Yamaha YFM250XN 2001 Supplementary Service Manual
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Yamaha YFM250XN 2001 Supplementary Service Manual

Yamaha YFM250XN 2001 Supplementary Service Manual

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2001
YFM250XN
4XE3-AE2
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM250XN 2001

  • Page 1 2001 YFM250XN 4XE3-AE2 SUPPLEMENTARY SERVICE MANUAL...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM250XN 2001. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM250XL ’99 SERVICE MANUAL: 4XE3-AE1...
  • Page 3 EB001000 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 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installation, removal, dis- assembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order.
  • Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject SPEC INFO of each chapter. 1 General information 2 Specifications INSP 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 MACHINE IDENTIFICATION ..............1 VEHICLE IDENTIFICATION NUMBER ..........1 MODEL LABEL ................. 1 SPECIFICATIONS ................... 2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............3 ENGINE .................... 3 CHASSIS ..................4 ELECTRICAL ................... 6 CABLE ROUTING ..................7 PERIODIC INSPECTIONS AND ADJUSTMENTS ........
  • Page 7 ELECTRICAL ....................39 ELECTRICAL COMPONENTS .............. 39 IGNITION SYSTEM ................40 CIRCUIT DIAGRAM ............... 40 TROUBLESHOOTING ..............41 ELECTRIC STARTING SYSTEM ............46 CIRCUIT DIAGRAM ............... 46 STARTING CIRCUIT OPERATION ..........47 TROUBLESHOOTING ..............48 YFM250XN 2001 WIRING DIAGRAM...

  • Page 8: General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XEC (CDN) 4XED (Europe and Oceania) Dimensions: Overall length 1,940 mm (76.4 in) Overall width 1,005 mm (39.6 in) Overall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clearance...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Shifter: Shifter type Shift drum and guide bar ---- Guide bar bending limit ---- 0.8 mm (0.032 in) Carburetor: I. D. mark 4XEC 22 ---- Main jet (M.J) ---- Main air jet (M.A.J) ---- Jet needle...

  • Page 11: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Rear suspension: Shock absorber travel 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- Spring rate 39 N/mm (3.9 kg/mm, 222.69 lb/in)/ ---- 0 ~ 85 mm (0 ~ 3.35 in) Optional spring...
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Parts Part to be tightened Thread size Q’ty Remarks name m·kg ft·lb M10 × 1.25 Front panel wheel and wheel hub M14 × 1.5 Wheel hub and steering knuckle M8 × 1.25 Steering knuckle and brake caliper Bolt M8 ×...

  • Page 13: 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 270 ~ 330 Ω at 20˚C (68˚F)/ Charging/rotor rotation direction detection ---- coil resistance/color Red/White/Blue C.D.I.

  • Page 14: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Å Do not route the handlebar Ç Fasten the handlebar switch 1 Rear brake lever switch lead 2 Rear brake cable switch assembly lead through assembly lead and rear brake 3 Cable guide the lower bracket cable guide. lever switch lead to the handle- ı...
  • Page 15 SPEC CABLE ROUTING 1 Cable guide B Rear brake breather hose 2 Main switch C Carburetor air vent hose 3 Fuel tank breather hose D CDI magneto lead 4 Taillight Å Route the main switch lead and indicator light lead to the side of 5 Final gear case breather hose 6 Carburetor overflow hose the cable guide.
  • Page 16 SPEC CABLE ROUTING Ç Make sure that the starter motor lead is not Ó Fasten the taillight lead to the box with the plas- slacked. tic clamp. Î Fasten the starter motor lead and wire harness È Route the carburetor overflow hose between the to the frame with the plastic band.
  • Page 17 SPEC CABLE ROUTING Ò Fasten the starter motor lead and wire harness ∏ Route the final gear case breather hose through to the frame with the plastic clamp. the cable guide. ˜ Route the rear brake cable and rear brake Œ...
  • Page 18 SPEC CABLE ROUTING Å Make sure that the battery breather hose is not kinked or bent. 1 Battery breather hose ı Route the rear brake cable through the cable guide on the cyl- 2 Spark plug cap 3 Ignition coil inder.
  • Page 19 SPEC CABLE ROUTING Å Fasten the wire harness to the frame with the plastic clamps. 1 Wire harness ı Make sure the starter motor lead and wire harness do not contact the 2 Starter motor lead 3 Rear brake cable ignition coil.
  • Page 20 SPEC CABLE ROUTING Ï Fasten the battery breather hose to the rear Ô Make sure that the grommet is installed with the fender with the plastic clamp and then insert the mark facing forward. clamp into the hole in the rear fender. Route the taillight lead through the lead holders Ì...

  • Page 21: Periodic Inspections And Adjustments

    INTRODUCTION/ INSP PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
  • Page 22 • Check that the breather hose is working prop- Battery* erly. • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. Lithium soap base grease. WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 23: Chassis

    FRONT BRAKE FLUID LEVEL INSPECTION/ INSP FRONT BRAKE PAD INSPECTION CHASSIS FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. NOTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal.

  • Page 24: Brake Hose Inspection

    BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1.Remove: Front carrier Front fender Refer to “FENDER AND FUEL TANK”. 2.Inspect: Brake hoses 1 Cracks/wear/damage → Replace. 3.Check: Brake hose clamp Loosen → Tighten. 4.Hold the machine in an upright position and apply the front or rear brake.
  • Page 25 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1.Bleed: Brake system ********************************************* Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2.

  • Page 26: Chassis

    CHAS FRONT WHEEL CHASSIS FRONT WHEEL TIRE AIR PRESSURE Cold Tire Pressure Front Rear 1 Wheel cap 7 Spacer 20 kPa 25 kPa 2 Cotter pin 8 Oil seal Standard (0.20 kg/cm (0.25 kg/cm 3 Axle nut 9 Bearing 2.9 psi) 3.6 psi) 4 Plain washer 0 Front wheel hub...

  • Page 27: Removal

    CHAS FRONT WHEEL REMOVAL 1.Place the machine on a level surface. 2.Loosen: Nuts (front wheel) Apply the front brake. 3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: Nuts 1 (front wheel) Front wheel 2 5.Remove: Wheel cap...

  • Page 28: Inspection

    CHAS FRONT WHEEL 8.Remove: Front brake disc 1 INSPECTION 1.Inspect: Wheel hub 1 Cracks/damage → Replace. – 21 –...

  • Page 29: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE 1 Brake master cylinder reservoir cap 0 Brake disc 2 Brake master cylinder reservoir diaphragm holder A Caliper bleed screw 3 Brake master cylinder reservoir diaphragm B Retaining bolt 4 Brake master cylinder C Brake caliper 5 Brake master cylinder kit D Pad shim 6 Copper washer...

  • Page 30: Brake Pad Replacement

    CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: Disassemble components unless abso- lutely necessary. Use solvents on internal brake compo- nents. Use contaminated brake fluid for clean- ing. Use only clean brake fluid. Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur.
  • Page 31 CHAS FRONT BRAKE 5.Remove: Brake pads 1 (with pad shim 2) Pad spring 3 NOTE: When pad replacement is required, also replace the pad spring and shim. Replace the pads as a set if either is found to be worn to the wear limit a. Wear limit a: 1.0 mm (0.04 in) 6.Install:...

  • Page 32: Caliper Disassembly

    CHAS FRONT BRAKE 7.Install: Retaining bolts Front brake caliper Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft • lb) 8.Install: Front wheel 9.Inspect: Brake fluid level Refer to “FRONT BRAKE FLUID LEVEL INSPECTION”.

  • Page 33: Master Cylinder Disassembly

    CHAS FRONT BRAKE 4.Remove: Union bolt 1 Copper washers 2 Brake hose 3 NOTE: Place the open end of the hose into a con- tainer and pump the oil fluid out carefully. 5.Remove: Caliper body 1 Caliper bracket 2 NOTE: Before removing the caliper body from the bracket, disconnect the dust boot from the guide shaft on the bracket.

  • Page 34: Inspection And Repair

    CHAS FRONT BRAKE 1.Remove: Brake lever 1 Union bolt 2 Copper washers 3 Brake hose 4 NOTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid. 2.Remove: Brake master cylinder reservoir cap 1 Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 35 CHAS FRONT BRAKE 1.Inspect: Caliper piston 1 → Scratches/rust/wear Replace caliper assembly. Caliper cylinder 2 Wear/scratches → Replace caliper assem- bly. Caliper body 3 Cracks/damage → Replace. Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seal whenever the cali- per is disassembled.
  • Page 36 CHAS FRONT BRAKE 6.Measure: Brake pads (thickness) a Out of specification → Replace. NOTE: When pad replacement is required, also replace the pad spring and shims. Replace the pads as a set if either is found to be worn to the wear limit a. Wear limit a: 1.0 mm (0.04 in) 7.Inspect:...

  • Page 37: Caliper Assembly

    CHAS FRONT BRAKE NOTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. Bolt (brake disc): 16 Nm (1.6 m • kg, 12 ft • lb) CALIPER ASSEMBLY WARNING All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed.
  • Page 38 CHAS FRONT BRAKE 3.Install: Brake caliper 1 (temporarily) Copper washers 2 Brake hose 3 Union bolt 4 Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) CAUTION: When installing the brake hose on the cali- per, make sure that the brake pipe touches the projection a on the brake caliper.
  • Page 39 CHAS FRONT BRAKE 6.Fill: Reservoir tank Recommended brake fluid: DOT 4 NOTE: If DOT 4 is not available, 3 can be used. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

  • Page 40: Master Cylinder Assembly

    CHAS FRONT BRAKE MASTER CYLINDER ASSEMBLY WARNING All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Recommended brake fluid: DOT 4 Replace the piston seals and dust seals whenever a brake master cylinder is dis- assembled.
  • Page 41 CHAS FRONT BRAKE 3.Install: Copper washers Brake hose Union bolt Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) NOTE: Tighten the union bolt while holding the brake hose as shown. Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.) by turning the handlebar left and right, and correct if necessary.
  • Page 42 CHAS FRONT BRAKE Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor per- formance. Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

  • Page 43: Rear Wheels/Rear Brake And Rear Axle

    CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut × TIRE SIZE: AT22 10-10 TIRE WEAR LIMIT: 2.0 mm (0.08 in) × C RIM SIZE: 8 10AT RIM RUNOUT LIMIT:...

  • Page 44: Front Shock Absorber And Front Arm

    CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing – 37 –...

  • Page 45: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 8 Swingarm 2 Thrust cover 9 Rubber boot 3 Locknut 0 Final gear case protector 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing SWINGARM FREE PLAY LIMIT: End: 1.0 mm (0.04 in) Side: 1.0 mm (0.04 in)

  • Page 46: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Reverse indicator light 8 Rectifier/regulator E Headlight 2 Neutral indicator light 9 CDI unit F Ignition coil 3 Main switch 0 Taillight 4 Rear brake lever switch A Battery 5 Handlebar switch B Starting circuit cut-off relay 6 Fuses C Reverse switch...

  • Page 47: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM – 40 –...

  • Page 48: Troubleshooting

    – ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 8.Main switch 1.Fuse 9.Pickup coil resistance 2.Battery 10. Charging/rotor rotation direction detection 3.Spark plug coil resistance 4.Ignition spark gap 11. Wiring connection 5.Spark plug cap resistance (the entire ignition system) 6.Ignition coil resistance...
  • Page 49 – ELEC IGNITION SYSTEM C0NTINUITY INCORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) CORRECT Repair or replace the spark plug. for CDN 4.Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown.
  • Page 50 – ELEC IGNITION SYSTEM 5.Spark plug cap resistance Remove the spark plug cap. Connect the pocket tester (Ω × 1 k) to the spark plug cap. OUT OF SPECIFICATION Check that the spark plug cap has the specified resistance. Spark plug cap resistance: Replace the spark plug cap.
  • Page 51 – ELEC IGNITION SYSTEM Check that the secondary coil has the specified resistance. OUT OF SPECIFICATION Secondary coil resistance: 6.3 ~ 9.5 kΩ at 20 ˚C (68˚F) BOTH MEET SPECIFICATION Replace the ignition coil. INCORRECT 7.Engine stop switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left).
  • Page 52 – ELEC IGNITION SYSTEM C0NTINUITY 10. Charging/rotor rotation direction detection coil resistance Disconnect the CDI magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the source coil terminal. Tester (+) lead → Red terminal 1 Tester (–) lead →...

  • Page 53: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM – 46 –...

  • Page 54: Starting Circuit Operation

    – ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neu- tral switch. If the main switch is on and engine stop switch is in the RUN position, the starter motor can be operated only if: The transmission is in neutral (the neutral...

  • Page 55: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 7.Engine stop switch 1.Fuse 8.Neutral switch 2.Battery 9.Rear brake lever switch 3.Starter motor 10. Start switch 4.Starting circuit cut-off relay 11. Wiring connection 5.Starter relay (the entire starting system) 6.Main switch NOTE:...
  • Page 56 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY WARNING 3.Starter motor A wire that is used as a jumper lead must Connect the battery positive terminal 1 have the equivalent capacity or more as and starter motor lead 2 using a jumper that of the battery lead, otherwise the lead 3 jumper lead may burn.
  • Page 57 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay Remove the starter relay from the wire har- ness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals. L/W L/B Battery (+) terminal → Blue/White terminal 1 NO CONTINUITY Battery (–) terminal →...
  • Page 58 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 9.Rear brake lever switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace the rear brake lever switch. INCORRECT 10.Start switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left). EB803028 POOR CONNECTION 11.Wiring connection Check the connections of the entire starting system.

  • Page 59: Yfm250Xn 2001 Wiring Diagram

    YFM250XN 2001 WIRING DIAGRAM 1 CDI magneto 2 Rectifier/regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut-off relay W/L W/R 9 CDI unit 0 Ignition coil A Spark plug (BLACK) B Neutral indicator light...

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