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Yamaha YP250A 1999 Supplementary Service Manual

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  • Page 3 YP250 (J) SUPPLEMENTARY SERVICE MANUAL: 4UC-AE2 YP250D SUPPLEMENTARY SERVICE MANUAL: 5DF-AE1 YP250A ’99 SUPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. First Edition, July 1998 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 4 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 scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair.
  • Page 5 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 sec- tion.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as SPEC thumb tabs to indicate the chapter’s number and INFO content. General information Specifications INSP Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical COOL CARB Troubleshooting CHAS ELEC Illustrated symbols are used to identify...

  • Page 7: Table Of Contents

    HU OPERATION TEST WHILE ABS IS WORKING ... . . YAMAHA ABS PROVIDES 3 MAIN ADVANTAGES ... . . SYSTEM LAYOUT .
  • Page 8 [C-1] ONLY ABS WARNING LIGHT DOES NOT GO ON WHEN THE MAIN SWITCH IS TURNED ON ......[C-2] ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT GOES ON .

  • Page 9: General Information

    ABS OUTLINE INFO GENERAL INFORMATION ABS OUTLINE Introduction YP250A is equipped with the ABS (Anti-lock Brake System). HU OPERATION TEST WHILE ABS IS WORKING With the scooter stopped, YP250A allows a driver to test the performance of brake lever reaction force which is generated when the ABS operates.
  • Page 10 ABS OUTLINE INFO 4. Turn the main switch on. NOTE: Wait until the ABS warning light goes off after turn- ing the main switch on.(2 seconds) 5. Turn on the starter switch 1 for longer than 4 seconds. CAUTION: Do not grip the brake lever in this case. 6.

  • Page 11: Yamaha Abs Provides 3 Main Advantages

    When the ABS works, the system informs the brake fluid pressure change to a rider via brake levers. 3. Weight of the hydraulic unit (HU) which is the main of system is 2.2 kg for YAMAHA ABS. We designed to gather the mass by locating this unit at the central portion of scooter.

  • Page 12: Total System Block Diagram

    ABS OUTLINE INFO TOTAL SYSTEM BLOCK DIAGRAM Rear master cylinder Front master cylinder Hydraulic unit Rear brake caliper Silencer chamber Front brake caliper Hydraulic pump Electronic control unit Electric motor Rear wheel sensor Buffer chamber Front wheel sensor Hydraulic control valve ABS warning light COMPOSITION OF PARTS Component...

  • Page 13: Composition And Operation Of Parts

    ABS OUTLINE INFO COMPOSITION AND OPERATION OF PARTS 1. Wheel sensor and sensor ring A wheel sensor is composed of magnet and coil and installed with front and rear wheels’ housings. The sensor ring attached to front and rear cast wheels have 36 serration each.
  • Page 14 ABS OUTLINE INFO 3. Hydraulic unit Hydraulic unit is composed of two pieces of hy- draulic control valve (solenoid valve, flow control valve), buffer chamber, pump and silencer cham- ber, and one motor. It adjusts the front/rear wheel brake fluid pressure to control the wheel rotation condition according to the signal sent from the electronic control unit.
  • Page 15 ABS OUTLINE INFO S Hydraulic control valve Hydraulic control valve is composed of the sole- noid valve and flow control valve. 1) When the normal brake is applied, the solenoid valve closes 2 , the spool 3 of flow control valve does not move and the hydraulic line be- tween the master cylinder and brake caliper is opened.
  • Page 16 ABS OUTLINE INFO 4. Electronic control unit Relation of the input signal and output signal is shown in the diagram. The circuit receives the signals from wheel sensors, processes them according to the programs in the mi- crocomputer and outputs the control signal to the hydraulic unit and ABS warning light. Electronic control unit (ECU) Power Voltage...
  • Page 17 ABS OUTLINE INFO 5. Fail-safe relay Fail-safe relay controls the power of hydraulic unit and it is located inside of the tail cover. Fail safe relay Composition and operation Fail-safe relay is composed of the solenoid relay and motor relay Solenoid relay is continued when the electronic control unit outputs the system start signal.

  • Page 18: System Operation

    ABS OUTLINE INFO SYSTEM OPERATION ABS system’s fluid pressure circuit has the 2 lines of front wheel and rear wheel systems. In this section, we describe about one system of a front wheel. Normal brake (ABS not activated) Port D of the solenoid valve is closed since the control signal from the electronic control unit is not sent to the hydraulic unit.
  • Page 19 ABS OUTLINE INFO At the time of urgent braking (When ABS works) 1) Decompressed state When the wheel is almost locked, the solenoid valve’s port D opens by the “decompression” signal from the electronic control unit. At this time, the spool 9 of flow control valve compresses the return valve to close the port B Brake fluid which has entered through port A 8 is restricted by the orifice Accordingly, the brake fluid from the brake caliper is sent in the line of Port C...
  • Page 20 ABS OUTLINE INFO 2) Pressurized state Port D of solenoid valve closes according to the “increase pressure” signal from the electronic control unit. Also, spool 9 of flow control valve compresses the return spring to close the port B Brake fluid entered through port A 8 is further restricted by the orifice Accordingly, the brake fluid in master cylinder is sent in the line of Port A 8 , Port C then to the brake caliper.

  • Page 21: Caution For Operation

    INFO CAUTIONS FOR OPERATION The YAMAHA ABS applies the double system control type with the independent hydraulic system for the front and rear wheels respectively. Accordingly, the brake operation is the same as usual scooters providing the right hand brake lever to be used for the front wheel and left hand brake lever for the rear wheel.

  • Page 22: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as 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 23: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YP250A Model code: 5DF3 (except for CH) 5DF4 (for CH) Dimensions: Overall length 2,110 mm Overall width ,780 mm Overall height 1,330 mm Seat height ,700 mm Wheelbase 1,500 mm Minimum ground clearance ,115 mm Minimum turning radius 2,600 mm...
  • Page 24 SPEC GENERAL SPECIFICATIONS Model YP250A Bulb wattage quantity: Headlight 12 V 60 W/55 W Marker light 12 V 5 W Tail/brake light 12 V 5 W/21 W Flasher light 12 V 21 W Meter light 12 V 1.7 W High beam indicator light 12 V 1.7 W Oil indicator light 12 V 1.7 W...

  • Page 25: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Carburetor: Type Y28V-1A I.D. mark 4UC 03 [4UD 03 (CH)] Ventuly outside diameter ø 28 Main jet (M.J) # 130 Main air jet (M.A.J) ø 0.9 Jet needle (J.N) 5D32-3/5 Throttle valve size (Th.V) Pilot air jet (P.A.J.1)

  • Page 26: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Front wheel sensor lead Rear wheel sensor A Route the rear brake hose through Wireharness (ABS) Crankcase the guide on the handlebar holder. Rear wheel sensor lead Over flow hose (fuel filler) B Fasten the wireharness to the stay Carburetor drain hose Hydraulic unit with a plastic band.
  • Page 27 SPEC CABLE ROUTING D Align the mark on the brake hoses J Route the rear wheel sensor as O Position the connector of plastic with clamp, and clamp them. illustration. band as illustration. E Fasten the throttle cable to the K Route the rear wheel sensor lead P Position the connector of the plas- frame with a plastic band.
  • Page 28 SPEC CABLE ROUTING Box light Starter switch Rear brake hose (OUT) Rectifier / regulator Battery Igniter Fuel sender Flasher relay Down tube Ignition coil Coolant reservoir tank Wireharness Roll over valve Crankcase breather hose Rear brake hose Seat lock cable Air filter case Battery leads Handlebar switch lead (right)
  • Page 29 SPEC CABLE ROUTING A Route the box light lead through E Fasten the seat box light switch I Route the seat lock cable through from the outside of the frame to the lead to the hinge with a plastic the pipe, and align the mark of seat inside of the pipe.
  • Page 30 SPEC CABLE ROUTING M Fasten the wireharness, seat lock P Route the front wheel sensor lead U Fasten the wireharness to the cable and pipe with a steel clamp through the guide. frame with a plastic band. on the frame. Q Fasten the pipe with a steel clamp V Route the brake hose, wirehar- N Fasten the front wheel sensor lead...
  • Page 31 SPEC CABLE ROUTING Seat lock AC magneto lead C Fasten the sidestand switch lead Air filter case Starter motor lead with a steel clamp on the frame. Engine ground lead Seat lock cable D Route the thermo switch lead out- Crankcase breather hose Fuel pump side of the frame.
  • Page 32 SPEC CABLE ROUTING H Fasten the sidestand switch lead L Fasten the AC magneto lead, Q Install the fuse box to the stay on and battery positive lead with a starter motor lead and engine the frame. steel clamp on the frame. ground lead with a steel clamp on R Fasten the front wheel sensor, I Fasten the sidestand switch lead...
  • Page 33 SPEC CABLE ROUTING Front turn signal light (right) Front wheel sensor C Route the front brake hose Front turn signal light (left) Horn through the right hole of the han- Handlebar switch lead (right) ABS test terminal dlebar under cover. Front stop switch lead Handlebar upper cover D Route the rear brake hose through...
  • Page 34 SPEC CABLE ROUTING F Route the handlebar switch (left) J Route the handlebar switch (left) lead and rear brake switch lead lead through the front side of the through the left side of the handlebar under cover. speedometer cable. G Route the front wheel sensor through the guide.

  • Page 35: Chassis

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) CHASSIS ANTI-LOCK BRAKE SYSTEM The YAMAHA ABS is the electronic control sys- tem applying the 2 system control type with the in- dependent hydraulic system for the front and rear wheels respectively. Accordingly, the brake operation is the same as...

  • Page 36: Brake Force And The Vehicle Stability

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) S Slip ratio When the brake is applied, slipping occurs be- tween tires and road surface, then the difference is made between the wheel speed and chassis speed. This is called a slip. Slip ratio is the value to show the rate of slipping and defined by the following formula.

  • Page 37: Wheel Slip And The Hydraulic Control

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SLIP AND THE HYDRAULIC CON- TROL The ABS computer calculates each wheel speed according to the rotation signal receiving from the front and rear wheel sensors. In addition, the com- puter calculates the vehicle travel speed and rate of speed reduction with wheels based on the wheel speed values.

  • Page 38: Electronics Abs Feature

    ELECTRONICS ABS FEATURE The YAMAHA ABS is the anti-lock brake system developed under the most advanced electronics technology. The control is processed with good response pro- viding various travel conditions for scooters.

  • Page 39: Abs Components Function

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) The ABS is composed of major components as follows. Front and rear wheels are equipped with sensors and sensor rotors respectively. Wheel sensor and the sensor rotor Electronic control unit (ECU) Hydraulic unit (HU) Fail-safe relay ABS harness In addition, there are relevant parts such as the ABS warning light in the meter panel, the test con-...
  • Page 40 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Electronic control unit (ECU) Electronic control unit 1 controls the ABS and is installed inside the taillight unit. To protect from water invasion, it is enveloped by a cover 2 . As shown in the block diagram below, the ECU takes in the wheel sensor signals from front and rear wheels and also receives the signals from various monitor circuits.
  • Page 41 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) The operation result is confirmed by the monitor circuit. Based on the result, the control signals of hydraulic unit (HU) and fail-safe relay will be is- sued. ABS control operation The ABS control operation performed in ECU is di- Soft wear operation flow vided into 2 parts as follows.

  • Page 42: Hydraulic Unit (Hu)

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) HYDRAULIC UNIT (HU) Hydraulic unit is composed of two pieces of hydraulic control valve (solenoid valve, flow control valve), buff- er chamber, pump and silencer chamber, and one motor. It adjusts the front/rear wheel brake fluid pressure to control the wheel rotation condition according to the signal transmitted from the electronic control unit.

  • Page 43: Other Abs Mechanism Components

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) OTHER ABS MECHANISM COMPONENTS ABS warning light The ABS warning light 1 is designed to inform the ABS self diagnostic result and located in the meter panel. Going on the ABS warning light 1. Turn the main switch on It goes on for about 2 seconds.
  • Page 44 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 4. Flashes while riding. No problem exists with the ABS function, but it is estimated that the input has unstable factors. Goes on (For details, refer to the troubleshooting sec- Goes off tion.) NOTE: warning light The test coupler adapter may be connected with the test connector.

  • Page 45: Abs Troubleshooting Outline

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light of meter panel alerts the malfunction.
  • Page 46 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) “Deleting the malfunction code” When the malfunction service is finished, check the normal operation of scooter then delete the malfunction code (Refer to [D-6]). By deleting the malfunction code memory, it is possible to pursue the cause correctly if the next defective phenomenon occurred.

  • Page 47: Abs Parts Location Chart

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS PARTS LOCATION CHART Electronic control unit (ECU) ABS warning light Hydraulic unit (HU) Brake light relay Test connector Fuse box Fail-safe relay Front sensor rotor Rear brake hose (Hydraulic unit- Front brake hose (Front brake Front wheel sensor rear brake caliper) master cylinder-Hydraulic unit)

  • Page 48: Abs Connector Location Chart

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS CONNECTOR LOCATION CHART...

  • Page 49: Abs Circuit Diagram

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS CIRCUIT DIAGRAM Main switch Rear wheel sensor ABS warning light Battery Fail safe relay Speedometer Fuse (main) Hydraulic unit Start switch Fuse (ABS motor) Front brake switch Fuse (ABS) ECU (electronic control unit) Brake light relay Front wheel sensor Rear brake switch...

  • Page 50: Basic Instruction For Troubleshooting

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) BASIC INSTRUCTION FOR TROUBLESHOOTING WARNING S Execute the troubleshooting on each malfunction from [A] to [D] in sequence. S Use the sufficiently charged regular batteries only. [A] Malfunction check by the ABS warning light [B] Detail check of malfunction Results by self diagnosis are displayed by the ABS warning light or tester according to the ECU’s opera- tion.

  • Page 51: Basic Process For Troubleshooting

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) BASIC PROCESS FOR TROUBLESHOOTING It does not go on. Goes on for 2 seconds and goes off afterward. Check the ABS warning light. Flashing Keeps going on. [B-5] [B-4] [B-1] [B-3] [B-2] Present Past Warning light Warning light Warning light malfunction...

  • Page 52: Abs Troubleshooting

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING [A] MALFUNCTION CHECK BY THE ABS WARNING LIGHT Turn the main switch on. (Do not start the engine.) ! [B-1] 1) Warning light does not go on. ! [B-2] 2) Warning light keeps going on. ! [B-3] 3) Warning light keeps flashing.

  • Page 53: [B-4] Malfunction Check By The Abs Self Diagnosis (Past Malfunction)

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Arrangement and the function of test couplers S ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded. S Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of voltage) is output at the T/F terminal.
  • Page 54 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION) NOTE: Before proceeding to [B-5], read the part of [B-3] “Arrangement and the function of test coupler”. Remove the screen and check the location of test connector. Connect the test coupler adapter with the test connector in order to ground the T/C terminal (sky-blue).

  • Page 55: [C] Supposing The Malfunction Cause And Position

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C] SUPPOSING THE MALFUNCTION CAUSE AND POSITION [C-1] ONLY ABS WARNING LIGHT DOES NOT GO ON WHEN THE MAIN SWITCH IS TURNED ON NOTE: Check following the numbers in sequence. 1. Visual check 1) Check the fuse 1 . (ABS) Check the cause of fuse blown, repair and replace with a new one.

  • Page 56: [C-2] Abs Warning Light And All Other Indicators Do Not Goes On

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C-2] ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT GOES ON NOTE: Check following the numbers in sequence. Electric system and the connection of scooter may have caused the problem. 1. Check the power supply system. 1) Is the battery correctly connected? 2) Is the battery voltage normal? 3) Is not the main fuse 1 blown? If it is blown, check the cause, correct and replace.

  • Page 57: [C-4] Abs Warning Light Flashes Every 0.5 Second

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C-4] ABS WARNING LIGHT FLASHES EVERY 0.5 SECOND. This state means that the ECU has not recorded the past malfunction. If the ABS warning light goes on once in a while but does not record the past malfunction, it is estimated that the ABS warning light went on or flashed because of failures on other places of scooter.

  • Page 58: [C-5] Diagnosis By The Malfunction Code

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C-5] DIAGNOSIS BY THE MALFUNCTION CODE Malfunction codes explained in [B-4] and [B-5] are used to judge what type of problems have occurred. They are judged by using the table as follows. NOTE: Records all indicated malfunction codes and check the contents for confirmation. Malfunc- Problem Check point...
  • Page 59 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Malfunction Problem Check point Reference code S Brake dragging Front wheel will not recover from the [C-5-10] S HU operation test locking tendency even though the signal is continuously sent from the (Refer to [D-6-3]) S Front wheel brake line ECU to release the hydraulic state.
  • Page 60 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C-5-1] Malfunction code “11” (Front wheel sensor signal does not come in correctly.) Turn the main switch off once, then turn on again after removing the test coupler adapter. 1) ABS warning light remains going on. ! Defective connection in the front wheel sensor circuit.
  • Page 61 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 4 Rear wheel sensor output drops S Sensor signal output may drop due to failures on wheel and sensor housing. Check if there are loose- ness, distortion or bending with the assembled condition of these components. NOTE: In the case of riding on the extremely uneven roads continuously, the ABS warning light may flash.
  • Page 62 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [C-5-5] Malfunction code “21” (Solenoid circuit is disconnected or short-circuited.) Check the following procedures. 1) Solenoid connector S Check if the solenoid connector terminal is disconnected. (Refer to ABS CONNECTOR LOCATION CHART) 2) HU solenoid S Check the continuity of solenoid (front or rear wheel) ! [D-5] S Check the insulation condition of all solenoid terminals and negative (–) terminal of battery.
  • Page 63 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 5) Wire harness S Check the continuity between the red/blue terminal of fail-safe relay’s coupler and positive (+) terminal of battery. S Remove the ECU fuse and check the continuity between the brown/white lead of fail-safe relay’s con- nector and ABS fuse (see the illustration below).
  • Page 64 S Check if the brake hose line is folded or broken. WARNING Using brake pipes, hoses and union bolts other than genuine YAMAHA parts may close the piping lines. Do not use them. S Check the connection of brake hose or pipe lines on the master cylinder and caliper sides to the HU are correct.
  • Page 65 S Check if the brake hose line is folded or broken. (Particularly between the HU ! rear caliper) WARNING Using brake pipes, hoses and union bolts other than genuine YAMAHA parts may close the piping lines. Do not use them.
  • Page 66 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) WARNING Rear wheel side inlet: Brake hose 1 from the rear master cylinder Rear wheel side outlet: Brake hose 2 from the rear brake caliper NOTE: S If the inlet and outlet to connect with the HU are mistaken, when the HU operation test is performed which is shown in [D-6], the brake lever enters down to full stroke without responding and will be pushed back slow- ly without pulsation.
  • Page 67 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 7) Battery voltage Measure the battery output voltage. [C-5-13]Malfunction code “52” (Rear wheel will not recover from the locking tendency even though the signal is continuously sent from the ECU to release the hydraulic state (while the battery voltage is low).) 1) Rotation of wheels Refer to [C-5-11] Malfunction code “42”...

  • Page 68: Ecu And Fail Safe Relay

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ECU AND FAIL SAFE RELAY Order Job name/Part name Q’ty Remarks ECU and fail safe relay removal Remove the parts in order list. Tail cover Refer to “TAIL COVER AND FUEL TANK” in Chapter 3. Cover Connector Disconnect the connectors.

  • Page 69: [D-1] Maintenance For Ecu

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-1] MAINTENANCE FOR ECU Removing the ECU 1. Remove: S ECU 1 NOTE: Carefully take out the ECU lead 3 not to damage the ECU connector and remove the ECU. 2. Remove: S ECU connector 1 S ECU connector 2 NOTE: To remove the ECU coupler, do not pull the ECU...

  • Page 70: [D-2] Maintenance Of The Abs Fail-Safe Relay

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-2] MAINTENANCE OF THE ABS FAIL-SAFE RELAY Removing the fail-safe relay 1. Remove: S ABS fail-safe relay coupler 1 NOTE: Do not pull the ABS fail-safe relay leads to remove the ABS fail-safe relay connector. Always press on the lock 2 and remove it.
  • Page 71 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Tester’s positive (+) lead ! Terminal 4 Fail-safe relay Tester’s negative (–) lead ! Terminal 5 If tester reading is “ ”. ! Replace the fail-safe Solenoid relay relay. Motor CAUTION: relay When connecting the relay and battery termi- nals, be careful not to short-circuit the bat- tery’s positive (+) and negative (–) terminals.

  • Page 72: Front Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) FRONT WHEEL SENSOR AND SENSOR ROTOR 70 Nm (7.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Front wheel sensor and sensor rotor Remove the parts in order list. removal Cowling body Refer to “COWLING”...

  • Page 73: [D-3] Maintenance Of The Front Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS wheel sensor and the sensor rotor CAUTION: S Care should be taken to handle the ABS com- ponents since they have been accurately ad- justed and set, and must be kept away from shocks and dirt. S ABS wheel sensor cannot be disassembled.
  • Page 74 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2. Measure: S Wheel sensor resistance Connect the pocket tester (Ω X 1) to the termi- nal of front wheel sensor connector. Tester’s positive (+) lead ! Terminal 1 Tester’s negative (–) lead ! Terminal 2 Regulated resistance: 1.19 to 2.21 kΩ...
  • Page 75 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2. Install: S Sensor housing 3. Install: S Front wheel NOTE: Align the slot of sensor housing with the projection part of front fork, then assemble them. CAUTION: Install after checking if foreign materials are mixed in the wheel hub.
  • Page 76 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 6. Install: S Wheel sensor lead 1...

  • Page 77: Rear Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) REAR WHEEL SENSOR AND SENSOR ROTOR 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Rear wheel sensor and sensor rotor Remove the parts in order list. removal Tail cover Rear wheel sensor Rear wheel sensor lead connector Disconnect the connector.

  • Page 78: [D-4] Maintenance Of The Rear Wheel Sensor And

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-4] MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR Removing the rear wheel sensor 1. Disconnect: S Wheel sensor lead connector 1 2. Remove: S Clamp 1 3. Remove: S Rear wheel sensor 1 CAUTION: Care should be taken not to allow the sensor electrode to contact the metal parts when re-...
  • Page 79 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Replacing the wheel sensor rotor Wheel sensor rotor of YP250A is pressed in by the special process and cannot be replaced as a single unit. To replace the sensor rotor, replace as a wheel assembly. Assembling the rear wheel sensor 1.

  • Page 80: Hydraulic Unit (Hu)

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) HYDRAULIC UNIT (HU) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Hydraulic unit removal Remove the parts in order list. Lower cover, footrest board Refer to “FOOTREST BOARD AND LOWER COVER” in Chapter 3. Drain the brake fluid.

  • Page 81: [D-5] Maintenance Of The Hydraulic Unit (Hu)

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-5] MAINTENANCE OF THE HYDRAULIC UNIT (HU) CAUTION: To check the solenoid resistance of hydraulic unit and continuity of motor, do not remove the hydraulic unit. CAUTION: S Care should be taken to handle the ABS com- ponents since they have been accurately ad- justed and set, and must be kept away from shocks and dirt.
  • Page 82 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Checking 1 the hydraulic unit (Resistance of solenoid valve/Continuity of motor) 1. Measure: S Resistance of solenoid valve (front side) Connect the pocket tester (Ω X 1) to the termi- nal of solenoid valve (front). Tester’s positive (+) lead ! Terminal 1 Tester’s negative (–) lead ! Terminal 2 Solenoid valve resistance:...
  • Page 83 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Removing the hydraulic unit 1. Remove: S Brake hose (Front IN) 1 S Brake hose (Front OUT) 2 S Brake hose (Rear IN) 3 S Brake hose (Rear OUT) 4 NOTE: Do not operate the brake lever while removing the brake hose.
  • Page 84 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Installing the hydraulic unit Proceed in the reverse order of disassembling paying attention to the following items. 1. Install: S Hydraulic unit 1 NOTE: Since dusts around the hydraulic unit may enter the brake fluid in a hose while assembling pro- cess, clean up dusts before assembling the brake hose.
  • Page 85 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 4. Connect: S Solenoid valve lead connector 1 5. Supply: S Reservoir tank Recommended brake fluid DOT #4 6. Bleed the air. 7. Check the operation of hydraulic unit according to the decompression. Refer to [D-6-3] HU OPERATION TEST2. CAUTION: Never forget to check the operation of hydrau- lic unit according to the decompression.

  • Page 86: Air Bleeding

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) AIR BLEEDING (ABS brake system) WARNING Always bleed air when the brake related parts are removed. CAUTION: Bleed air following these steps. a 1st step: Front brake caliper b 2nd step: Rear brake caliper S Front brake lever 1 S Rear brake lever 2 Front brake hose (IN) Rear brake hose (IN)

  • Page 87: [D-6-1] Checking The Reservoir Tank Fluid Level

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-6-1] CHECKING THE RESERVOIR TANK FLUID LEVEL 1. Check: S Brake fluid level Keep the reservoir cap horizontal and check the level. Less than the low level ! Add the brake fluid more than low level 1 . Recommended Brake fluid DOT #4 CAUTION:...

  • Page 88: [D-6-3] Hu Operation Test 2

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-6-3] HU OPERATION TEST 2 WARNING Be careful to prevent the scooter from falling down. 1. Move the scooter to the flat place and use the centerstand. 2. Remove: S Battery case cover 3. Check: S Battery terminal voltage Battery terminal voltage Higher than 12.8V.
  • Page 89 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 5. Turn the main switch to “ON” while operating the front brake and rear brake levers simulta- neously. NOTE: S When turning the main switch on, it is impossible to check unless the both front brake and rear brake levers are operated simultaneously.

  • Page 90: [D-6-4] Deleting The Malfunction Code

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) [D-6-4] DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter 1 to the test connector 2 . Refer to [B-5]. 2. Turn the main switch on. Previously recorded malfunction code is dis- played by the ABS warning light. 3.

  • Page 91: [D-6-5] Trial Run

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 7. Turn the main switch on again. Check that the ABS warning light goes on for 2 seconds, then goes out for 3 seconds and Main starts flashing. switch 8. Turn the main switch off. Flashing seconds warning light...

  • Page 92: Rear Shock Absorber And Swing Arm

    CHAS REAR SHOCK ABSORBER AND SWING ARM REAR SHOCK ABSORBER AND SWING ARM 40 Nm (4.0 mSkg) 19 Nm (1.9 mSkg) 7 Nm (0.7 mSkg) 135 Nm (13.5 mSkg) 20 Nm (2.0 mSkg) 30 Nm (3.0 mSkg) 20 Nm (2.0 mSkg) 53 Nm (5.3 mSkg) Order Job name/Part name...

  • Page 93: Yp250A '99 Wiring Diagram

    AC magneto YP250A ’99 WIRING DIAGRAM Rectifier/ Regulator Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ABS motor) Doide Terminal Thermo switch Auto choke Ignition unit Ignition coil Spark plug ECU (electronic control unit) Front wheel sensor Rear wheel sensor Fail safe relay Hydraulic unit Grip warmer switch (option)

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