nut (upper) 75 Nm (7. then loosen the ring nut 1/4 turn. tighten the ring nut (lower) approximately 22 Nm (2. 3. Final.2 m:kg) by using the torque wrench.MAINTENANCE SPECIFICATIONS SPEC NOTE: 1. 12 .8 m:kg) by using the torque wrench.5 m:kg) by using the torque wrench. First. Second. 2. tighten the ring nut (lower) approximately 38 Nm (3. Align the slots both ring nut and install the lock washer.

000 r/min Electrical type 189 231 Ω at 20_C/ Yellow – Blue J4T117/MITSUBISHI F6T507 /MITSUBISHI 6 mm 3.400 r/min 32_ at 5.8 Ω at 20_C 10. magneto F4T370 /MITSUBISHI 14 V 19.7 14.) Advanced type T.T.0017 0.I.7 mm SPEC limit ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: 4 mm ::: 570 g 27 mm ::: 13 .D.0027 Ω at 20_C 10 mm 2 pcs.5 A at 5.: Pickup coil resistance/color T.9 V 18 A 200 V Constant mesh type SM-13/MITSUBA/SM-13454 12 V 0. 8.I. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Normal output Stator coil resistance/color Rectifire/regulator: Model/manufacturer No load regulated voltage Capacity Withstand voltage Electric starter system: Type Starter motor: Model/manufacturer /ID number Operation voltage Output Armature coil resistance Brush overall length Brash quantity Spring force Commutator diameter Mica undercut (depth) Standard 10_ at 1.82 N (899 g) 28 mm 0.C.C.C.T.C.37 0.45 Ω at 20_C/ White – White SH640A-12/SHINDENGEN 14.D.5 kΩ at 20_C Resin type 10 kΩ A.MAINTENANCE SPECIFICATIONS ELECTRICAL Item Ignition timing: Ignition timing (B.) Advanced timing (B.65 kW 0.6 4.C.000 r/min 0.1 14.

SPEC limit ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: ::: 14 . 10 A 1 pc. 15 A 1 pc. 10 A 1 pc.2 X 4. 15 A 1 pc. 7. 15 A 1 pc.MAINTENANCE SPECIFICATIONS Item Starter relay: Model/manufacturer Amperage rating Coil winding resistance Horn: Model/manufacturer Maximum amperage Flasher/hazard relay Type Model/manufacturer Flasher frequency Fuel gage: Model/manufacturer Sender unit resistance – full Sender unit resistance – empty Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Electric fan motor: Model/manufacturer Thermo switch (electric fan): Model/manufacturer Thermo switch (auto choke): Model/manufacturer Thermo unit: Model/manufacturer Circuit breaker: Type MAIN HEAD LIGHT SIGNALING SYSTEM IGNITION RADIATOR BACK UP Reserve Reserve Reserve Reserve Standard MS5F-421 /JIDECO 180 A 4. 30 A 1 pc. 4A 1 pc.6 Ω at 20_C YF-12/NIKKO 3A Full transistor type FE246BH/DENSO 75 X 95 cycle/min 5GM/NIPPON SEIKI 4 X 10 Ω 90 X 100 Ω ACA12115-1/MATSUSHITA 72 X 88 Ω 5GM/MITSUBA 5GH/NIHON THERMOSTAT 5GM/NIHON THERMOSTAT 46X/NIPPON SEIKI Fuse 30 A 1 pc.5 A 1 pc.5 A 1 pc. 7.

1215 Symbol 15 . EX) Valve stem end (lN. 1215 Yamaha bond No.LUBRICATION POINTS AND GRADE OF LUBRICANT SPEC LUBRICATION POINTS AND GRADE OF LUBRICANT ENGINE Lubrication Point 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) 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 Crankcase breather plug Stator grommet Suction pipe Yamaha bond No.

LUBRICATION POINT AND GRADE OF LUBRICANT
CHASSIS Lubrication Point 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

SPEC

Symbol

16

CABLE ROUTING

SPEC

CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Speed sensor Front brake hose Throttle cable Relay Brake hose assembly Thermo switch lead Fan motor lead Switch assembly Carburetor fuel drain hose Carburetor coolant drain hose Carburetor air ventilation hose Coolant pipe Sidestand switch Ignitor unit

15 16 17 18 19 20 21 22 23 24

Frame Seat lock cable Footrest board Handlebar Handlebar under cover Handlebar upper cover Right handlebar switch lead Front brake switch lead Left handlebar switch lead Rear brake switch lead

A Route the brake hose assembly through the guide on the handlebar. B Fasten the front brake hose, brake hose assembly throttle cable to the frame with a plastic band. C Fasten the brake hose assembly, throttle cable to the frame with a band and the end of band is backward.

17

CABLE ROUTING

SPEC

D Clamp the brake hose assembly. I Throttle cable pull side. (White P Fasten the wire harness to the E Fasten the seat lock cable nut) frame with a band and the end of throttle cable and wireharness to J Throttle cable push side. (Black band inside. the frame with a band, and the and white nut) Q Roll the tape because of fix the end of band is downward. K Clamp the fuel hose. protection tube to the fuel pum F Clamp the switch assembly lead L Route the carburetor coolant lead. with a band and cut the end of drain hose, carburetor fuel drain R Clamp the fuel pump lead and band. It’s downward. hose through the clamp. sidestand switch lead. G Fasten the throttle cable with a M Route the carburetor drain hose S Fasten the throttle cable and the band and more than 10 mm through the centerstand spring end of band backward. between throttle cable and box. hook. T Lubricate the silicone grease H Don’t scrub each other when fix N Clamp the sidestand switch befor fasten the cable and the throttle cables. lead. hoses. O Touch the protection tube on the fuel pump.

18

A’ Fasten the left handlebar switch V Route the seat lock cable lead and rear brake switch lead through the footrest board. Z Route the brake hose assembly through the left hole of the handlebar under cover. cut the end of locking lead through front side of the tie at 5 mm or less.CABLE ROUTING U More than 10 mm. to the handlebar with a plastic W Route the left handlebar switch locking tie. SPEC 19 . B’ Don’t catch the seat lock cable X Route the right handlebar switch between footrest board and box. handlebar under cover. lead through the clamp. Y Route the front brake hose through the right hole of handlebar under cover.

C Fix the seat lock to the box. 20 . C. B Route the brake hose assembly through the clamp of engine bracket. magneto lead Starter motor lead A Fasten the wireharness to the frame with a plastic locking tie. E Clamp the rear brake hose. G Fasten the seat lock cable and wireharness with a band and band of the end on inside of the frame. D Fasten the wireharness to the frame with a plastic locking tie.CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 SPEC Box light Rectifire/ regulator Air induction system air filter Wireharness Battery negative lead Battery positive lead Seat lock cable assembly Battery Rodiator reservoir tank Ignition coil Air induction system Engine ground 13 14 15 16 Engine bracket Rear brake hose A. F Clamp the wireharness to the frame with a plastic locking tie.

I Clamp the radiator reservoir and another clamps to outside. hose and starter motor lead to band on rearside.CABLE ROUTING SPEC H Fasten the wireharness to the M Clamp the speed sensor lead to Q Clamp the speed sensor lead the front brake hose. Don’t loose. sor) to front of the upper clamp fork. U Fasten the rodiator reservoir lead and front brake hose hose and starter motor lead on through the clamp on the frame. the frame with a plastic clamp. J Fasten the wireharness to the N Through the speed sensor lead between front brake caliper and S Clamp the radiator reservoir stay with a band and the end of bolt. the frame with a plastic clamp. Position the and that caliper tightning bolt frame with a band and the band clamp (locatio of the speed senand clamp in parallel with front of end on inside of the frame. L Route the front speed sensor P When pull the speed sensor lead. board. T Fix the fuse box to the footrest the stay. R Fix the starter relay to the foothose. rest board. (front side: speed sensor lead rear side: front brake hose) 21 . K Fasten the speed sensor lead to O Route the speed sensor lead through the guide.

X Route the parking cable and rear brake hose through the guide. Y Clamp the A. W Fasten the starter motor lead and engine ground lead on the frame with the plastic clamp. C. SPEC 22 . magneto.CABLE ROUTING V Fix the turn signal relay on the footboard.

E Fix the seat lock cable along the guide of panel. C. C Set the fuel tank sender lead and I Route the battery negative lead sub lead. cable through the left side of H Route the starter relay lead toframe. the fuel tank brocket with a plasB Route the gray seat lock outer tic locking tie. G Fasten the starter motor lead on when fix the hose. toward inside.CABLE ROUTING Air filter case Seat lock Tensioner Crankcase breather hose Fuel sender Throttle cable Seat lock cable assembly Panel Footrest board Radiator resorvoir tank breather hose 11 Vacuum hose 12 Throttle position sensor lead 13 Seat lock 1 2 3 4 5 6 7 8 9 10 14 15 16 17 18 19 SPEC D Fasten the wireharness on the frome with a band and the end of band match the tank rail pipe angle. F Fasten the wireharness on the frame with a plastic clamp. A Don’t turn the idle adjust screw. Auto choke lead Brake hose assembly A. ward inside. magneto lead Starter motor lead Engine ground lead Wireharness 23 .

M Route the crankcase breather hose into the hole of air filter case. C.CABLE ROUTING J Route the thermo unit lead through the shortest distance and dont roll another lead but loose the thermounit lead. magneto lead starter motor lead and engine ground lead to the clamp on the engine bracket. SPEC 24 . L Fasten the A. K Route the black seat lock cable outer through right side of frame.

B Route the speed sensor lead through the brake hose holder. 25 .CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 SPEC Front right turn signal light Relay Front left turn signal light Front brake hose assembly Horn lead (Hi) Horn (Hi) Throttle cable Speed sensor lead Front brake hose Horn (Lo) Stay Seat lock cable Leg sealed Seat lock cable assembly Inner fender 16 Panel 17 Auxiliary light lead A Don’t loosen the break hose when fix the break hose. C Fix the front brake hose on the front brake hose holder. D Align the white mark H of headlight assembly with the white tape of coupler lead E Install in stay 1 F To the headlight assembly G Clamp near the caupler side root of auxiliary light lead.

: Correct if necessary. : Check operation. The need for costly overhaul work will be greatly reduced. (Warm engine before draining. : Change oil. : Check operation. : Check oil level and vehicle for oil leakage. : Lubricate and repair if necessary. : Replace if necessary. : Adjust if necessary. : Correct if necessary. : Check condition. : Check condition. fluid level and vehicle for fluid leakage. : Clean.000 km 20. if followed. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. : Check operation. : Check operation and for oil leakage. YP301000 PERIODIC MAINTENANCE/LUBRICATION INTERVALS No. No 1 2 3 4 5 6 7 ITEM * Fuel line Fuel filter Spark plug * Valves Air filter V-belt case air filter * Front brake CHECKS AND MAINTENANCE JOB : Check fuel hoses and vacuum hose for cracks or damage. runout and for damage.000 km Clean or replace every 6. : Replace if necessary. : Adjust if necessary. : Replace if necessary. : Tighten if necessary. All service technicians should be familiar with this entire chapter. : Make sure that all nuts. will ensure more reliable vehicle operation and a longer service life.000 km 21 * Engine oil strainer Coo g system 22 * Cooling sys e 23 Final gear oil 24 * V-belt 26 . : Replace brake pads if necessary. : Change coolant. : Change. : : : : Check tread depth and for damage. fluid level and vehicle for fluid leakage. : Lubricate with lithium soap base grease. Correct if necessary. Replace if necessary. : Replace if necessary. Check air pressure.000 km ANNUAL CHECK 8 9 * Rear brake * Brake hoses 10 * Wheels 11 * Tires 12 * Wheel bearings 13 * Steering bea gs 3 S ee g bearings 14 * Chassis fasteners 15 Sidestand / centerstand : Check bearing for looseness or damage. : Replace if necessary. : Clean or replace if necessary. : Check operation and shock absorbers for oil leakage.) : Clean or replace if necessary. : Check valve clearance.INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 INSP ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. : Correct accordingly. 16 * Sidestand switch 17 * Front fork 18 * Rear shock absorber assemblies 19 * Carburetor 20 Engine oil Replace every 3. : Check coolant level and vehicle for coolant leakage. : Correct accordingly. : Replace. : Correct accordingly. bolts and screws are properly tightened. : Correct accordingly. : Replace brake pads if necessary. regap or replace if necessary.000 km) EVERY 10. : Check engine idling speed and starter operation. : Rebalance or replace if necessary. : Replace shock absorber assembly if necessary. : Check for cracks or damage. : Check bearing play and steering for roughness. : Check oil level and vehicle for oil leakage. : Clean or replace if necessary. : Check operation. These preventive maintenance procedures. : Check balance. Initial (1.

27 . : Hydraulic brake system : When disassembling the master cylinder or caliper. always replace the brake fluid. : Check all lights. signals and switches function. : Adjust or replace if necessary. : Lubricate if necessary. : Correct if necessary. : The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ITEM Front / Rear brake switch Moving parts and cables Electrical components CHECKS AND MAINTENANCE JOB : Check operation.PERIODIC MAINTENANCE/LUBRICATION INTERVALS No No.000 km) 10. Check the brake fluid level regularly and fill as required. data and technical skills.000 km or 20.000 km ANNUAL CHECK Initial (1.000 km maintenance was performed in the same year. EAU02970 NOTE: The annual checks must be performed once a year unless a 10. : Replace the oil seals on the inner parts of the master cylinder and caliper every two years. they should be serviced by a Yamaha dealer. INSP ADJ EVERY 20.000 km 25 * 26 27 * *: Since these items require special tools. : Replace the brake hoses every four years or if cracked or damaged. : Adjust headlight beam if necessary.

1 2 3 4 5 6 7 1 1 1 1 1 1 1 Reverse the removal procedure for installation.8 m:kg) Order Job name/Part name Side cover.COVER AND PANEL INSP ADJ COVER AND PANEL SIDE COVER. 28 . SIDE COVER MOLE. Side cover panel and passenger seat removal Passenger seat Standing handle Side cover mole 3 Cap 1 Cap 2 Side cover 1 Side cover 2 Q’ty Remarks Remove the parts in order.6 m:kg) 8 Nm (0. PASSENGER SEAT 16 Nm (1.

7 8 9 Coupler (Seat switch lead) Pin Bottom plate 1 1 1 29 .3 m:kg) 16 Nm (1.6 m:kg) 7 Nm (0.7 m:kg) Order 1 2 3 4 5 6 Job name/Part name Rider seat and main box removal Fuel tank cap Cover Rider seat Side cover 3 Clip Damper assembly Q’ty 1 1 1 1 1 1 Remarks Remove the parts in order NOTE: Install the damper assembly to the body with its rod side backward and labels up ward.COVER AND PANEL RIDER SEAT AND MAIN BOX INSP ADJ 13 Nm (1. NOTE: Disconnect the couplers.

Reverse the removal procedure for installation.COVER AND PANEL RIDER SEAT AND MAIN BOX INSP ADJ 13 Nm (1.3 m:kg) 16 Nm (1.7 m:kg) Order 10 11 12 13 Job name/Part name Bracket Coupler (Main box light read) Seat lock Main box Q’ty 1 1 2 1 Remarks NOTE: Disconnect the couplers. 30 .6 m:kg) 7 Nm (0.

7 m:kg) Order 1 2 3 4 5 6 7 8 9 10 11 12 Job name/Part name Q’ty Remarks Remove the parts in order.COVER AND PANEL SIDE COVER MOLE AND FOOTREST BOARD INSP ADJ 7 Nm (0. 31 . Side panel and footrest board removal 1/1 Mat (footrest board) (left/right) 1/1 Cover (footrest board) (left/right) 1 Cover 2 1 Battery negative (–) lead 1 Battery positive (+) lead 1 Battery 1 Flasher relay 1 Fuse box 1 Starter relay 1 Side cover mole 1 1 Side cover mole 2 1 Footrest board Reverse the removal procedure for installation.

METER ASSEMBLY INSP ADJ 7 Nm (0. 32 . meter assembly removal Upper cover Wind screen Inner panel Meter assembly Coupler (Meter lead) Cowling body Handle cover Coupler (headlight lead) Coupler (front flasher light lead (left)) Coupler (front flasher light lead (right)) Q’ty Remarks Remove the parts in order. Reverse the removal procedure for installation. NOTE: Disconnect the couplers. handle cover. HANDLE COVER.7 m:kg) Order Job name/Part name Cowling. 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 2 1 1 NOTE: Disconnect the couplers.COVER AND PANEL COWLING.

33 .COVER AND PANEL LEGSHIELD AND FUEL TANK INSP ADJ 10 Nm (1.6 m:kg) 7 Nm (0.7 m:kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Legshield and fuel tank removal Legshield Inner fender Front under braket Fuel tank braket Fuel hose Coupler (fuel sensor lead) Fuel tank Rivet Cover Q’ty 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in order. NOTE: Disconnect the couplers.7 m:kg) 16 Nm (1.0 m:kg) 7 Nm (0. Revers the removal procedure for installation.

ENGINE OIL REPLACEMENT INSP ADJ ENGINE ENGINE OIL REPLACEMENT 1. Check: : Engine oil level Refer to “ENGINE OIL LEVEL INSPECTION” section. : Release the reset button 1 and the oil indicator light will go off. Remove: : Drain plug 1 : Gasket Drain the crankcase of its oil. 7. To reset the oil indicator light before it comes on: Release the reset button and the oil indicator light will come on for 1. before the 3.000 km oil change interval is reached). 2. so that it will come on at the correct time to indicate the next 3. be sure to reset the oil indicator light after changing the oil. 34 . NOTE: If the oil is changed before the oil indicator light comes on (i. Start the engine and let it warm up for several minutes.e. : Push and hold in the reset button for 2 to 5 seconds.000 km oil replacement. Install: : Gasket New : Drain plug 1 20 Nm (2.4 seconds. Turn off the engine and place an oil pan under the engine.0 m:kg) 5. 4. 3.4 L 6. Reset: : Engine oil indicator circuit Resetting steps: : Turn the main switch to on. Fill: : Crankcase Oil quantity: 1.

Inspect: : Crankcase filter element Damaged ! Replace. 4. Install: : Crankcase filter element : Crankcase filter cover seal : Crankcase filter cover 7 Nm (0. 2. besure its sealing surface matches the sealing surface of the case so there is no air leak. 3. Clean: : Crankcase filter element 1 Blow out the dust in the element from the outer surface using compressed air.7 m:kg) 35 . Remove: : Crankcase filter cover 1 : Crankcase filter cover seal : Crankcase filter element NOTE: When installing the element in its case.CRANKCASE FILTER CLEANING INSP ADJ CRANKCASE FILTER CLEANING 1. Be careful not to stain with grease or water. CAUTION: This element is a dry type.

Remove: : Side cover mole 3 : Passenger seat : Standing handle : Side cover 2 Refer to “COVER AND PANEL” section. Install: : Side cover 2 : Standing handle : Passenger seat : Side cover mole 3 36 .AIR INDUCTION SYSTEM INSPECTION INSP ADJ AIR INDUCTION SYSTEM INSPECTION 1. 2. 3. 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.

slowly loosen to remove the radiator cap and drain the coolant. Remove: : Drain bolt 1 : Rivet 2 : Cover 3 : Radiator cap Open the front trunk. When the engine has cooled. remove the cover. press down on the cap while turning counterclockwise and remove it. open the radiator cap as follows: Place a thick rag or a towel over the radiator cap. 37 . 4. Remove: : Hose 1 (reservoir tank) Drain the reservoir tank of its coolant. Remove: : Side cover mole Refer to the “COVERS AND PANEL” section. which could cause serious injury. Scalding hot fluid and steam may be blown out under pressure. 3. NOTE: : Remove the radiator cap after removing the drain bolt. Clean: : Radiator Fill soft water into the filler neck support 1 (reservoir tank). : Place the scooter upright on a level surface when draining the coolant completely. 2.COOLANT REPLACEMENT YP303180 INSP ADJ COOLANT REPLACEMENT 1. Slowly rotate the cap counterclockwise toward the detent. This allows any residual pressure to escape. WARNING Do not remove the radiator cap when the engine and radiator are hot. When the hissing sound has stopped.

until the coolant comes out from the carburetor drain pipe.0 m:kg) 6.COOLANT REPLACEMENT 5. Fill: : Radiator (to specified level 1 ) Fill the coolant slowly.4 L Handling notes for coolant: Coolant is potentially harmful and should be handled with special care. Coolant 2 and water 3 (soft water): Mixed ratio: 50%/50% Total amount: 1. Connect: : Hose (reservoir tank) 8. Install: : Gasket 1 New : Drain bolt 2 INSP ADJ 10 Nm (1. : Reservoir tank (to maximum level a ) Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminium engine. Loosen: : Screw 1 (carburetor bleed) 7.4 L Reservoir tank capacity: 0. 38 .

Tighten: : Screw (carburetor bleed) Fill the coolant slowly to the specified level. Refer to “COOLANT LEVEL INSPECTION” section. 9. : Do not use water containing impurities or oil. Use only distilled water if soft water is not available. 12. Stop the engine and inspect the level. make sure it is soft water. CAUTION: : Hard water or salt water is harmful to engine parts. 13. If it does. 10. : If coolant splashes on your clothes: quickly wash it away with water and then with soap and water. wash them straightaway with water. : Take care that no coolant splashes onto painted surfaces. : Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. NOTE: Wait a few minutes until the coolant settles before inspecting the coolant level.COOLANT REPLACEMENT WARNING INSP ADJ : If coolant splashes in your eyes: thoroughly wash your eyes with water and consult a doctor. 39 . Start the engine and let it warm up for several minutes. Install: : Radiator cap 11. Install: : Side cover mole Refer to “COVER AND PANEL” section. : If you use tap water. : If coolant is swallowed: quickly make the person who has swallowed it vomit and then take him to a doctor.

Left headlight Turning in ! Headlight beam moves left. 2. Adjust : Headlight beam (horizontal) Turn the adjuster 1 in or out. Right head light Turning in ! Headlight beam moves right. Turning out ! Headlight beam moves left.HEADLIGHT BEAM ADJUSTMENT INSP ADJ ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Turning out ! Headlight beam moves right. Turning in ! Headlight beam moves lower. Turning out ! Headlight beam moves higher. Adjust : Headlight beam (vertical) Turn the adjuster 1 in or out. 40 .

CABLE. Carburetor Spark plug cap Thermo unit lead Startor coil/Pick up coil lead Starting motor lead Earth lead Q’ty Remarks Remove the parts in order. Refer to “CARBURETOR” section. Refer to “COVER AND PANEL” section. Refer to “COOLANT REPLACEMENT” section.0 m:kg) 7 Nm (0. 1 1 1/1 1 1 1 2 3 4 5 41 . cables and rear brake removal Side cover Main box Footrest board Drain the coolant. REAR BRAKE 10 Nm (1.7 m:kg) Order Job name/Part name Wireharness.ENGINE REMOVAL EB400000 ENG ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS.

0 m:kg) Order 6 7 8 Job name/Part name Caliper assembly Brake hose 1 Air induction system hose Q’ty 1 1 1 Remarks Reverse the removal procedure for installation. 42 .ENGINE REMOVAL ENG 10 Nm (1.0 m:kg) 40 Nm (4.

1 2 3 4 5 6 7 8 9 Hoses. air filter case.2 m:kg) 64 Nm (6.ENGINE REMOVAL HOSES. 43 . engine mounting bolt and engine removal 1 Crankcase breather hose 1 Inlet hose (water pump) 1 Outlet hose (cylinder head) 1 Air filter case assembly 2 Bolt 1/1 Self locknut/Plane washer 1 Bolt 1/2/1 Bolt/Plane washer/Rod assembly 1 Engine (Rear shock absorber – lower) Refer to “ENGINE REMOUNTING” section.0 m:kg) 32 Nm (3. ENGINE MOUNTING BOLT AND ENGINE ENG 20 Nm ( 2. Reverse the removal procedure for installation.4 m:kg) Order Job name/Part name Q’ty Remarks Remove the parts in order. AIR FILTER CASE.

Side cover Main box Footrest board Carburetor Thermo unit lead Plug cap Hose Outlet hose (cylinder head) Vacuum hose Breather hose (crankcase) Carburetor joint Joint O-ring Q’ty Remarks Remove the parts in the order.CYLINDER HEAD ENG CYLINDER HEAD 10 Nm (1.0 m:kg) 10 Nm (1.0 m:kg) Order Job name/Part name Cylinder head removal Drain the coolant.2 m:kg) 22 Nm (2.2 m:kg) 8 Nm (0. 1 2 3 4 5 6 7 8 9 1 1 2 1 1 1 1 1 2 44 . Refer to the “COVER AND PANELS” section.8 m:kg) 10 Nm (1.0 m:kg) 12 Nm (1. Refer to “CARBURETOR” section.

8 m:kg) 10 Nm (1.2 m:kg) 22 Nm (2. Reverse the removal procedure for installation.CYLINDER HEAD ENG 10 Nm (1.0 m:kg) 10 Nm (1.0 m:kg) Order 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Job name/Part name Crankcase filter cover Pipe 1 Gasket Plug/O-ring Cam sprocket cover/O-ring Valve cover (intake side)/O-ring 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 Q’ty 1 1 1 1/1 1/1 1/1 1/1 1 1 1 1/1 1 1 2 Remarks Refer to “CYLINDER HEAD REMOVAL AND INSTALLATION” section.2 m:kg) 8 Nm (0.0 m:kg) 12 Nm (1. 45 .

0 m:kg) 10 Nm (1. CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG V-BELT.V-BELT.0 m:kg) Order Job name/Part name Crankcase filter cover and crankcase cover (left) removal Side cover panel Crankcase filter cover Crankcase cover protector Crankcase cover (left) Crankcase cover gasket Q’ty Remarks Remove the parts in order Refer “COVER AND PANEL” section. CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) 10 Nm (1. 46 . 1 2 3 4 1 1 1 1 Reverse the removal procedure for installation.

0 m:kg) 60 Nm (6. 47 . clutch and secondary/ primary sheave removal Nut/Plain washer Primary fixed sheave Bracket Nut Spacer/O-ring Clutch housing Clutch assembly V-belt Primary sliding sheave Collar Primary sheave cap Q’ty Remarks Remove the parts in order.2 m:kg) 60 Nm (6.0 m:kg) Order Job name/Part name V-belt. Refer to “SECONDARY SHEAVE AND V-BELT REMOVAL” section. CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG *Shell BT grease No. CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT. Refer to “PRIMARY SHEAVE ASSEMBLY” section.V-BELT. 3 (90890-69927) 3 Nm (0. 1 2 3 4 5 6 7 8 9 10 11 1/1 1 1 1 1/1 1 1 1 1 1 1 Refer to “PRIMARY SHEAVE REMOVAL” section.3 m:kg) 22 Nm (2. Refer to “SECONDARY SHEAVE INSTALLATION” section.

0 m:kg) Order 12 13 14 15 16 Cam Weight Slider Spacer Oil seal Job name/Part name Q’ty 1 8 4 4 1 Remarks Refer to “PRIMARY SHEAVE ASSEMBLY” section.0 m:kg) 60 Nm (6. Reverse the removal procedure for installation. CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG *Shell BT grease No.V-BELT.3 m:kg) 22 Nm (2.2 m:kg) 60 Nm (6. 3 (90890-69927) 3 Nm (0. 48 .

CLUTCH. Drain the transmission oil. 1 2 3 4 5 6 7 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 49 .TRANSMISSION ENG TRANSMISSION 16 Nm (1. Refer to “V-BELT. Refer to “REAR WHEEL/REAR BRAKE” section.6 m:kg) Order Job name/Part name Transmission removal Rear wheel Crankcase cover (left) Q’ty Remarks Remove the parts in order. SECONDARY/PRIMARY SHEAVE” section. Refer to “TRANSMISSION OIL REPLACEMENT” section.

6 m:kg) Order 8 9 10 11 12 13 Job name/Part name Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Plain washer Q’ty 1 1 1 1 1 1 Remarks Reverse the removal procedure for installation.TRANSMISSION ENG 16 Nm (1. 50 .

AIR INDUCTION SYSTEM ENG AIR INDUCTION SYSTEM Order 1 2 3 4 5 6 7 Job name/Part name Air induction system removal Clip Hose 2 Clip Vacuum hose Clip Hose 1 Air induction system assembly Q’ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order Reverse the removal procedure for installation 51 .

: crankshaft 1 Remove the crankshaft assembly with the crankcase separating tool 2 CAUTION: Do not tap on the crankshaft. 52 . Remove: : Timing chain 1 NOTE: : Before removing the crankshaft assembly. : If the timing chain hooks to the crankshaft sprocket. Crankshaft separating tool 90890-01135 CRANKSHAFT REMOVAL 1. Install: : Crankshaft 1 : Crankcase 2 Install the crankshaft assembly with the crankshaft installer pot 3 . Crankshaft separating tool 90890-01135 CRANKSHAFT INSTALLATION 1. the crankshaft cannot be removed. remove the timing chain from the crankshaft sprocket. NOTE: Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installing tool with the other. crankshaft installer bolt 4 . Do not tap on the crankshaft. adapter 5 . Remove : Crankcase 2 1 ENG CRANKCASE AND CRANKSHAFT NOTE: : Remove the crankshaft assembly with the crankcase separating tool 2 . : Make sure that the crankcase separating tool is centered over the crankshaft assembly. Turn the crankshaft installing tool until the crankshaft assembly bottoms against the bearing.CRANKCASE AND CRANKSHAFT CRANKCASE REMOVAL 1. spacer 6 .

Install: : Crankcase 2 1 Install the crankshaft assembly with the crankshaft installer pot 2 . Crankshaft installer pot 2 90890-01274 Crankshaft installer bolt 3 90890-01275 Adapter 4 90890-01280 Spacer 5 90890-01288 53 . Install: : Timing chain 1 NOTE: Install the timing chain not to be seen through the crankshaft hole a on the crankcase (left) 2 . crankshaft installer bolt 3 . Apply: : sealant (onto the left crankcase mating surface) Yamaha bond No. Clean all the gascket mating surface and crankcase surface thoroughly. spacer 5 . 3.CRANKCASE AND CRANKSHAFT ENG Crankshaft installer pot 3 90890-01274 Crankshaft installer bolt 4 90890-01275 Adapter 5 90890-01478 Spacer 6 90890-01016 2. adapter 4 .1215 4. 5.

3 m:kg) 23 Nm (2. 54 .3 m:kg) Order Job name/Part name Radiator removal Drain the coolant Fuel tank Footrest board. 1 2 3 4 5 6 1 2 1 1 1 1 Reverse the removal procedure for installation. Refer to “COVER AND PANEL” section. Refer to “COOLANT REPLACEMENT” section.RADIATOR YP500000 COOL COOLING SYSTEM RADIATOR 23 Nm (2. under cover Cowling body. leg shield Fan motor leads Thermo switch leads Filler hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator Q’ty Remarks Remove the parts in order.

Reverse the removal procedure for installation. 55 . Refer to “COVER AND PANEL” section. 1 2 3 4 5 6 7 8 Auto choke lead coupler Throttle position sensor lead Inlet/Outlet hose (carburetor) Fuel hose Throttle cable Air filter joint Nut Carburetor assembly 1 1 1/1 1 2 1 2 1 CAUTION: Do not bend the air filter joint clamp when installing the carburetor.CARBURETOR EB600000 CARB CARBURETOR CARBURETOR 10 Nm (1. Refer to “COOLANT REPLACEMENT” section.0 m:kg) Order Job name/Part name Carburetor removal Side panel Main box Drain the coolant Q’ty Remarks Remove the parts in order.

56 . Refer to “CARBURETOR ASSEMBLY” section.CARBURETOR CARB CARBURETOR DISASSEMBLY Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Cover/Diaphragm spring Piston valve Jet needle assembly Coasting enricher Accererating pump Float chamber Float pin Q’ty 1 1 1 1/1 1 1 1 1 1 1 Remarks Disassemble the parts in order. Refer to “CARBURETOR ASSEMBLY” section.

57 .CARBURETOR CARB Order 11 12 13 14 15 16 Job name/Part name Float Needle valve Main jet Pilot jet Main nozzle Throttle position sensor Q’ty 1 1 1 1 1 1 Remarks Refer to “CARBURETOR ASSEMBLY” section. Reverse the disassembly procedure for assembly.

CARBURETOR

CARB

THROTTLE POSITION SENSOR ADJUSTMENT NOTE: : Before adjusting the throttle position sensor the engine idling speed should be properly adjusted. : When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer, Refer to the adjustment 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 1 tester (–) lead ! black 2 Throttle position sensor in put voltage 5V 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 of specification ! Adjust or replace. NOTE: When check the throttle position sensor must be connect the throttle sensor coupler to the wireharness. 4. Tighten: : Throttle position sensor screws

58

FRONT WHEEL

CHAS

CHASSIS
FRONT WHEEL
SPEED SENSOR AND SENSOR ROTOR

70 Nm (7.0 m:kg)

23 Nm (2.3 m:kg)

Order

Job name/Part name Speed sensor and sensor rotor removal Cowling body Speed sensor Brake caliper Axle nut Wheel axle Front wheel Sensor housing Collar Front wheel sensor lead connector

Q’ty

Remarks Remove the parts in order. Refer to “COVER AND PANEL” section.

1 2 3 4 5 6 7 8

1 1 1 1 1 1 1 1

Disconnect the connecter. Reverse the removal procedure for installation.

59

FRONT WHEEL

CHAS

SPEED SENSOR AND THE SENSOR ROTOR

CAUTION:
: Speed sensor cannot be disassembled. Never disassemble it. If failed, replace with a new one.

SPEED SENSOR REMOVAL 1. Remove: : Clamp 1 NOTE: Clamp can be easily removed by moving the clamp tip of brake hose and speed sensor leads up and down. 2. Remove: : caliper 1 : Speed sensor 2

CAUTION:
: Care should be taken not to allow the sensor 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 INSPECTION 1. Check: : Speed sensor 1 Cracks, bending and distortion ! Replace Iron powder and dust ! Clean

60

replace it as a wheel assembly. 1. Measure: : Speed sensor resistance Connect the pocket tester (Ω 1) to the terminal of speed sensor connector.19 to 2. Apply: : Litium soap base grease 1 Wheel axle 61 .FRONT WHEEL CHAS 2. Tester’s positive (+) lead ! Terminal 1 Tester’s negative (–) lead ! Terminal 2 Regulated resistance: 1. SPEED SENSOR ASSEMBLY Proceed in the reverse order of disassembling paying attention to the following items. To replace the sensor rotor. Check: : Sensor rotor 1 Cracks and damage ! Replace the wheel assembly NOTE: Sensor rotor of YP250 is inserted under pressure by the special process and cannot be replaced as a single unit.21 kΩ at 20_C Out of specification ! Replace 3.

CAUTION: To route the speed sensor lead. 4. Install: : Sensor housing CHAS 3. CAUTION: Install after checking if foreign materials are mixed in the wheel hub. Install: : Front wheel : Wheel axle : Axle nut 70 Nm (7.FRONT WHEEL 2. it causes to damage the sensor rotor and speed sensor. check if the speed sensor lead is twisted or foreign matters attached to the electrode.0 m:kg) NOTE: Align the slot of sensor housing with the projection part of front fork. If foreign materials are mixed. 62 . then assemble them.0 m:kg) NOTE: When installing the speed sensor. refer to the CABLE ROUTING.3 m:kg) 50 Nm (5. Install: : Speed sensor 1 : Brake caliper 2 : Clamp 3 23 Nm (2.

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

64 .REAR WHEEL REAR WHEEL CHAS Order Job name/Part name Rear wheel and brake disc removal Swingarm Q’ty Remarks Refer to “REAR SHOCK ABSORBER AND SWINGARM” section. 1 2 3 4 Plate O-ring Collar Rear wheel 1 1 1 1 Reverse the removal procedure for installation.

REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.5 m:kg) 53 Nm (5. NOTE: Remove with the rear brake applied.0 m:kg) 40 Nm (4. 65 .5 m:kg) 35 Nm (3.0 m:kg) 135 Nm (13.3 m:kg) Order Job name/Part name Rear shock absorber and swingarm removal Side panels Q’ty Remarks Remove the parts in order. Refer to “COVER AND PANEL” section. NOTE: Loosen. 1 2 3 4 5 6 7 8 9 10 Nut Muffler assembly Axle nut Rear shock absorber Rear caliper assembly Swingarm Collar Oil seal Bearing Oil seal 2 1 1 2 1 1 1 1 1 1 Reverse the removal procedure for installation.0 m:kg) 20 Nm (2.

ELECTRICAL COMPONENTS EB800000 ELEC ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Main switch Ignition coil Spark plug cap Fuel sender Rectifier/ Regulator Wireharness Thermo unit Ignitor unit 9 10 11 12 13 14 15 16 Fuel pump Sidestand switch Flasher relay Battery Starter relay Starting circuit cut-off relay Horn Fuel pump relay 66 .

CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM 67 .

COLOR CODE B Br Ch Dg G L O P R Y Black Brown Chocolate Dark green Green Blue Orange Pink Red Yellow W B/R B/W Br/L Br/W G/R G/Y L/B L/G L/R White Black/Red Black/White Brown/Blue Brown/White Green/Red Green/Yellow Blue/Black Blue/Green Blue/Red L/Y L/W R/G R/Y R/W Y/R Y/L W/G Blue/Yellow Blue/White Red/Green Red/Yellow Red/White Yellow/Red Yellow/Blue White/Green 68 . magneto Pickup coil Rectifier regulator Main switch Backup fuse Battery Main fuse Starter relay Starter motor Diode Starting circuit cut-off relay Thermo switch (Auto choke) Auto choke Ignitor unit Ignition coil Spark pulg Throttle position sensor Speed sensor Fuel pump Fuel pump relay Sidestand switch Light switch Start switch Engine stop switch Right handlebar switch Ignition fuse Seat switch Box light Head light fuse Fan fuse Signal fuse 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Thermo switch (Fan) Fan motor Brake light switch Flasher relay Horn Turn switch Horn switch Dimmer switch Pass switch Left handlebar switch License plate light Tail/ brake light Rear flasher light Front flasher light Head light (LO) Head light (HI) Auxiliary light Trun signal indicator light High beam indicator light Meter light Oil indicator light Fuel gauge Thermometer Clock Speedometer Meter assembly Fuel sender Thermo unit Alarm Grip warmer switch (OPUTION) Grip warmer (OPUTION) Ground NOTE: : Starter switch is closed while the button (switch) is pushed. : Brake switch is closed while the brake is applied.CIRCUIT DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 ELEC A.C. : Sidestand switch is closed while the side stand is upped.

fault ! Repair or replace.CHECKING SWITCHES YP***** ELEC CHECKING SWITCHES SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the 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. 69 .

like the one shown on the left. “ ” indicates terminals between which there is continuity. “OFF” positions several times. Pocket tester: 90890-03112 NOTE: : Turn the switch to the “ON”. In this chart: “Br and R” have continuity with the switch in the “ON” position. i. the main switch. handlebar switch. 70 . lighting switch etc.) The column on the extreme left indicates the different switch positions. brake switch. : Set the pocket tester selector to “ 1” Ω.e.CHECKING SWITCHES YP-N ELEC CHECKING SWITCHES CHECKING STEPS Using pocket tester. check switches for continuity between their terminals to determine whether they are correctly connected.g. Replace the switch component if any of the combinations does not produce the correct reading. SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts. a closed circuit. the top line indicates the colors of the leads connected to the terminals on the switch. showing the terminal connections of switches (e. in the given switch position. : Adjust the pocket tester to correct “0” position before checking switches.

IGNITION SYSTEM EB802000 ELEC IGNITION SYSTEM CIRCUIT DIAGRAM 2 4 6 7 14 15 16 21 24 60 Pickup coil Main switch Battery Main fuse Ignitor unit Ignition coil Spark plug Sidestand switch Engine stop switch Alarm 71 .

ELECTRIC STARTING EB80300 ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 4 6 7 8 9 11 21 23 24 26 31 34 60 Main switch Battery Main fuse Starter relay Starter motor Starting circuit cut-off relay Sidestand switch Starter switch Engine stop switch Ignition fuse Signal fuse Brake light switch Alarm 72 .

LIGHTING SYSTEM EB804000 ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM 4 5 6 7 22 27 28 29 39 Main switch Backup Fuse Battery Main fuse Lights switch Seat switch Box light Head light fuse Dimmer switch 40 42 45 46 47 48 50 51 Pass switch License plate light Tail/Brake light Head light (Lo) Head light (HI) Auxiliary light High beam indicator light Meter lights 73 .

CONTINUITY : 74 Replace the right handlebar switch. 1) Rider seat 2) Passenger seat 3) Box 4) Legshield 5) Cowling body Use the special tools specified in the troubleshooting section. BOX LIGHT.LIGHTING SYSTEM YP805010 ELEC TROUBLESHOOTING IF THE HEADLIGHT. CORRECT YP****** Clean battery terminals. . Recharge or replace battery. Replace the main switch. TAILLIGHT. CONTINUITY YP****** NO CONTINUITY 4. Fuse (Main. Procedure Check: 1. Backup) 2. Seat switch 7. CONTINUITY YP****** INCORRECT 2. Main switch 4. LICENSE PLATE LIGHT AND/ OR METER LIGHT FAIL TO COME ON. Lights switch Refer to “CHECKING SWITCHES” section. Replace the fuse. Main switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY 3. Battery Check the battery condition. Wiring connection (entire lighting system) YP****** 1. Battery 3. Fuse Refer to “CHECKING SWITCHES” section. Lights switch NOTE: Remove the following parts before troubleshooting. Dimmer switch and pass switch 6. HIGH BEAM INDICATOR LIGHT. Pocket tester 90890-03112 NO CONTINUITY 5. Refer to “BATTERY INSPECTION” section in CHAPTER 3.

Headlight: Tester (+) lead ! Green 1 or Yellow 2 lead Tester negative (–) lead ! Black 3 lead High beam indicator light: Tester (+) lead ! Yellow 4 lead Tester (–) lead ! Black 5 lead : 75 . Check the condition of each of the lighting system’s circuits. B When dimmer switch is on high beam or the Pass switch is pushed. Replace the left handlebar switch. Dimmer switch/Pass switch Refer to “CHECKING SWITCHES” section. Wiring connection Check the connections of the entire lighting system. If the headlight and the high beam indicator light fail to come on. 1. A When the dimmer switch is on low beam. Refer to “LIGHTING SYSTEM CHECK” YP805020 LIGHTING SYSTEM CHECK 1. POOR CONNECTIONS Correct.LIGHTING SYSTEM : YP****** ELEC NO CONTINUITY 5. Refer to “WIRING DIAGRAM”. YP****** NO CONTINUITY 6. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Seat switch Refer to “CHECKING SWITCHES” section. CONTINUITY 2. YP****** 7. Replace the handlebar switch. Voltage Connect the pocket tester (DC20 V) to the headlight and high beam indicator light couplers. NO CONTINUITY Replace the bulb and/or bulb socket.

Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Repair. 2. Turn the lights switch to on or pilot position. OUT OF SPECIFICATION The wiring circuit from main switch to bulb socket is faulty. Turn the main switch to on. MEETS SPECIFICATION This circuit is not faulty. Check the voltage (12 V) of the leads on the bulb socket connector. YP805021 ELEC OUT OF SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty. Repair. CONTINUITY 2. Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. Turn the light switch to on position. NO CONTINUITY 1. Turn the dimmer switch to low beam or high beam. Check for voltage (12 V) on the lead at bulb socket connectors. MEETS SPECIFICATION This circuit is not faulty. 76 . If the meter light fails to come on.LIGHTING SYSTEM : Turn the main switch to on. Voltage Connect the pocket tester (DC20 V) to the bulb socket coupler. Pass switch to push in.

77 . Repair. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. The taillight fails to come on. S Check the voltage (12 V) on the bulb socket connector. S Turn the lights switch to on or pilot position. Bulb and bulb socket Refer to “CHECKING SWITCHES” section.LIGHTING SYSTEM YP805022 ELEC 3. Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. NO CONTINUITY 1. OUT OF SPECIFICATION S Turn the main switch to on. MEETS SPECIFICATION This circuit is not faulty. CONTINUITY 2. The wiring circuit from main switch to bulb connector is faulty.

LIGHTING SYSTEM YP805022 ELEC 3. NO CONTINUITY 1. The wiring circuit from main switch to bulb connector is faulty. 78 . Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. S Turn the lights switch to on or pilot position. Repair. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. MEETS SPECIFICATION This circuit is not faulty. CONTINUITY 2. OUT OF SPECIFICATION S Turn the main switch to on. S Check the voltage (12 V) on the bulb socket connector. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. The license plate light fails to come on.

If the auxiliary light fails to come on. NO CONTINUITY 1. Tester (+) lead ! Blue/Red terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. S Check the voltage (12 V) on the bulb socket connector.LIGHTING SYSTEM YP805023 ELEC 4. 79 . The wiring circuit from main switch to bulb connector is faulty. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. S Turn the lights switch to on or pilot position. Repair. CONTINUITY 2. OUT OF SPECIFICATION S Turn the main switch to on. MEETS SPECIFICATION This circuit is not faulty.

SIGNAL SYSTEM EB806000 ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM 4 6 7 31 34 35 36 37 Main switch Battery Main fuse Signal fuse Brak light switch Flasher relay Horn Turn switch 38 43 44 45 49 53 58 Horn switch Tail/ Brake light Rear flasher lights Front flasher lights Turn indicator lights Fuel gauge Fuel sender 80 .

signal) 2. Fuse Refer to “CHECKING SWITCHES” section. Battery Check the battery condition. Wiring connection (entire signal system) YP****** 1.SIGNAL SYSTEM YP806010 ELEC TROUBLESHOOTING IF THE FLASHER LIGHT. CONTINUITY YP****** INCORRECT 2. Main switch Refer to “CHECKING SWITCHES” section. Pocket tester: 90890-03112 NO CONTINUITY 3. 1) Cowling body 2) Side panels Use the special tools in the troubleshooting section. IF THE HORN FAILS TO SOUND. BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON. Procedure Check: 1. Replace the fuse. Fuse (Main. CONTINUITY : 81 . Refer to “BATTERY INSPECTION” section in CHAPTER 3. CORRECT YP****** Clean battery terminals. NO CONTINUITY 3. Recharge or replace battery. Battery NOTE: Remove the following parts before troubleshooting. Main switch 4. Replace the main switch.

Refer to “CIRCUIT SYSTEM WIRING DIAGRAM” section. Refer to “SIGNAL SYSTEM CHECK” section. POOR CONNECTION Correct. Wireharness Check the connections of the entire signal system. 82 .SIGNAL SYSTEM : YP****** ELEC 4. CONTINUITY Check condition of each of the signal system’s circuits.

83 . 1. MEETS SPECIFICATION 3.SIGNAL SYSTEM YP806020 ELEC SIGNAL SYSTEM CHECK 1. S Check for voltage on the “Pink” lead to frame ground. NO CONTINUITY Replace the horn. Repair. Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Frame ground S Turn the main switch to on. Tester (+) lead ! Pink 1 terminal Tester (–) lead ! Frame ground S Turn the main switch to on. S Check for voltage (12 V) on the “Brown” lead at the horn terminal. If the horn fails to sound. CONTINUITY 2. OUT OF SPECIFICATION The wiring circuit from the main switch to the horn is faulty. CONTINUITY Adjust or replace horn. Voltage S Connect the pocket tester (DC20 V) to the horn lead. Horn S Connect the pocket tester (DC20 V) to the horn at the “Pink” terminal. HORN switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace the left handlebar switch.

Tester (+) lead ! Yellow terminal 1 Tester (–) lead ! Black terminal 2 Replace brake switch. MEETS SPECIFICATION This circuit is not faulty. CONTINUITY 3. S Check for voltage (12 V) of the “Yellow” lead on the bulb socket connector. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. Wiring connection S Wiring circuit from the main switch to the bulb socket connector is faulty. Repair. 84 . Refer to “SIGNAL SYSTEM WIRING DIAGRAM”. If the brake light fails to come on: NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. NO CONTINUITY S Turn the main switch to on. S The brake lever is pulled in. CONTINUITY 2. Replace the bulb and/or bulb socket. OUT OF SPECIFICATION 4.SIGNAL SYSTEM YP806022 ELEC 2. Brake switch (Front/Rear) Refer to “CHECKING SWITCHES” section.

If the flasher light and/or turn indicator light fails to blink. Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Frame ground Turn the main switch to on.SIGNAL SYSTEM YP806023 ELEC 3. Tester (+) lead ! Brown/White terminal 1 Tester (–) lead ! Frame ground Turn the main switch to on. Voltage Connect the pocket tester (DC20 V) to the flasher relay coupler. CONTINUITY 3. MEETS SPECIFICATION : OUT OF SPECIFICATION The flasher relay is faulty. Turn switch Refer to “CHECKING SWITCHES” section. Check for voltage (12 V) of the “Brown” 1 lead at the flasher relay terminal. 4. Replace the left handlebar switch. MEETS SPECIFICATION OUT OF SPECIFICATION The wiring circuit from main switch to flasher relay connector is faulty. Voltage Connect the pocket tester (DC20 V) to the flasher relay coupler. Replace the bulb and/or bulb socket. Repair. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. CONTINUITY NO CONTINUITY 2. Replace. NO CONTINUITY 1. Check for voltage (12 V) on the “Brown/ White” lead at the flasher relay terminal. 85 .

86 . Refer to “CIRCUIT DIAGRAM”. Wiring connection Wiring circuit from the turn switch to bulb socket connector is fault. OUT OF SPECIFICATION 6. At flasher light (left) Tester (+) lead ! Chocolate lead 1 Tester (–) lead ! Black terminal 3 At flasher light (right) Tester (+) lead ! Dark green lead 2 Tester (–) lead ! Black terminal 3 Turn the main switch to on. Voltage Connect the pocket tester (DC20 V) to the bulb socket connector. MEETS SPECIFICATION This circuit is not faulty. Repair. Turn the turn switch to left or right.SIGNAL SYSTEM : ELEC 5. Check for voltage (12 V) on the “Chocolate” lead and “Dark green” at the flasher light terminal.

1. Voltage Connect the pocket tester (DC20 V) to the fuel gauge coupler. Connect the pocket tester (Ω 10) to the fuel sender coupler lead. Refer to “CHECKING OF CONNECTIONS”. Disconnect the fuel sender coupler from the wireharness. Fuel sender Remove the fuel sender from the fuel tank. Tester (+) lead ! Green terminal 1 Tester (–) lead ! Black terminal 2 Check the fuel sender for specificated resistance. Float position UP 3 DOWN 4 Specificated resistance 4 10 Ω 90 100 Ω BOTH MEET SPECIFICATION 2. Refer to “CIRCUIT DIAGRAM”. MEETS SPECIFICATION : OUT OF SPECIFICATION Check the connection of the entire signal system. Turn the main switch to “ON”. Check for voltage (12 V) of the “Brown” lead on the fuel sender lead.SIGNAL SYSTEM YP806027 ELEC 4. 87 . Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Frame ground OUT OF SPECIFICATION Replace the fuel sender. If the fuel gauge fails to operate.

88 . DOES NOT MOVE Replace the fuel gauge.SIGNAL SYSTEM : ELEC 3. Turn the main switch to “ON”. Float position Float “UP” 1 Float “DOWN” 2 Needle moves “F” “E” MOVES This circuit is not faulty. Check the fuel gauge needle moves “F” or “E”. NOTE: Before reading the meter. Fuel gauge Connect the fuel sender to wireharness. stay put the float for more than three minutes respectively at “UP” or “DOWN”. Move the float to “UP” 1 or “DOWN” 2.

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

FUEL PUMP SYSTEM EB808010 ELEC FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 2 3 4 5 6 7 8 Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump 90 .

Main switch 4. Refer to “BATTERY INSPECTION” section in CHAPTER 3. 1) Rider seat 2) Passenger seat 3) Box 4) Legshield Use the special tools specified in the troubleshooting section. 91 . Fuse Refer to “CHECKING SWITCHES” section.FUEL PUMP SYSTEM EB808020 ELEC TROUBLESHOOTING The fuel pump fails to operate. NO CONTINUITY 3. Pocket tester 90890-03112 NO CONTINUITY 5. Main switch Refer to “CHECKING SWITCHES” section. Recharge or replace battery. CORRECT YP****** Clean battery terminals. Replace the fuse. Battery 3. Procedure Check: 1. CONTINUITY YP****** INCORRECT 2. Wiring connection (engine fuel pump system) YP****** 1. Battery Check the battery condition. Engine stop switch NOTE: Remove the following parts before troubleshooting. Fuel pump 7. Replace the main switch. CONTINUITY : Replace the right handlebar switch. Engine stop switch Refer to “CHECKING SWITCHES” section. Fuse (Main and Ignition) 2. Relay unit (fuel pump relay) 6. CONTINUITY YP****** NO CONTINUITY 4.

Connect the pocket tester (Ω 1) to the fuel pump coupler (fuel pump side) as shown. Wiring connection POOR CONNECTION Check the entire fuel pump system’s wiring. Tester positive probe ! black/blue 1 Tester negative probe ! black 2 Measure the fuel pump resistance.FUEL PUMP SYSTEM : ELEC 5. Fuel pump resistance Disconnect the fuel pump coupler from the wire harness. CORRECT Replace the ignition unit Correct. CONTINUITY 6. Check the starter relay for continuity. Relay unit (fuel pump relay) Disconnect the relay unit from the coupler. Replace the fuel pump OUT OF SPECIFICATION Replace the starter relay NO CONTINUITY 92 . Battery positive terminal ! red/white 1 Battery negative terminal ! blue/red 2 Tester positive probe ! red/white 3 Tester negative probe ! blue/black 4 Turn the main switch to on. Fuel pump resistance 11 13 Ω at 20_C CORRECT 7. Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit terminals as shown. Refer to “CIRCUIT DIAGRAM”.

Connect the battery (12 V) to the fuel pump coupler as shown. Be extremely careful and note the following points: S Stop the engine before refuelling. make sure that the engine is completely cool before performing the following test. sparks or any other source of fire. d. Check: S Fuel pump operation a. Turn the fuel cock to “ON” or “RES”. b. 93 . S Do not smoke and keep away from open flames. Therefore. Battery positive lead ! black/blue 1 Battery negative lead ! black 2 e. If fuel does not flow. replace the fuel pump.FUEL PUMP SYSTEM EB808410 ELEC CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. 1. S If gasoline touches the engine when it is hot. a fire may occur. S If you do accidentally spill gasoline. Put the end of the fuel hose into an open container. the fuel pump is OK. wipe it up immediately with dry rags. If fuel flows out of the fuel hose. Fill the fuel tank. c.

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. . Br . .. G / Y. .. L/Y . .. . Br / L . L/G . . ...... . . . .. Black Brown Chocolate Dark green Green Blue Orange Pink Red Yellow White Black / Red Black / White Brown / Blue Br / W .. . . . .. magneto Pickup coil Rectifier regulator Main switch Backup fuse Battery Main fuse Starter relay Starter motor Diode Starting circuit cut-off relay Thermo switch (Auto choke) Auto choke Ignitor unit Ignition coil Spark pulg Throttle position sensor Speed sensor Fuel pump Fuel pump relay Sidestand switch Light switch Start switch Engine stop switch Right handlebar switch Ignition fuse Seat switch Box light Head light fuse Fan fuse Signal fuse Thermo switch (Fan) Fan motor Brake light switch Flasher relay Horn Turn switch Horn switch Dimmer switch Pass switch 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Left handlebar switch License plate light Tail / brake light Rear flasher light Front flasher light Head light (LO) Head light (HI) Auxiliary light Trun signal indicator light High beam indicator light Meter light Oil indicator light Fuel gauge Thermometer Clock Speedometer Meter assembly Fuel sender Thermo unit Alarm Grip warmer switch (OPTION) Grip warmer (OPTION) Ground COLOR CODE B . . .. . .. . ...YP250 2000 WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 A. . . . Ch .. . ... . . Brown / White Green / Red Green / Yellow Blue / Black Blue / Green Blue / Red Blue / Yellow Blue / White Red / Green Red / Yellow Red / White Yellow / Red Yellow / Blue White / Green . L/B . . Dg . . . B/R. . .. .. . ... .. . ... W . . . .. L .. C. R. . . Y . . . . ... .. . .... . .. R/Y. L/R . L/W . . . B/W .. G/R . . ... . . Y/L . . . P . R/G . O ... . . ..... . . . . .. Y/R. . . W/G .. . . .. . . . .. . ... . R/W . . .. . . . ... . . . . . . G .