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Related Manuals for Yamaha YFM250X 2002
Summary of Contents for Yamaha YFM250X 2002
- Page 1 2002 YFM250X 4XE3-AE3 SUPPLEMENTARY SERVICE MANUAL...
- Page 3 YFM250XL’99 SERVICE MANUAL: 4XE3-AE1 YFM250XN 2001 SUPPLEMENTARY SERVICE MANUAL: 4XE3-AE2 YFM250X(P) 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. First Edition, June 2001 All rights reserved. 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 machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
- Page 5 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter sym- bol.
- Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...
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Page 7: Table Of Contents
CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATION ............2 ENGINE ....................2 CHASSIS ....................3 ELECTRICAL ..................3 CABLE ROUTING ..................4 PERIODIC CHECKS AND ADJUSTMENTS ..........12 INTRODUCTION ..................12 PERIODIC MAINTENANCE/LUBRICATION INTERVALS.......12 CHASSIS ....................14 ADJUSTING THE FRONT BRAKE .............14 ADJUSTING THE REAR BRAKE LIGHT SWITH .......14 ELECTRICAL ....................15 CHECKING THE SWITCH ..............15 CHECKING THE SWITCH ..............15... -
Page 9: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XEF (CDN, Europe and Oceania) Dimensions: Overall length 1,940 mm (76.4 in) Overall width 1,080 mm (42.5 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 Specification
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.001 in) Measuring point Lines indicate straightedge measurement. Piston: Piston to cylinder clearance 0.04 ~ 0.06 mm 0.15 mm (0.0016 ~ 0.0024 in) (0.0059 in) Piston size “D”... -
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: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead È Do not route the handlebar Ë Fasten the handlebar switch 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- 4 Front brake hose É... - Page 13 SPEC CABLE ROUTING 1 Cable guide É Insert the carburetor air vent hose, rear brake 2 Main switch breather hose, and final gear case breather hose 3 Fuel tank breather hose into the air duct after routing them through the fuel 4 Carburetor overflow hose tank grommet.
- Page 14 SPEC CABLE ROUTING 1 Tail/brake light È Make sure that the starter motor lead has no 2 Final gear case breather hose slack. 3 Front brake light switch lead É Fasten the starter motor lead and wire harness 4 Carburetor air vent hose to the frame with the plastic band.
- Page 15 SPEC CABLE ROUTING Í Fasten the tail/brake light lead to the storage box Ò Fasten the rear brake cable and rear brake with the plastic clamp. breather hose to the swingarm with the plastic Î Fasten the starter motor lead and wire harness clips.
- Page 16 SPEC CABLE ROUTING 1 Battery breather hose È Make sure that the battery breather hose is not 2 Rear brake cable kinked or bent. 3 Spark plug cap É Route the rear brake cable through the cable 4 Ignition coil guide on the cylinder.
- Page 17 SPEC CABLE ROUTING 1 Rectifier/regulator È Fasten the battery + lead and starter motor lead 2 CDI unit to the rear fender with the plastic clamps. 3 Starting circuit cut-off relay lead É Install the starter circuit cut-off relay onto the tab 4 Starter relay lead with its terminal side facing down.
- Page 18 SPEC CABLE ROUTING Í Make sure that the grommet is installed with the mark facing forward. Î 5 mm (0.2 in) – 10 –...
- Page 19 SPEC CABLE ROUTING 1 Rear brake cable Ê Make sure the starter motor lead and wire har- 2 Throttle cable ness do not contact the ignition coil. 3 Wire harness Ë Fasten the wire harness, starter motor lead, and 4 Starter motor lead ignition coil lead to the frame with the plastic 5 Tail/brake light lead locking tie.
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Page 20: Periodic Checks And Adjustments
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC CHECKS 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 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 21 • Check specific gravity. Battery* • Check that the breather hose is working properly. • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid.
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Page 22: Chassis
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”. (Manual No.: 4XE3-AE2) Brake lever free play (at brake lever end): 0 mm (0 in) -
Page 23: Electrical
– ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test. -
Page 24: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 16 –... -
Page 25: Checking The Signal System
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. -
Page 27: Yfm250X(P) 2002 Wiring Diagram
YFM250X(P) 2002 WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay W/G R R W/G 7 Starter motor W/R W/L W/L W/R 8 Starting circuit cut-off relay 9 CDI unit (BLACK) 0 Ignition coil W/R R R/B A Spark plug W/L O...