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.
EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual, so it is assumed that anyone who uses this book to perform maintenance and re-
pairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures
of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the
scooter unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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.

NOTE:
Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or

death to the scooter operator, a bystander or a person inspecting or re-
pairing the scooter.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.

NOTE: A NOTE provides key information to make procedures easier or clearer.

YP002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-
bols”)
1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each
page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of
each section. It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures ac-
companied by corresponding illustrations.

EXPLODED DIAGRAMS
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 easy-to-read way by the use of symbol
marks 6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in
addition to the exploded diagram and the job instruction chart.

2 1 4 3

5
8

6
6

7
 EB003000

1 2 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number
and content.
3 4
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 6 5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
7 8

9 10 Illustrated symbols 10 to 17 are used to iden-

tify the specifications appearing in the text.
10 Possible to maintain with engine mounted
11 Filling fluid
11 12 12 Lubricant
13 Special tool
14 Tightening
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
13 14

15 16 17
Illustrated symbols 18 to 23 in the exploded
diagrams indicate the types of lubricants
and lubrication points.
18 19 20 18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
21 22 23 23 Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded
diagrams indicate the where to apply lock-
ing agent 24 and when to install new parts
24 25 25 .
24 Apply locking agent (LOCTITE)
25 Use new one
 CONTENS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCOOTER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL 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)

 GEN
SCOOTER IDENTIFICATION INFO
YP100000

GENERAL INFORMATION
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.

1
 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YP250
Model code: 4UC3 (except for CH, A, AUS)
4UD3 (for CH, A)
4UC4 (for AUS)
Tire pressure (cold tire):
Maximum load-except motorcycle 197 kg
Loading condition A* 0  90 kg
front 175 kPa (1.75 kg/cm2, 1.75 bar)
rear 200 kPa (2.0 kg/cm2, 2.0 bar)
Loading condition B* 90  197 kg
front 200 kPa (2.0 kg/cm2, 2.0 bar)
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
High-speed riding
front 200 kPa (2.0 kg/cm2, 2.0 bar)
rear 250 kPa (2.5 kg/cm2, 2.5 bar)
Wheel travel:
Front wheel travel 100 mm
Rear wheel travel 90 mm
Bulb wattage
quantity:
Headlight 12V 60 W/55 W
1
Marker light 12V 5 W
1
Tail/brake light 12V 5 W/21 W
1
Flasher light 12V 21W
4
Meter light 12V 1.7W
4
High beam indicator light 12V 1.7 W
1
Oil indicator light 12V 1.7 W
1
Turn indicator light 12V 3.4 W
2
License light 12V 5 W
1
*Load is the total weight of cargo, rider, passenger, and accessories.

2
 MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE

Item Standard Limit

V-belt:
V-belt width 23.0 mm 21.0 mm
Carburetor:
Type Y28V-1B-1
I.D. mark 4UC 00 [4UD 00 (CH, A)]



Ventuly outside diameter ø28



Main jet (M.J) #130



Main air jet (M.A.J) ø0.9



Jet needle (J.N) 5D32-3/5



Throttle valve size (Th.V) 11



Pilot air jet (P.A.J.1) ø1.2



Needle jet (N.J) #85



Pilot outlet (P.O) ø0.8



Pilot jet (P.J) #44



Bypass (B.P) 0.7
3



Pilot screw (P.S) 1 1/2



Valve seat size (V.S) 1.4



Starter jet 1 (G.S.1) ø0.5



Starter jet 2 (G.S.2) ø1.3



Float height (F.H) 27 mm



Engine idle speed 1,350  1,450 r/min



Intake vacuum 220  260 mmHg



Oil temperature 65  75C



Cooling water temperature 80C



CHASSIS

Item Standard Limit

Steering system:
Steering bearing type Ball and angular bearing



Front suspension:
Front fork travel 100 mm



Fork spring free length 265.8 mm 265 mm
Spring rate (K1) 5.7 N/mm (0.57 kg/mm)



Stroke (K1) 0  100 mm



Oil capacity 0.142 L (142 cm3)



Oil level 80 mm



Oil grade Fork oil 15 WT or equivalent



Inner tube vend limit


0.2 mm

3
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Rear suspension:
Shock absorber stroke 106 mm



Spring free length 265 mm 260 mm
Fitting length 317 mm



Spring rate (K1) 7.7 N/mm (0.77 kg/mm)



(K2) 12.6 N/mm (1.26 kg/mm)



(K3) 25.8 N/mm (2.58 kg/mm)



Stroke (K1) 0
40 mm



(K2) 40
75 mm



(K3) 75
106 mm



ELECTRICAL

Item Standard limit

Spark plug cap:
Type Resin type



Resistance 10 kΩ



Charging system:
Type A.C. magneto



Model/manufacturer F4T252/MITSUBISHI



Normal output 14 V 16 A at 5,000 r/min



Stator coil resistance/color 0.54
0.66 Ω at 20C/



White – White
Rectifire/regulator:
Model/manufacturer SH640D-12/SHINDENGEN



No load regulated voltage 14.7 V



Capacity 14 A



Withstand voltage 200 V



Battery:
Specific gravity 1.320



Electric starter system:
Type Constant mesh type
Starter motor:
Model/manufacturer/ID number SM-13/MITSUBA/SM-13454



Operation voltage 12 V



Output 0.65 kW



Armature coil resistance 0.0012
0.0022 Ω at 20C



Brush overall length 10 mm 4 mm
Brash quantity 2 pcs.



Spring force 570
920 g 570 g
Commutator diameter 28 mm 27 mm
Mica undercut (depth) 0.7 mm

4
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard limit

Starter relay:
Model/manufacturer MS5F-471JIDECO



Amperage rating 100 A



Coil winding resistance 4.2
4.6 Ω at 20C



Horn:
Model/manufacturer YF-12/NIKKO



Maximum amperage 3A



Flasher relay:
Type Full transistor type



Model/manufacturer FE246BH/DENSO



Flasher frequency 75
95 cycle/min



Starting circuit cut-off relay:
Model/manufacturer ACA12115-1/MATSUSHITA



Coil winding resistance 72
88 Ω



Thermo unit:
Model/manufacturer 11H/NIPPON SEIKI

5
 CABLE ROUTING SPEC

CABLE ROUTING
1 Box light 15 Reservoir tank A Pass the box light lead from
2 Rectifier/ regulator 16 Battery negative (–) lead outside of frame through
3 Fuel sender 17 Battery positive (+) lead inside of protector.
4 Roll over valve 18 Ignition coil B Clamp the fuel sender lead to
5 Fuse 19 Breather hose the pipe.
6 Seat lock cable 20 Air filter C Clamp the fuel sender lead
7 Handlebar switch lead (right) 21 Mudguard and auto choke lead to the
8 Front brake switch lead 22 Seat lock cable frame.
9 Brake hose 23 Down tube D Pass the box switch lead
10 Speedometer cable 24 Wireharness through under the fuel tank
11 Pipe 25 Ground lead hinge projection.
12 Starter relay 26 Engine bracket E Align the mark on seat lock
13 Battery 27 AC magnet leads cable to the protector end.
14 Flasher relay 28 Starter motor lead F Clamp the wireharness
(white tape) to frame.

6
 CABLE ROUTING SPEC
G Install the meter cable with
its sheaved side facing to the
meter gear.
H Install 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.

7
 CABLE ROUTING
1 Throttle cable (pull side) 11 Throttle cables
2 Throttle cable (push side) 12 Radiator
3 Carburetor drain hose 13 Throttle cables
4 Carburetor coolant drain hose 14 Wireharness
5 Air vent hose 15 Stay
6 Steering head
7 Rear brake cable A Pass the air vent hose,
8 Steering head coolant drain hose, and
9 Wireharness fuel drain hose through the
10 Down tube “U” clamp on the holder.
SPEC
B Pass the drain hose through
the clamp (spring hook).
C Clamp the brake cable 2 to the
frame.
(Up and down)
Align the locating mark of the
brake cable 2 with the under
clamp.
D Pass the overflow hose from
the tank through the clamp
inside the frame pipe.

8
 CABLE ROUTING SPEC
1 Air filter 13 Fuel cock A Install the positive (+) lead
2 Chain tensioner 14 Fuel tank between the battery and the
3 Fuel tank breather hose 15 Over flow hose starter relay to the starter relay
4 Vacuum hose 16 Starting circuit cutoff relay along the chassis.
5 Fuel hose 17 Auto choke unit lead B Put the coupler of the A.C.
6 Fuel hose 18 Protector magneto lead and the auto
7 Vacuum hose 19 Seat lock cable choke lead along the frame
8 Sidestand switch lead 20 Seat lock pipe after connection.
9 Fan motor lead 21 Ground lead C Clamp the wireharness, A.C.
10 Thermo switch lead 22 Starter motor lead magneto leads, starter motor
11 Fuel hose 23 AC magneto leads lead and grand lead to the
12 Vacuum hose frame.
D Clamp the AC magneto leads,
starter motor lead and ground
lead to the engine bracket.

9
 CABLE ROUTING SPEC
1 Front flasher light (right) 13 Handlebar switch (right) A Install the brake hose with its
2 Front flasher light (left) 14 Front brake switch marking facing to the stopper
3 Rear brake cable 15 Seat lock cable side.
4 Throttle cable 16 Throttle cable B Pass the speedometer cable
5 Speedometer cable 17 Brake hose and the brake hose through
6 Brake hose 18 Handlebar switch (left) the clamps on the frame.
7 Horn 19 Rear brake switch (Front: Speedometer cable
8 Stay 20 Rear brake cable Rear: Brake hose)
9 Mark 21 Under handlebar cover C Do not interfere each other
10 Brake hose stopper 22 Speedometer cable after installing the handlebar
11 Grip heater lead 23 Stay upper cover.
12 Ararm terminal

10
 INSP
COVER AND PANEL ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
COVER AND PANEL
SIDE PANEL AND SEAT

Order Job name/Part name Q’ty Remarks

Side panel and seat removal Remove the parts in order.
1 Rear panel 1
2 Side panel (left) 1
3 Side panel (right) 1
4 Rivet 2
5 Front panel 1
6 Clip 2 NOTE:
7 Damper assembly 1 Install the damper assembly to the
body with its rod side backward and
labels upward.

8 Seat 1

Reverse the removal procedure for

installation.

11
 SIGNAL SYSTEM ELEC

 

  
 

3 Main switch 39 Turn indicator lights

4 Battery 44 Fuel gauge
5 Main fuse 50 Fuel sender
24 Rear brake switch 52 Box light
25 Front brake switch 53 Box light switch
26 Flasher relay
27 Horn
28 Turn switch
29 Horn switch
33 Tail/ Brake light
35 Rear flasher lights
36 Front flasher lights

12
 SIGNAL SYSTEM ELEC
SIGNAL SYSTEM CHECK
If the box light fails to come on.
1. Bulb and bulb socket.

Disconnect the bulb socket connector.

Connect the pocket tester (Ω
1) to the
bulb socket connector.

NO CONTINUITY

Check the bulb socket for continuity. Replace the bulb and/or bulb socket.

CONTINUITY

2. Box light switch

Disconnect the box light switch coupler.

Connect the pocket tester (Ω
1) to the
box light switch.
Tester (+) lead
Read 11 terminal.
Tester (–) lead
Blue/Green 22 terminal.

Check the box light switch for continuity. 1 2
NO CONTINUITY
CONTINUITY

3. Wiring connection Replace the box light switch.

Wiring circuit from the main switch to the
bulb socket connector is faulty. Repair.
Refer to “SIGNAL SYSTEM WIRING DIA-
GRAM”.

13
YP250 ’98 WIRING DIAGRAM (FOR EUROPE)
1 A.C. magneto
2 Rectifier regulator
3 Main switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
8 Alarm (option)
9 Thermo switch (auto choke)
10 Auto choke
11 Ignitor unit
12 Ignition coil
13 Spark plug
14 Pickup coil
15 Sidestand switch
16 Starting circuit cut-off relay
17 Lights switch
18 Starter switch
19 Engine stop switch
20 Handlebar switches (right)
21 Fuse (fan)
22 Thermo switch
23 Fan motor
24 Rear brake switch
25 Front brake switch
26 Flasher relay
27 Horn
28 Turn switch
29 Horn switch
30 Dimmer switch
31 Pass switch
32 Handlebar 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
COLOR CODE 53 Box light switch
B ........ Black O ....... Orange B/R . . . . . . Black/Red L/R . . . . . . Blue/Red Y/R . . . . . . Yellow/Red
Br . . . . . . . Brown P ........ Pink Br/W . . . . . Brown/White L/W . . . . . Blue/White
Ch . . . . . . Chocolate R........ Red G/R . . . . . Green/Red L/Y . . . . . . Blue/Yellow
Dg . . . . . . Dark green Sb . . . . . . . Sky blue G/Y . . . . . . Green/Yellow R/W . . . . . Red/White
G ....... Green W ....... White L/B . . . . . . Blue/Black R/Y . . . . . . Red/Yellow
L ........ Blue Y ........ Yellow L/G . . . . . . Blue/Green W/G . . . . . White/Green
YP250J WIRING DIAGRAM (FOR OSEANIA)
1 A.C. magneto
2 Rectifier regulator
3 Main switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
8 Alarm (option)
9 Thermo switch (auto choke)
10 Auto choke
11 Ignitor unit
12 Ignition coil
13 Spark plug
14 Pickup coil
15 Sidestand switch
16 Starting circuit cut-off relay
17 Starter switch
18 Engine stop switch
19 Handlebar switches (right)
20 Fuse (fan)
21 Thermo switch
22 Fan motor
23 Rear brake switch
24 Front brake switch
25 Flasher relay
26 Horn
27 Turn switch
28 Horn switch
29 Dimmer switch
30 Pass switch
31 Handlebar 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

COLOR CODE
B ........ Black O ....... Orange B/R . . . . . . Black/Red L/W . . . . . Blue/White Y/R . . . . . . Yellow/Red
Br . . . . . . . Brown P ........ Pink Br/W . . . . . Brown/White L/Y . . . . . . Blue/Yellow
Ch . . . . . . Chocolate R........ Red G/R . . . . . Green/Red R/B . . . . . . Red/Black
Dg . . . . . . Dark green Sb . . . . . . . Sky blue G/Y . . . . . . Green/Yellow R/W . . . . . Red/White
G ....... Green W ....... White L/B . . . . . . Blue/Black R/Y . . . . . . Red/Yellow
L ........ Blue Y ........ Yellow L/G . . . . . . Blue/Green W/G . . . . . White/Green