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Yamaha YP250 5GM2-AE1 2000 Service Manual

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  • Page 3 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.

  • Page 4: Important Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha/MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yama- ha/MBK scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair.

  • Page 5: How To Use This Manual

    YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 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.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as SPEC thumb tabs to indicate the chapter’s number INFO and content. 1 General information 2 Specifications INSP 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis COOL CARB...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION SCOOTER IDENTIFICATION ....... . VEHICLE IDENTIFICATION NUMBER (for E) .
  • Page 8 V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ..CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) ..........V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE .
  • Page 9 FUEL PUMP SYSTEM ........CIRCUT DIAGRAM .

  • Page 11: General Information

    SCOOTER IDENTIFICATION INFO YP100000 GENERAL INFORMATION SCOOTER IDENTIFICATION YP100010 VEHICLE IDENTIFICATION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame. NOTE: The vehicle identification number is used to identify your scooter and may be used to regis- ter your scooter with the licensing authority in your country.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 13: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YP250 Model code: 5GM2, 5GM3 Dimensions: Overall length 2,140 mm Overall width ,780 mm Overall height 1,350 mm Seat height ,730 mm Wheelbase 1,535 mm Minimum ground clearance ,120 mm Minimum turning radius 2,700 mm Basic weight: With oil and full fuel tank...
  • Page 14 SPEC GENERAL SPECIFICATIONS Model YP250 Carburetor: Type/quantity Y28V-1E/1 Manufacturer TEIKEI Spark plug: Type DR8EA Manufacturer 0.6 X 0.7 mm Spark plug gap Clutch type: Dry, centrifugal automatic Transmission: Primary reduction system Helical gear Primary reduction ratio 40/15 (2.666) Secondary reduction system Helical gear Secondary reduction ratio 38/15 (2.533)
  • Page 15 SPEC GENERAL SPECIFICATIONS Model YP250 Brake: Front brake type Single disc brake operation Right hand operation Rear brake type Single disc brake operation Left hand operation Suspension: Front suspension Telescopic fork Rear suspension Unit swing Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Oil damper...

  • Page 16: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.05 mm Cam chain: Cam chain type/No. of links DID SC:A-0404A SDH/104 Cam chain adjustment method Automatic Automatic centrifugal clutch: Clutch shoe thickness 3.3 mm 2.0 mm Clutch housing inside diameter 135 mm 135.5 mm...
  • Page 17 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Radiator: Type Cooling fin with electric fan Width/height/thickness 140/238/24 mm 110 X 140 kPa (1.1 X 1.4 kg/cm Radiator cap opening pressure 1.1 X 1.4 bar) Radiator capacity 1.4 L Reservoir tank capacity 0.4 L...

  • Page 18: Tightning Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size m:kg Oil check bolt — Exhaust pipe stud bolt — Air induction system pipe stud bolt — Spark plug — Cam sprocket cover Bolt Cylinder head and cylinder Cylinder head and cylinder...
  • Page 19 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size m:kg Cover (oil pump) Bolt Timing check plug Plug One way clutch — Clutch housing Bolt Grease stopper (Primary sheave) — Primary fixed sheave —...

  • Page 20: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 100 mm Fork spring free length 268 mm 263 mm Spring rate (K1) 4.82 N/mm (0.49 kg/mm) Spring rate (K2) 8.84 N/mm (0.9 kg/mm) Stroke (K1) 40 mm Stroke (K2) 100 mm...

  • Page 21: Tightning Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size Remarks m:kg Frame and engine bracket 1.25 Engine bracket, compression rod and engine 1.25 Compression rod and frame 1.25 Sidestand (bolt and frame) 1.25 Sidestand (bolt and nut) 1.25 Rear footrest bracket Swingarm...
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS NOTE: 1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 m:kg) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 m:kg) by using the torque wrench, then finger tighten the ring nut (center).

  • Page 23: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard limit Ignition timing: Ignition timing (B.T.D.C.) 10_ at 1,400 r/min Advanced timing (B.T.D.C.) 32_ at 5,000 r/min Advanced type Electrical type T.C.I.: 231 Ω at 20_C/ Pickup coil resistance/color Yellow – Blue T.C.I. unit model/manufacturer J4T117/MITSUBISHI Ignition coil: Model/manufacturer...
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Item Standard limit Starter relay: Model/manufacturer MS5F-421 /JIDECO Amperage rating 180 A 4.2 X 4.6 Ω at 20_C Coil winding resistance Horn: Model/manufacturer YF-12/NIKKO Maximum amperage Flasher/hazard relay Type Full transistor type Model/manufacturer FE246BH/DENSO 75 X 95 cycle/min Flasher frequency Fuel gage: Model/manufacturer...

  • Page 25: Lubrication Points And Grade Of Lubricant

    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 Yamaha bond No. 1215 Crankcase breather plug Stator grommet Yamaha bond No. 1215 Suction pipe...

  • Page 26: Chassis

    SPEC LUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Symbol 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...

  • Page 27: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Speed sensor Frame A Route the brake hose assembly Front brake hose Seat lock cable through the guide on the handle- Throttle cable Footrest board bar. Relay Handlebar B Fasten the front brake hose, Brake hose assembly Handlebar under cover brake hose assembly throttle Thermo switch lead...
  • Page 28 SPEC CABLE ROUTING 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.
  • Page 29 SPEC CABLE ROUTING U More than 10 mm. A’ Fasten the left handlebar switch V Route the seat lock cable lead and rear brake switch lead through the footrest board. to the handlebar with a plastic W Route the left handlebar switch locking tie, cut the end of locking lead through front side of the tie at 5 mm or less.
  • Page 30 SPEC CABLE ROUTING Box light Engine bracket D Fasten the wireharness to the Rectifire/ regulator Rear brake hose frame with a plastic locking tie. Air induction system air filter A. C. magneto lead E Clamp the rear brake hose. Wireharness Starter motor lead F Clamp the wireharness to the Battery negative lead...
  • Page 31 SPEC CABLE ROUTING H Fasten the wireharness to the M Clamp the speed sensor lead to Q Clamp the speed sensor lead frame with a band and the band the front brake hose. Position the and that caliper tightning bolt of end on inside of the frame.
  • Page 32 SPEC CABLE ROUTING V Fix the turn signal relay on the footboard. W Fasten the starter motor lead and engine ground lead on the frame with the plastic clamp. X Route the parking cable and rear brake hose through the guide. Y Clamp the A.
  • Page 33 SPEC CABLE ROUTING Air filter case Auto choke lead D Fasten the wireharness on the Seat lock Brake hose assembly frome with a band and the end of Tensioner A. C. magneto lead band match the tank rail pipe Crankcase breather hose Starter motor lead angle.
  • Page 34 SPEC CABLE ROUTING J Route the thermo unit lead through the shortest distance and dont roll another lead but loose the thermounit lead. K Route the black seat lock cable outer through right side of frame. L Fasten the A. C. magneto lead starter motor lead and engine ground lead to the clamp on the engine bracket.
  • Page 35 SPEC CABLE ROUTING Front right turn signal light Panel Relay Auxiliary light lead Front left turn signal light Front brake hose assembly A Don’t loosen the break hose Horn lead (Hi) when fix the break hose. Horn (Hi) B Route the speed sensor lead Throttle cable through the brake hose holder.

  • Page 36: Periodic Inspections And Adjustments

    INTRODUCTION/ INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 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 vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa- tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 37 27 * nents : Adjust headlight beam if necessary. Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU02970 NOTE: The annual checks must be performed once a year unless a 10,000 km or 20,000 km maintenance was performed in the same year.

  • Page 38: Cover And Panel

    INSP COVER AND PANEL COVER AND PANEL SIDE COVER, SIDE COVER MOLE, PASSENGER SEAT 16 Nm (1.6 m:kg) 8 Nm (0.8 m:kg) Order Job name/Part name Q’ty Remarks Side cover, Side cover panel and Remove the parts in order. passenger seat removal Passenger seat Standing handle Side cover mole 3...

  • Page 39: Rider Seat And Main Box

    INSP COVER AND PANEL RIDER SEAT AND MAIN BOX 13 Nm (1.3 m:kg) 16 Nm (1.6 m:kg) 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks Rider seat and main box removal Remove the parts in order Fuel tank cap Cover Rider seat Side cover 3...
  • Page 40 INSP COVER AND PANEL RIDER SEAT AND MAIN BOX 13 Nm (1.3 m:kg) 16 Nm (1.6 m:kg) 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks NOTE: Bracket Coupler (Main box light read) Disconnect the couplers. Seat lock Main box Reverse the removal procedure for installation.

  • Page 41: Side Cover Mole And Footrest Board

    INSP COVER AND PANEL SIDE COVER MOLE AND FOOTREST BOARD 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks Side panel and footrest board removal Remove the parts in order. Mat (footrest board) (left/right) Cover (footrest board) (left/right) Cover 2 Battery negative (–) lead Battery positive (+) lead Battery...

  • Page 42: Cowling, Handle Cover, Meter Assembly

    INSP COVER AND PANEL COWLING, HANDLE COVER, METER ASSEMBLY 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks Cowling, handle cover, meter Remove the parts in order. assembly removal Upper cover Wind screen Inner panel Meter assembly NOTE: Coupler (Meter lead) Disconnect the couplers.

  • Page 43: Legshield And Fuel Tank

    INSP COVER AND PANEL LEGSHIELD AND FUEL TANK 10 Nm (1.0 m:kg) 7 Nm (0.7 m:kg) 16 Nm (1.6 m:kg) 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks Legshield and fuel tank removal Remove the parts in order. Legshield Inner fender Front under braket...

  • Page 44: Engine

    INSP ENGINE OIL REPLACEMENT ENGINE ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and place an oil pan un- der the engine. 3. Remove: : Drain plug 1 : Gasket Drain the crankcase of its oil.

  • Page 45: Crankcase Filter Cleaning

    INSP CRANKCASE FILTER CLEANING CRANKCASE FILTER CLEANING 1. Remove: : Crankcase filter cover 1 : Crankcase filter cover seal : Crankcase filter element NOTE: When installing the element in its case, besure its sealing surface matches the sealing surface of the case so there is no air leak. 2.

  • Page 46: Air Induction System Inspection

    INSP AIR INDUCTION SYSTEM INSPECTION AIR INDUCTION SYSTEM INSPECTION 1. Remove: : Side cover mole 3 : Passenger seat : Standing handle : Side cover 2 Refer to “COVER AND PANEL” section. 2. Inspect: : Hose 3 1 : Air filter case 2 : Hose 2 3 : Air induction system assembly 4 : Vacuum hose 5...

  • Page 47: Coolant Replacement

    INSP COOLANT REPLACEMENT YP303180 COOLANT REPLACEMENT 1. Remove: : Side cover mole Refer to the “COVERS AND PANEL” section. 2. Remove: : Hose 1 (reservoir tank) Drain the reservoir tank of its coolant. 3. Remove: : Drain bolt 1 : Rivet 2 : Cover 3 : Radiator cap Open the front trunk, remove the cover, slow-...
  • Page 48 INSP COOLANT REPLACEMENT 5. Install: : Gasket 1 : Drain bolt 2 10 Nm (1.0 m:kg) 6. Loosen: : Screw 1 (carburetor bleed) 7. Connect: : Hose (reservoir tank) 8. Fill: : Radiator (to specified level 1 ) Fill the coolant slowly, until the coolant comes out from the carburetor drain pipe.
  • Page 49 INSP COOLANT REPLACEMENT WARNING : If coolant splashes in your eyes: thoroughly wash your eyes with water and consult a doctor. : If coolant splashes on your clothes: quickly wash it away with water and then with soap and water. : If coolant is swallowed: quickly make the person who has swal- lowed it vomit and then take him to a doc-...

  • Page 50: Electrical

    INSP HEADLIGHT BEAM ADJUSTMENT ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Adjust : Headlight beam (vertical) Turn the adjuster 1 in or out. Turning in ! Headlight beam moves lower. Turning out ! Headlight beam moves higher. 2. Adjust : Headlight beam (horizontal) Turn the adjuster 1 in or out.

  • Page 51: Engine Removal

    ENGINE REMOVAL EB400000 ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS, CABLE, REAR BRAKE 10 Nm (1.0 m:kg) 7 Nm (0.7 m:kg) Order Job name/Part name Q’ty Remarks Wireharness, cables and rear brake Remove the parts in order. removal Side cover Main box Refer to “COVER AND PANEL”...
  • Page 52 ENGINE REMOVAL 10 Nm (1.0 m:kg) 40 Nm (4.0 m:kg) Order Job name/Part name Q’ty Remarks Caliper assembly Brake hose 1 Air induction system hose Reverse the removal procedure for installation.

  • Page 53: Hoses, Air Filter Case, Engine Mounting Bolt And Engine

    ENGINE REMOVAL HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE 20 Nm ( 2.0 m:kg) 32 Nm (3.2 m:kg) 64 Nm (6.4 m:kg) Order Job name/Part name Q’ty Remarks Hoses, air filter case, engine mounting Remove the parts in order. bolt and engine removal Crankcase breather hose Inlet hose (water pump)

  • Page 54: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD 10 Nm (1.0 m:kg) 12 Nm (1.2 m:kg) 22 Nm (2.2 m:kg) 8 Nm (0.8 m:kg) 10 Nm (1.0 m:kg) 10 Nm (1.0 m:kg) Order Job name/Part name Q’ty Remarks Cylinder head removal Remove the parts in the order. Drain the coolant.
  • Page 55 CYLINDER HEAD 10 Nm (1.0 m:kg) 12 Nm (1.2 m:kg) 22 Nm (2.2 m:kg) 8 Nm (0.8 m:kg) 10 Nm (1.0 m:kg) 10 Nm (1.0 m:kg) Order Job name/Part name Q’ty Remarks 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...

  • Page 56: Belt, Clutch And Secondary/Primary Sheave

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) 10 Nm (1.0 m:kg) 10 Nm (1.0 m:kg) Order Job name/Part name Q’ty Remarks Crankcase filter cover and crankcase Remove the parts in order cover (left) removal Side cover panel Refer “COVER AND PANEL”...

  • Page 57: Belt, Clutch And Secondary/Primary Sheave

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE *Shell BT grease No. 3 (90890-69927) 3 Nm (0.3 m:kg) 22 Nm (2.2 m:kg) 60 Nm (6.0 m:kg) 60 Nm (6.0 m:kg) Order Job name/Part name Q’ty Remarks V-belt, clutch and secondary/ Remove the parts in order.
  • Page 58 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE *Shell BT grease No. 3 (90890-69927) 3 Nm (0.3 m:kg) 22 Nm (2.2 m:kg) 60 Nm (6.0 m:kg) 60 Nm (6.0 m:kg) Order Job name/Part name Q’ty Remarks Weight Refer to “PRIMARY SHEAVE Slider ASSEMBLY” section. Spacer Oil seal Reverse the removal procedure for...

  • Page 59: Transmission

    TRANSMISSION TRANSMISSION 16 Nm (1.6 m:kg) Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in order. Rear wheel Refer to “REAR WHEEL/REAR BRAKE” section. Crankcase cover (left) Refer to “V-BELT, CLUTCH, SECONDARY/PRIMARY SHEAVE” section. Drain the transmission oil. Refer to “TRANSMISSION OIL REPLACEMENT”...
  • Page 60 TRANSMISSION 16 Nm (1.6 m:kg) Order Job name/Part name Q’ty Remarks Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Plain washer Reverse the removal procedure for installation.

  • Page 61: Air Induction System

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

  • Page 62: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE REMOVAL 1. Remove : Crankcase 2 1 NOTE: : Remove the crankshaft assembly with the crankcase separating tool 2 . : Make sure that the crankcase separating tool is centered over the crankshaft assembly. Crankshaft separating tool 90890-01135 CRANKSHAFT REMOVAL...
  • Page 63 2. Clean all the gascket mating surface and crankcase surface thoroughly. 3. Apply: : sealant (onto the left crankcase mating surface) Yamaha bond No.1215 4. Install: : Timing chain 1 NOTE: Install the timing chain not to be seen through the crankshaft hole a on the crankcase (left) 2 .

  • Page 64: Cooling System

    COOL RADIATOR YP500000 COOLING SYSTEM RADIATOR 23 Nm (2.3 m:kg) 23 Nm (2.3 m:kg) Order Job name/Part name Q’ty Remarks Radiator removal Remove the parts in order. Drain the coolant Refer to “COOLANT REPLACEMENT” section. Fuel tank Refer to “COVER AND PANEL” section. Footrest board, under cover Cowling body, leg shield Fan motor leads...

  • Page 65: Carburetor

    CARB CARBURETOR EB600000 CARBURETOR CARBURETOR 10 Nm (1.0 m:kg) Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in order. Side panel Refer to “COVER AND PANEL” section. Main box Drain the coolant Refer to “COOLANT REPLACEMENT” section. Auto choke lead coupler Throttle position sensor lead Inlet/Outlet hose (carburetor)

  • Page 66: Carburetor Disassembly

    CARB CARBURETOR CARBURETOR DISASSEMBLY Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in order. Auto choke unit Throttle stop screw set Pilot screw set Cover/Diaphragm spring Piston valve Jet needle assembly Coasting enricher Accererating pump Refer to “CARBURETOR ASSEMBLY” section.
  • Page 67 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Float Needle valve Refer to “CARBURETOR ASSEMBLY” Main jet section. Pilot jet Main nozzle Throttle position sensor Reverse the disassembly procedure for assembly.

  • Page 68: Throttle Position Sensor Adjustment

    CARB CARBURETOR THROTTLE POSITION SENSOR ADJUST- MENT NOTE: : Before adjusting the throttle position sensor the engine idling speed should be properly ad- justed. : When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer, Refer to the ad- justment procedure below.

  • Page 69: Chassis

    CHAS FRONT WHEEL 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 Q’ty Remarks Speed sensor and sensor rotor Remove the parts in order. removal Cowling body Refer to “COVER AND PANEL” section. Speed sensor Brake caliper Axle nut...

  • Page 70: Speed Sensor And The Sensor Rotor

    CHAS FRONT WHEEL 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.

  • Page 71: Speed Sensor Assembly

    CHAS FRONT WHEEL 2. Measure: : Speed sensor resistance Connect the pocket tester (Ω 1) to the ter- minal of speed sensor connector. Tester’s positive (+) lead ! Terminal 1 Tester’s negative (–) lead ! Terminal 2 Regulated resistance: 1.19 to 2.21 kΩ at 20_C Out of specification ! Replace 3.
  • Page 72 CHAS FRONT WHEEL 2. Install: : Sensor housing 3. Install: : Front wheel : Wheel axle : Axle nut 70 Nm (7.0 m:kg) NOTE: Align the slot of sensor housing with the projec- tion part of front fork, then assemble them. CAUTION: Install after checking if foreign materials are mixed in the wheel hub.
  • Page 73 CHAS FRONT WHEEL 5. Install: : Speed sensor lead 1...

  • Page 74: Rear Wheel

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

  • Page 75: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.0 m:kg) 20 Nm (2.0 m:kg) 40 Nm (4.0 m:kg) 135 Nm (13.5 m:kg) 35 Nm (3.5 m:kg) 53 Nm (5.3 m:kg) Order Job name/Part name Q’ty Remarks Rear shock absorber and swingarm Remove the parts in order.

  • Page 76: Electrical Electrical Components

    ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS Main switch Fuel pump Ignition coil Sidestand switch Spark plug cap Flasher relay Fuel sender Battery Rectifier/ Regulator Starter relay Wireharness Starting circuit cut-off relay Thermo unit Horn Ignitor unit Fuel pump relay...

  • Page 77: Circuit Diagram

    ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM...
  • Page 78 ELEC CIRCUIT DIAGRAM A.C. magneto Thermo switch (Fan) Pickup coil Fan motor Rectifier regulator Brake light switch Main switch Flasher relay Backup fuse Horn Battery Turn switch Main fuse Horn switch Starter relay Dimmer switch Starter motor Pass switch Diode Left handlebar switch Starting circuit cut-off relay License plate light...

  • Page 79: Checking Switches

    ELEC CHECKING SWITCHES YP***** 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.

  • Page 80: Checking Steps

    ELEC CHECKING SWITCHES YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester, check switches for continu- ity between their terminals to determine wheth- er they are correctly connected. Replace the switch component if any of the combinations does not produce the correct reading.

  • Page 81: Ignition System

    ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM Pickup coil Main switch Battery Main fuse Ignitor unit Ignition coil Spark plug Sidestand switch Engine stop switch Alarm...

  • Page 82: Electric Starting System

    ELEC ELECTRIC STARTING EB80300 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 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...

  • Page 83: Lighting System

    ELEC LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch Pass switch Backup Fuse License plate light Battery Tail/Brake light Main fuse Head light (Lo) Lights switch Head light (HI) Seat switch Auxiliary light Box light High beam indicator light Head light fuse Meter lights Dimmer switch...

  • Page 84: Troubleshooting

    ELEC LIGHTING SYSTEM YP805010 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, BOX LIGHT, LICENSE PLATE LIGHT AND/ OR METER LIGHT FAIL TO COME ON. Procedure Check: 5. Dimmer switch and pass switch 1. Fuse (Main, Backup) 6. Seat switch 2.
  • Page 85 ELEC LIGHTING SYSTEM NO CONTINUITY YP****** 5. Dimmer switch/Pass switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. NO CONTINUITY YP****** 6. Seat switch Refer to “CHECKING SWITCHES” section. Replace the handlebar switch. YP****** 7. Wiring connection POOR CONNECTIONS Check the connections of the entire lighting system.
  • Page 86 ELEC LIGHTING SYSTEM Turn the main switch to on. OUT OF SPECIFICATION Turn the light switch to on position. Turn the dimmer switch to low beam or high beam. Pass switch to push in. The wiring circuit from the main switch to Check for voltage (12 V) on the lead at bulb bulb socket connector is faulty.
  • Page 87 ELEC LIGHTING SYSTEM YP805022 3. The taillight fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector.
  • Page 88 ELEC LIGHTING SYSTEM YP805022 3. The license plate light fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector.
  • Page 89 ELEC LIGHTING SYSTEM YP805023 4. If the auxiliary light fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector.

  • Page 90: Signal System

    ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM Main switch Horn switch Battery Tail / Brake light Main fuse Rear flasher lights Signal fuse Front flasher lights Brak light switch Turn indicator lights Flasher relay Fuel gauge Horn Fuel sender Turn switch...

  • Page 91: Troubleshooting

    ELEC SIGNAL SYSTEM YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON. IF THE HORN FAILS TO SOUND. Procedure Check: 3. Main switch 1. Fuse (Main, signal) 4. Wiring connection (entire signal system) 2. Battery NOTE: Remove the following parts before trouble- shooting.
  • Page 92 ELEC SIGNAL SYSTEM YP****** 4. Wireharness POOR CONNECTION Check the connections of the entire signal system. Refer to “CIRCUIT SYSTEM WIRING DIA- Correct. GRAM” section. CONTINUITY Check condition of each of the signal sys- tem’s circuits. Refer to “SIGNAL SYSTEM CHECK” section.

  • Page 93: Signal System Check

    ELEC SIGNAL SYSTEM YP806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound. NO CONTINUITY 1. HORN switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the horn lead.
  • Page 94 ELEC SIGNAL SYSTEM YP806022 2. If the brake light fails to come on: NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2. Brake switch (Front/Rear) Refer to “CHECKING SWITCHES” section. Replace brake switch.
  • Page 95 ELEC SIGNAL SYSTEM YP806023 3. If the flasher light and/or turn indicator light fails to blink. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2. Turn switch Refer to “CHECKING SWITCHES”...
  • Page 96 ELEC SIGNAL SYSTEM 5. Voltage Connect the pocket tester (DC20 V) to the bulb socket connector. At flasher light (left) Tester (+) lead ! Chocolate lead Tester (–) lead ! Black terminal At flasher light (right) Tester (+) lead ! Dark green lead Tester (–) lead ! Black terminal Turn the main switch to on.
  • Page 97 ELEC SIGNAL SYSTEM YP806027 4. If the fuel gauge fails to operate. 1. Fuel sender Remove the fuel sender from the fuel tank. Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester (Ω 10) to the fuel sender coupler lead. Tester (+) lead ! Green terminal Tester (–) lead ! Black terminal Check the fuel sender for specificated resis-...
  • Page 98 ELEC SIGNAL SYSTEM 3. Fuel gauge Connect the fuel sender to wireharness. NOTE: Move the float to “UP” or “DOWN” Before reading the meter, stay put the float for more than three minutes respectively at “UP” or “DOWN”. Turn the main switch to “ON”. DOES NOT MOVE Check the fuel gauge needle moves “F”...

  • Page 99: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Ignitor unit Fuel pump Fuel pump relay Engine stop switch Ignition fuse...

  • Page 100: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump...

  • Page 101: Troubleshooting

    ELEC FUEL PUMP SYSTEM EB808020 TROUBLESHOOTING The fuel pump fails to operate. Procedure Check: 5. Relay unit (fuel pump relay) 1. Fuse (Main and Ignition) 6. Fuel pump 2. Battery 7. Wiring connection 3. Main switch (engine fuel pump system) 4.
  • Page 102 ELEC FUEL PUMP SYSTEM 5. Relay unit (fuel pump relay) Disconnect the relay unit from the coupler. Connect the pocket tester (Ω 1) and bat- tery (12 V) to the relay unit terminals as shown. Battery positive terminal ! red/white Battery negative terminal ! blue/red Tester positive probe ! red/white NO CONTINUITY...

  • Page 103: Checking The Fuel Pump

    ELEC FUEL PUMP SYSTEM EB808410 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks or any other source of fire.
  • Page 105 YP250 2000 WIRING DIAGRAM 1 A. C. magneto 41 Left handlebar switch 2 Pickup coil 42 License plate light 3 Rectifier regulator 43 Tail / brake light 4 Main switch 44 Rear flasher light 5 Backup fuse 45 Front flasher light 6 Battery 46 Head light (LO) 7 Main fuse...

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