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Related Manuals for Yamaha YP250D 98
Summary of Contents for Yamaha YP250D 98
- Page 3 YP250 SERVICE MANUAL: 4UC-AE1 YP250 (J) SUPPLEMENTARY SERVICE MANUAL: 4UC-AE2 YP250D ’98 SUPPLEMENTARY SERVICE MANUAL 1997 by Yamaha Motor Co., Ltd. First Edition, December 1997 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
- Page 4 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. Re- pairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use.
- 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 section.
- Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols are used to identify...
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Page 7: Table Of Contents
CONTENTS SPECIFICATIONS ..........GENERAL SPECIFICATIONS . -
Page 9: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YP250D Model code: 5DF1 (except for CH, A, AUS) 5DF2 (for CH, A) Basic weight: With oil and full fuel tank 164 kg Transmission: Primary reduction system Helical gear Primary reduction ratio 38/15 (2.533) Secondary reduction system Sper gear Secondary reduction ratio... -
Page 10: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Automatic centrifugal clutch: Clutch shoe thickness 3.0 mm 2.0 mm Clutch housing inside diameter 135 mm 135.5 mm Clutch shoe spring free length 28.1 mm Weight outside diameter 20 mm 19.5 mm 2,250 X 2,850 r/min Clutch - in revolution 3,700 X 4,700 r/min... -
Page 11: Electrical
SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear disc brake: Type Single Disc outside diameter x thickness 230 x 5.3 mm Pad thickness 5.3 mm 0.8 mm Master cylinder inside diameter 11 mm Caliper cylinder outside diameter 22.2 + 22.2 mm Brake fluid type DOT #4 ELECTRICAL... -
Page 12: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Fuel tank cap over flow hose A Pass the rear brake hose E Pass the carburetor air Throttle cable (pull side) through the handlebar holder. ventilation hose, coolant drain Throttle cable (return side) B Use a plastic band to fasten hose and carburetor fuel drain Carburetor fuel drain hose the rear brake cable to the... - Page 13 SPEC CABLE ROUTING H Pass the fuel tank over flow hose through inside of the frame clamp. I Use a plastic band to fasten the throttle cable to frame. J Use a plastic band to fasten the wireharness to the headlight stay.
- Page 14 SPEC CABLE ROUTING Box light Reservoir tank A Connect the taillight lead connector on the mud guard. Rectifire regulator Fuel tank breather hose B Use a plastic clamp to fasten Fuel sender Air filter the fuel sender lead to the Roll over valve Mud guard pipe.
- Page 15 SPEC CABLE ROUTING G Align white tape on the wireharness to the clamp, then fasten it. H Pass the reservoir tank over flow hose through the clamp inside of the frame. I Pass the rear brake hose, wireharness, battery (+) / (–) leads through the guide.
- Page 16 SPEC CABLE ROUTING Fuel tank breather hose Fuel cock A Use a steel clamp on the frame Fuel hose Fuel tank to fasten the sidestand lead. Vacuum hose Rear trun signal light cover B Pass the thermo switch lead Fan motor lead Rear turn signal light lead through outside of frame.
- Page 17 SPEC CABLE ROUTING Front turn signal light (right) Rear brake switch lead A Pass the speedometer cable Front turn signal light (left) Handlebar under cover and front brake hose through Rear brake hose the holder. Throttle cable B Use a steel clamp on headlight Speedometer cable stay to fasten the headlight Front brake hose...
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Page 18: Periodic Inspection 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 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 19 Final gear oil Replace every 10,000 km D Change oil at initial 1,000 km and thereafter every 10,000 km. *: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU00477 NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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Page 20: Cover And Panel
INSP COVER AND PANEL COVER AND PANEL SIDE PANEL AND SEAT Order Job name/Part name Q’ty Remarks Side panel and seat removal Remove the parts in order. Rear panel Side panel (left) Side panel (right) Rivet Front panel NOTE: Clip Damper assembly Install the damper assembly to the body with its rod side backward and labels up-... -
Page 21: Adjusting The Rear Brake
ADJUSTING THE REAR BRAKE/ INSP CHECKING THE REAR BRAKE FLUID LEVEL EB304014 ADJUSTING THE REAR BRAKE 1. Check: S brake lever free play Out of specification ! Adjust. Brake lever free play 2 X 5 mm 2. Adjust: S brake lever free play Handlebar side a. -
Page 22: Checking The Rear Brake Pads
CHECKING THE REAR BRAKE FLUID LEVEL/CHECKING THE INSP REAR BRAKE PADS/BLEEDING THE HYDRAULIC BRAKE SYSTEM S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. - Page 23 INSP BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Remove: S Reservoir cap S Reservoir diaphragm NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to over- flow. S When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake.
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Page 24: Adjusting The Rear Shock Absorber Assemblies
INSP ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES After bleeding the hydraulic brake system, check the brake operation. EB304164 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. S Securely support the motorcycle so that there is no danger of it falling over. -
Page 25: Chassis
CHAS REAR WHEEL AND BRAKE DISC CHASSIS REAR WHEEL AND BRAKE DISC 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Rear wheel and brake disc removal Swingarm Refer to “REAR SHOCK ABSORBER AND SWINGARM” section. Rear wheel Brake disc Reverse the removal procedure for installation. -
Page 26: Checking The Brake Disc
CHAS REAR WHEEL AND BRAKE DISC CHECKING THE BRAKE DISC 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 4.8 mm 3. -
Page 27: Rear Brake
CHAS REAR BRAKE REAR BRAKE BRAKE PAD 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Brake pad removal Remove the parts in order. Caliper support bolt Refer to “REPLACING THE BRAKE Caliper assembly PADS” section. Brake pad Pad support Reverse the removal procedure for installation. -
Page 28: Replacing The Brake Pads
CHAS REAR BRAKE REPLACING THE BRAKE PADS NOTE: It is not necessary t disassemble the brake cali- per and brake hose to replace the brake pads. 1. Remove: S Caliper assembly 1 2. Remove: S Brake pads 1 NOTE: S Install new brake pad springs when the brake pads have to be replaced. -
Page 29: Caliper
CHAS REAR BRAKE CALIPER 26 Nm (2.6 mSkg) 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Caliper removal Remove the parts in order. Drain the brake fluid Refer to “BRAKE FLUID Brake hose holder REPLACEMENT”... -
Page 30: Caliper Disassembly
CHAS REAR BRAKE CALIPER DISASSEMBLY 6 Nm (0.6 mSkg) Order Job name/Part name Q’ty Remarks Caliper disassembly Remove the parts in order. Brake pad Pad support Caliper piston Refer to “BRAKE CALIPER Dust seal DISASSEMBLY/ASSEMBLY” section Piston seal in Chapter 7. Bleed screw/Cap Reverse the disassembly procedure for assembly. -
Page 31: Installing The Rear Brake Caliper
CHAS REAR BRAKE INSTALLING THE REAR BRAKE CALIPER 1. Install: S Caliper 1 S Caliper support bolt 2 23 Nm (2.3 mSkg) S Brake hose 3 S Plain washer 4 S Union bolt 5 26 Nm (2.6 mSkg) CAUTION: When installing the brake hose to the caliper, lightly touch the brake hose with the stopper a on the caliper. -
Page 32: Master Cylinder
CHAS REAR BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job name/Part name Q’ty Remarks Master cylinder removal Remove the parts in order. Drain the brake fluid Refer to “BRAKE FLUID REPLACEMENT” section in CHAPTER 3. Rear view mirror (left) Brake lever/compression spring Brake switch... -
Page 33: Master Cylinder Disassembly
CHAS REAR BRAKE MASTER CYLINDER DISASSEMBLY Order Job name/Part name Q’ty Remarks Master cylinder disassembly Remove the parts in order. Master cylinder boot Circlip Refer to “MASTER CYLINDER Master cylinder assembly ASSEMBLY” section in Chapter 7. Spring Reverse the disassembly procedure for assembly. -
Page 34: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 7 Nm (0.7 mSkg) 40 Nm (4.0 mSkg) 49 Nm (4.9 mSkg) 16 Nm (1.6 mSkg) 130 Nm (13.0 mSkg) 20 Nm (2.0 mSkg) 53 Nm (5.3 mSkg) Order Job name/Part name Q’ty Remarks...