Yamaha YFM250BT 2004 Supplementary Service Manual
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Yamaha YFM250BT 2004 Supplementary Service Manual

Yamaha YFM250BT 2004 Supplementary Service Manual

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YFM250BT
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-41
4XE-F8197-13

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Summary of Contents for Yamaha YFM250BT 2004

  • Page 1 YFM250BT SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-41 4XE-F8197-13...
  • Page 2 YFM250XN SUPPLEMENTARY SERVICE MANUAL: LIT-11616-14-17 (4XE-F8197-11) YFM250XP SUPPLEMENTARY SERVICE MANUAL: LIT-11616-15-03 (4XE-F8197-12) YFM250BT SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. First edition, July 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 3: Important Information

    EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers 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 repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 4 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in 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.
  • Page 5 EBS00005 SYMBOLS The following symbols are not relevant to SPEC every machine. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis CARB DRIV...

  • Page 6: Table Of Contents

    CONTENTS SPECIFICATIONS .....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATIONS ............2 ENGINE ....................2 CHASSIS ....................3 ELECTRICAL ..................4 CABLE ROUTING ..................5 PERIODIC CHECKS AND ADJUSTMENTS ...........14 INTRODUCTION ..................14 PERIODIC MAINTENANCE/LUBRICATION ..........14 SEAT, CARRIERS, FENDERS AND FUEL TANK ........16 SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ..............16 REAR CARRIER AND REAR FENDER ..........18 FUEL TANK ..................20...
  • Page 7 ELECTRICAL ....................37 ELECTRICAL COMPONENTS ..............37 YFM250BT WIRING DIAGRAM...

  • Page 8: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 1P01 Dimensions: Overall length 1,916 mm (75.4 in) Overall width 1,038 mm (40.9 in) Overall height 1,118 mm (44.0 in) Seat height 772 mm (30.4 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clearance 150 mm (5.9 in) Minimum turning radius...

  • Page 9: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Carburetor: I. D. mark 1P01 00 ---- Main jet (M.J) #93.8 ---- Main air jet (M.A.J) ---- Jet needle (J.N) 5EP17-2 ---- Needle jet (N.J) P-2M (826) ---- Pilot air jet (P.A.J.1) ---- Pilot air jet...

  • Page 10: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Brake lever and brake pedal: Front brake lever free play (at lever pivot) 0 mm (0 in) ---- Rear brake lever free play (at lever pivot) 5 ~ 7 mm (0.20 ~ 0.28 in) ---- Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in)

  • Page 11: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manufacturer F4T259/MITSUBISHI ---- 189 ~ 231 Ω at 20 °C (68 °F)/ Pickup coil resistance/color ---- White/Green – White/Red 0.065 ~ 0.080 Ω at 20 °C (68 °F)/ Rotor rotation direction detection coil resis- ---- tance/color Red –...

  • Page 12: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake light switch lead 0 Fuel tank breather hose 2 Starter cable A Handlebar switch assembly lead 3 Rear brake cable B Rectifier/regulator 4 Lower bracket cable guide 5 Front brake hose 6 Front brake light switch lead 7 Throttle cable 8 Reverse indicator light 9 Neutral indicator light...
  • Page 13 SPEC CABLE ROUTING È Do not route the handlebar switch assembly Ì Fasten the handlebar switch assembly lead, rear lead through the lower bracket cable guide. brake light switch lead, and starter cable to the É Fasten the front brake light switch lead to the handlebar with the plastic bands.
  • Page 14 SPEC CABLE ROUTING 1 Headlight lead A Negative battery lead 2 Lower bracket cable guide B A.C. magneto lead 3 Indicator light lead C Starter cable 4 Main switch lead D Rear brake cable 5 Indicator light E Select lever control cable 6 Main switch F Throttle cable 7 Fuel tank breather hose...
  • Page 15 SPEC CABLE ROUTING È Fasten the headlight lead to the front bumper Ì Route the carburetor overflow hose between the with the plastic band. engine and upper rear engine mount and then É Route the main switch lead and indicator light between the engine and swingarm.
  • Page 16 SPEC CABLE ROUTING 1 A.C. magneto lead couplers A Rear brake light switch lead 2 Wire harness B Rear brake cable 3 Starter motor lead C A.C. magneto lead 4 Tail/brake light lead 5 Battery breather hose È Make sure that the starter motor lead has no 6 Final gear case breather hose slack.
  • Page 17 SPEC CABLE ROUTING Ë Fasten the negative battery lead with the plastic Ñ 100 mm (4.0 in) Ò Route the rear brake breather hose through the clamp. Ì Fasten the tail/brake light lead and negative bat- cable guide. Ó Route the final gear case breather hose through tery lead with the plastic locking tie.
  • Page 18 SPEC CABLE ROUTING 1 Battery breather hose È Fasten the battery breather hose to the frame 2 Rear brake cable with the plastic band. 3 Select lever control cable É Fasten the starter motor lead to the frame with 4 Spark plug cap the plastic clamps.
  • Page 19 SPEC CABLE ROUTING 1 Positive battery lead È Fasten the wire harness, starter motor lead, and 2 Battery select lever control cable to the frame with the 3 Tail/brake light lead plastic band. 4 Negative battery lead É 5 mm (0.2 in) 5 CDI unit Ê...
  • Page 20 SPEC CABLE ROUTING 1 Headlight leads É Make sure the starter motor lead and wire har- 2 Wire harness ness do not contact the ignition coil. 3 Starter motor lead Ê 50 mm (2.0 in) 4 Rear brake cable Ë Route the throttle cable, select lever control 5 Throttle cable cable and rear brake cable through the cable 6 Starter cable...

  • Page 21: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 22 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. * It is recommended that these items be serviced by a Yamaha dealer. NOTE: • Recommended brake fluid: DOT 4 • Brake fluid replacement: 1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required.

  • Page 23: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 24 SEAT, CARRIERS, FENDERS AND FUEL TANK 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft •...

  • Page 25: Rear Carrier And Rear Fender

    SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND REAR FENDER 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 26 SEAT, CARRIERS, FENDERS AND FUEL TANK 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 27: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat and fuel tank cover Refer to “SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT...

  • Page 28: Footrest Boards

    FOOTREST BOARDS FOOTREST BOARDS 7 Nm (0.7 m kg, 5.1 ft • • 65 Nm (6.5 m kg, 47 ft 7 Nm (0.7 m kg, 5.1 ft • • • • (12) (12) 34 Nm (3.4 m kg, 24 ft •...

  • Page 29: Engine

    ADJUSTING THE STARTER CABLE ENGINE ADJUSTING THE STARTER CABLE 1. Adjust: M MMM M MMM M MMM M MMM M MMM a. Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable.

  • Page 30: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1. Remove: • right footrest board Refer to “FOOTREST BOARDS”. 2. Check: • brake pedal height a •...
  • Page 31 ADJUSTING THE REAR BRAKE d. Loosen the locknut 3 and fully screw in the brake lever cable adjusting bolt 4. e. Fully loosen the brake lever cable adjusting nut 5. f. Turn the brake pedal adjusting nut 6 until the brake pedal free play is within the speci- fied limits.

  • Page 32: Adjusting The Select Lever Control Cable

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 FORWARD 2 REVERSE 3 Control cable 4 Select lever shift rod WARNING Before moving the select lever, bring the machine to a complete stop and return the throttle lever to its closed position.

  • Page 33: Adjusting The Headlight Beam

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ADJUSTING THE HEADLIGHT BEAM/ REPLACING A HEADLIGHT BULB e. Check that locknuts 2 are tightened cor- rectly. f. If the operation of the select lever is incor- rect, adjust the select lever control cable 3 with the adjuster 4.
  • Page 34 REPLACING A HEADLIGHT BULB 2. Remove: • bulb holder 1 • bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb by unhooking the headlight bulb holder tabs 2. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot.

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