KYMCO YUP 250 Manual

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Table of Contents

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YUP 250

By KWANG YANG Motor Co., Ltd.

First Edition, Mar 2003

use without the written permission of KWANG YANG

Motor Co., Ltd.

is expressly prohibited.

4122-LBB5-S00

www.PlanDeGraissage.org

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for KYMCO YUP 250

Page 1 YUP 250 By KWANG YANG Motor Co., Ltd. First Edition, Mar 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LBB5-S00 www.PlanDeGraissage.org...
Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the EXHAUST MUFFLER/FRAME COVERS technical features and servicing procedures for the KYMCO YUP 250. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual. ENGINE REMOVAL/INSTALLATION Read them carefully before any operation is started.
Page 3 . GENERAL INFORMATION YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER--------------------------------------------- 1-1 SPECIFICATION---------------------------------------------------------- 1-2 SERVICE PRECAUTIONS----------------------------------------------- 1-3 TORQUE VALUES ------------------------------------------------------- 1-7 SPECIAL TOOLS --------------------------------------------------------- 1-8 LUBRICATION POINTS------------------------------------------------- 1-9 CABLE & HARNESS ROUTING-----------------------------------------1-11 WIRING DIAGRAM-------------------------------------------------------------------1-17 TROUBLESHOOTING --------------------------------------------------1-18...
Page 4 . GENERAL INFORMATION YUP 250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number www.PlanDeGraissage.org...
Page 5 . GENERAL INFORMATION YUP 250 Cooling Type Water cooling SPECIFICATIONS Name & Model No. SH50AA Motorcycle Name & Type YUP 250 Overall length 2060mm Overall width 740mm Air cleaner type & No Paper element, wet Overall height 1165mm Fuel capacity 10.5 liters...
Page 6: General Information
. GENERAL INFORMATION YUP 250 n Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n After reassembly, check all parts for proper tightening and operation.
Page 7 . GENERAL INFORMATION YUP 250 n If the fuse is burned out, find the cause and n The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. n If the double connector has a lock, lock it at the correct position.
Page 8 . GENERAL INFORMATION YUP 250 n After clamping, check each wire to make n Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight n Do not squeeze wires against the weld or its clamp.
Page 9 . GENERAL INFORMATION YUP 250 n After routing, check that the wire harnesses are not twisted or kinked. n Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the n Wire harnesses routed along with handlebar specified points.
Page 10: Torque Values
. GENERAL INFORMATION YUP 250 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 4.5_ 5mm screw 3.5_ 6mm bolt, nut 6mm screw, SH bolt 8mm bolt, nut 6mm flange bolt, nut 10mm bolt, nut...
Page 11: Special Tools
. GENERAL INFORMATION YUP 250 FRAME Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks Steering stem lock nut Front axle nut Rear axle nut 110_ Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt (frame side) Engine hanger bolt (ENG.
Page 12: Lubrication Points
. GENERAL INFORMATION YUP 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE15W-40) Camshaft protruding surface •API SJ Engine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut...
Page 13 . GENERAL INFORMATION YUP 250 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
Page 14: Cable & Harness Routing
. GENERAL INFORMATION YUP 250 CABLE & HARNESS ROUTING Front Brake Fluid Tube Meter Wire Ignition Switch Radiator Overflow Tube Ignition Switch Wire Water Fill Hose Radiator Air Vent Tube EMI Filter Wire Fan Motor Wire Radiator Air Reserve Water...
Page 15 . GENERAL INFORMATION YUP 250 Ignition Coil Wire Throttle Cable Speedometer Cable Fuel Unit Wire Front Brake Fluid Tube Rear Brake Fluid Tube Radiator Air Ventilated Tube 1-12 www.PlanDeGraissage.org...
Page 16 . GENERAL INFORMATION YUP 250 Fuse Box Luggage Box Light Switch Earth Wire (To Frame) Coupler Ignition Unit Heater Control Unit A.C.Generator/ Ignition Unit Wire Regulator/Recti fier/ Start Relay coupler Heat Control Unit Wire Coupler Ignition Coil Harness Wire (To...
Page 17 . GENERAL INFORMATION YUP 250 Heater Control Unit Fuse Box Resister Battery (-) Cable Ignition Unit Regulator/ Rectifier Battery (+) Cable Carburetor Start Relay Ignition Coil Spark Plug Cap Wire Harness Side Stand Switch 1-14 www.PlanDeGraissage.org...
Page 18 . GENERAL INFORMATION YUP 250 Front Brake Fluid Tube Meter Wire Speedometer Cable Rear Brake Fluid Tube Radiator Overflow Tube Throttle Cable Radiator Air Harness Wire Vent Tube Fuel Filter EMI Filter Fuel Level Indicator Horn Reserve Water Tank Side Stand Switch Prepared...
Page 19 . GENERAL INFORMATION YUP 250 Throttle Cable Radiator Air Vent Tube Rear Brake Fluid Tube Harness Wire Side Stand Switch Prepared Wire Coupler Side Stand Switch Coupler Fuel Unit Wire Fuel Filter Secondary Air Vacuum Tube Ignition Unit Fuel Pump...
Page 20: Wiring Diagram
. GENERAL INFORMATION YUP 250 WIRING DIAGRAM 1-17 www.PlanDeGraissage.org...
Page 21: Troubleshooting
. GENERAL INFORMATION YUP 250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by ÅEmpty fuel tank loosening drain screw ÇClogged carburetor fuel inlet tube, vacuum tube or fuel tube ÉClogged auto fuel valve...
Page 22 . GENERAL INFORMATION YUP 250 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate ÅClogged air cleaner lightly for observation ÇRestricted fuel flow ÉClogged fuel line between fuel tank and carburetor Engine speed Engine speed does ÑClogged exhaust muffler...
Page 23 . GENERAL INFORMATION YUP 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty ignition unit Correct timing Incorrect timing ÇFaulty A.C. generator Check carburetor pilot screw adjustment ÅMixture too rich (turn screw...
Page 24 . GENERAL INFORMATION YUP 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty ignition unit Correct timing Incorrect timing ÇFaulty A.C. generator Check valve clearance ÅImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance ÇWorn valve seat...
Page 25 . GENERAL INFORMATION YUP 250 ENGINE NOISE Symptom Probable Cause ÅValve clearance too large Valve noise ÇWorn camshaft lobe ÅWorn piston rings ÇWorn piston pin and connecting rod Piston noise small end ÉExcessive carbon build-up in combustion chamber ÅDamaged cam chain tensioner ÇWorn cam gear teeth...
Page 26 . GENERAL INFORMATION YUP 250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause ÅWorn or slipping drive belt ÇBroken ramp plate ÉBroken drive face spring Engine starts but ÑSeparated clutch lining motor-cycle does not ÖDamaged driven pulley shaft splines move ÜDamaged final gear...
Page 27 . GENERAL INFORMATION YUP 250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustmen Probable Cause Check operation of stop switch by ÅBurned out fuse applying brake ÇWeak or dead battery Stoplight does not ÉFaulty stop switch Stoplight comes come on ÑLoose or disconnected...
Page 28 . GENERAL INFORMATION YUP 250 closed NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark ÅFaulty spark plug Check spark plug cap and high-tension wire...
Page 29 . GENERAL INFORMATION YUP 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals ÅFaulty AC generator Voltage does not Normal voltage ÇFaulty regulator/rectifier increase ÉFaulty battery Measure resistance...
Page 30 . GENERAL INFORMATION YUP 250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn ÅBurned out fuse signals ÇWeak or dead battery Signals operate Signals dim, remain ÉFaulty ignition switch properly on or don‘t...
Page 31 . GENERAL INFORMATION YUP 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) ÅSteering stem nut too tight Steering is heavy ÇBroken steering steel balls ÅExcessive wheel bearing play Front or rear wheel is ÇBent rim...
Page 32 . EXHAUST MUFFLER/FRAME COVERS YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-10 www.PlanDeGraissage.org...
Page 33: Schematic Drawing
. EXHAUST MUFFLER/FRAME COVERS YUP 250 SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 34: Service Information
. EXHAUST MUFFLER/FRAME COVERS YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 35: Frame Covers Removal
. EXHAUST MUFFLER/FRAME COVERS YUP 250 FRAME COVERS REMOVAL RIGHT AND LEFT BACK MIRROR REMOVAL Loosen the nut on the back mirror. Remove the back mirror. Nuts HANDLEBAR FRONT COVER REMOVAL Remove the four screws attaching handlebar rear cover to separate from handlebar rear cover.
Page 36: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS YUP 250 Wire Connectors and Disconnect all of the wire connectors and Couplers couplers. Remove the bolt on the handlebar rear cover. Remove the handlebar rear cover. Blot Handlebar Rear Cover FRONT COVER REMOVAL Remove the two screws attaching the leg shield.
Page 37 . EXHAUST MUFFLER/FRAME COVERS YUP 250 Remove the two nuts on the front body cover and six screws attaching the leg shield. Disconnect the front body cover from leg shield and front under cover. Nuts Screws Disconnect all of the wire couplers.
Page 38 . EXHAUST MUFFLER/FRAME COVERS YUP 250 FRONT UNDER COVER REMOVAL Remove front cover, ( 2-4) front body cover ( 2-4) and right/left side cover. ( 2-5) Remove two screws combine front under cover with leg shield. Remove two screws combine front under cover with the floor board.
Page 39 . EXHAUST MUFFLER/FRAME COVERS YUP 250 Nuts Bolts Remove two bolts and two nuts on the met-in box. Fuse Box Cap Fuse Box Remove fuse box cap. Push the clip and depress fuse box. Clip Luggage Box Wire Couplers Disconnect luggage box wire couplers.
Page 40 . EXHAUST MUFFLER/FRAME COVERS YUP 250 REAR FENDER A REMOVAL Remove two screws and two nuts on the rear fender A. Screw Screw Licence Light Coupler Disconnect the licence light coupler. Remove rear fender A. REAR BODY COVER REMOVAL Remove rear carrier ( 2-6 ), met-in box ( 2- 6 ), center cover ( 2-7 ) and rear fender A.
Page 41 . EXHAUST MUFFLER/FRAME COVERS YUP 250 Disconnect air cleaner tube from air cleaner. Air Cleaner Tube Tail/Stop Light Coupler Disconnect tail/stop light coupler, then remove rear body cover. Screw REAR FENDER B REMOVAL Remove rear carrier ( 2-6 ), met-in box ( 2- 6 ), center cover ( 2-7 ), rear fender A.
Page 42: Exhaust Muffler Removal
. EXHAUST MUFFLER/FRAME COVERS YUP 250 Screw Screw Remove two screws on the foot board, then remove foot board. Key Molding LEG SHIELD REMOVAL Remove front cover ( 2-4 ), front body cover ( 2-4 ), front under cover ( 2-6 ), right/left side cover ( 2-5 ), center cover ( 2-7 ) and foot board.
Page 43 . EXHAUST MUFFLER/FRAME COVERS YUP 250 When installing, first install the exhaust muffler packing collar onto the engine and Packing Collar then install the exhaust muffler. Torques: Exhaust muffler lock bolt: 38N- Exhaust muffler joint lock nut: 18_ 22N- ＊...
Page 44 . INSPECTION/ADJUSTMENT YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3 THROTTLE OPERATION --------------------------------------------- 3- 3 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5...
Page 45: Inspection/Adjustment
. INSPECTION/ADJUSTMENT YUP 250 SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas, which may cause death to people.
Page 46: Maintenance Schedule
. INSPECTION/ADJUSTMENT YUP 250 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T: Tighten Regular Service Mileage (km) Whichever Frequency comes...
Page 47: Fuel Line/Fuel Filter
. INSPECTION/ADJUSTMENT YUP 250 Fuel Filter FUEL LINE/FUEL FILTER Remove the right side cover. ( 2-5 ) Check the fuel lines and replace any parts, which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged.
Page 48: Engine Oil
. INSPECTION/ADJUSTMENT YUP 250 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on level ground by its main stand. Wait for 2_ 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.
Page 49: Air Cleaner
. INSPECTION/ADJUSTMENT YUP 250 Air Cleaner Case Cover AIR CLEANER Remove the eight air cleaner case cover screws and the air cleaner case cover. Screws Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.
Page 50: Valve Clearance
. INSPECTION/ADJUSTMENT YUP 250 Cylinder Head Bolts Cover VALVE CLEARANCE ＊ • Inspect and adjust valve clearance while the engine is cold (below 35℃ ). Remove the met-in box ( 2-6 ) and center cover. ( 2-7 ) Remove two nuts and four bolts on the cylinder head.
Page 51: Cylinder Compression
. INSPECTION/ADJUSTMENT YUP 250 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug. Insert a compression gauge. Open the throttle valves fully and pushes the starter button to test the compression.
Page 52: Final Reduction Gear Oil
. INSPECTION/ADJUSTMENT YUP 250 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL ＊ • Place the scooter on its main stand on level ground. Stop the engine and remove the oil checks bolt. The oil level shall be at the oil check blowhole.
Page 53: Headlight Aim
. INSPECTION/ADJUSTMENT YUP 250 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.
Page 54: Brake System
. INSPECTION/ADJUSTMENT YUP 250 Radiator Cap Remove the front cover. Remove the radiator cap. Remove the drain bolt to drain the coolant and tilt the scooter to the right and the coolant will drain more easily. Drain the coolant in the reserve tank.
Page 55: Nuts/Bolts/Fasteners
. INSPECTION/ADJUSTMENT YUP 250 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Pressure Gauge Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.
Page 56 . LUBRICATION SYSTEM YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY ------------------------------------------- 4-4 OIL PUMP INSPECTION ---------------------------------------------- 4-5...
Page 57 . LUBRICATION SYSTEM YUP 250 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump www.PlanDeGraissage.org...
Page 58: Lubrication System
. LUBRICATION SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Drain the coolant before starting any operations. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 59: Engine Oil/Oil Filter
. LUBRICATION SYSTEM YUP 250 Oil Dipstick ENGINE OIL/OIL FILTER ＊ Place the motorcycle upright on • level ground for engine oil level check. Run the engine for 2_ • minutes and check the oil level after the engine is stopped for 2_ 3 minutes.
Page 60: Oil Pump Removal
. LUBRICATION SYSTEM YUP 250 Bolts OIL PUMP REMOVAL First drain the coolant. Remove the right crankcase cover. ( 10-3) Remove the A.C. generator starter driven gear. ( 10-3) Remove the attaching bolt and oil separator cover. Oil Separator Cover...
Page 61: Oil Pump Inspection
. LUBRICATION SYSTEM YUP 250 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Inner Rotor Measure the rotor end-to-pump body clearance.
Page 62: Oil Pump Installation
. LUBRICATION SYSTEM YUP 250 Pump Hole Screw Cover Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.
Page 63 . ENGINE REMOVAL/INSTALLATION YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 5-1 ENGINE HANGER REMOVAL --------------------------------------- 5-2 ENGINE REMOVAL --------------------------------------------------- 5-3 www.PlanDeGraissage.org...
Page 64 5. ENGINE REMOVAL/INSTALLATION YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal.
Page 65: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION YUP 250 ENGINE HANGER REMOVAL Remove rear carrier ( 2-6 ), met-in box ( 2- 6 ), center cover ( 2-7 ), rear fender A ( 2- 8 ), and rear body cover. ( 2-8 ) Remove two bolts on air cleaner.
Page 66 5. ENGINE REMOVAL/INSTALLATION YUP 250 Starter Motor Remove two bolts, then remove the starter motor. Bolts Engine Hanger Bolts (frame side) Remove the engine hanger nut, then remove the engine hanger bolt (engine side). Remove the engine hanger bolts (frame side) and collar, then remove the engine hanger.
Page 67 . ENGINE REMOVAL/INSTALLATION YUP 250 Rubber Sheath Open the rubber sheath and remove the nut, then disconnect the starter motor lead. Rear Brake Fluid Tube Clamps Disconnect rear brake fluid tube from clamps. Remove the bolt on right crankcase cover for disconnect ground wire lead.
Page 68 5. ENGINE REMOVAL/INSTALLATION YUP 250 Rear Fender C Remove three screws, then remove rear fender Screws Screw Right Rear Shock Absorber Lower Bolt Remove the right rear shock absorber lower bolt, rear axle nut, collar and two rear fork bolt.
Page 69 . ENGINE REMOVAL/INSTALLATION YUP 250 Screw Carburetor Loosen band screw, then disconnect carburetor. Remove the left rear shock absorber lower bolt. Bolt Remove engine hanger nut and bolt (engine side). Bolt Remove and pull the engine assembly to back of the machine.
Page 70 5. ENGINE REMOVAL/INSTALLATION YUP 250 Move the engine assembly by rear wheel. ENGINE ASSEMBLY Bushes INSTALLATION Install the engine assembly in the reverse order of removal. ＊ • Apply grease onto the bushes before install the engine assembly. Tighten bolts and nuts...
Page 71 . CYLINDER HEAD/VALVES YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 6- 1 SERVICE INFORMATION -------------------------------------------- 6- 2 TROUBLESHOOTING ------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ----------------------------- 6- 4 CAMSHAFT REMOVAL----------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL --------------------------------------- 6- 6...
Page 72: Schematic Drawing
. CYLINDER HEAD/VALVES YUP 250 SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 73: Service Information
. CYLINDER HEAD/VALVES YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 74: Cylinder Head/Valves
. CYLINDER HEAD/VALVES YUP 250 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low • Worn valve stem or valve guide •...
Page 75: Cylinder Head Cover Removal
. CYLINDER HEAD/VALVES YUP 250 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the met-in box ( 2-6) and center cover. ( 2-7) Remove two nuts and four bolts on the cylinder head. Place the scooter on its side stand for remove the cylinder head cover.
Page 76 . CYLINDER HEAD/VALVES YUP 250 Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: IN: 34.14mm replace if below EX:34.02mm replace if below...
Page 77: Cylinder Head Removal
. CYLINDER HEAD/VALVES YUP 250 Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. ＊ If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.
Page 78: Cylinder Head Disassembly
. CYLINDER HEAD/VALVES YUP 250 Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. ＊ Be sure to compress the valve • springs with a valve spring compressor.
Page 79: Cylinder Head Assembly
. CYLINDER HEAD/VALVES YUP 250 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if...
Page 80: Cylinder Head Installation
. CYLINDER HEAD/VALVES YUP 250 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters. ＊ Be careful not to damage the valves. Cylinder Head Gasket CYLINDER HEAD INSTALLATION Install the cam chain guide.
Page 81: Camshaft Installation
. CYLINDER HEAD/VALVES YUP 250 Punch Marks CAMSHAFT INSTALLATION Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the...
Page 82: Cylinder Head Cover Installation
. CYLINDER HEAD/VALVES YUP 250 Tensioner Screw Turn the cam chain tension screw counter clockwise to release it. O-ring Apply engine oil to a new O-ring and install Tighten the cam chain tension cap screw. ＊ Be sure to install the gasket into the groove properly.
Page 83 . CYLINDER/PISTON YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL ---------------------------------------------------- 7-3 PISTON INSTALLATION --------------------------------------------- 7-7 CYLINDER INSTALLATION----------------------------------------- 7-7 www.PlanDeGraissage.org...
Page 84: Schematic Drawing
. CYLINDER/PISTON YUP 250 SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 85: Cylinder/Piston
. CYLINDER/PISTON YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 86: Cylinder Removal
. CYLINDER/PISTON YUP 250 Cylinder Cam Chain Guide CYLINDER REMOVAL Remove the cylinder head. ( CHAPTER 6) Remove the water hose from the cylinder. Water Hose Remove the cam chain guide. Remove the cylinder. Gasket Remove the cylinder gasket and dowel pins.
Page 87 . CYLINDER/PISTON YUP 250 Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ • Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
Page 88 . CYLINDER/PISTON YUP 250 Measure the piston pin O.D. Service Limit: 16.96mm replace if below Measure the piston O.D. ＊ • Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 72.60mm replace if below Measure the piston-to-piston pin clearance.
Page 89 . CYLINDER/PISTON YUP 250 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.
Page 90: Piston Installation
. CYLINDER/PISTON YUP 250 PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ • Be careful not to drop foreign matters into the crankcase. Piston Install the piston, piston pin and a new piston pin clip. ＊ Position the piston “IN” mark •...
Page 91 . CYLINDER/PISTON YUP 250 Install the cam chain guide. ＊ • Insert the tab on the cam chain guide into the cylinder groove. Dowel Pin Install the cylinder gasket and dowel pins. Connect the water hose to the cylinder. Install the cylinder head. ( CHAPTER 6) Tighten the cylinder base bolt.
Page 92: Drive And Driven Pulleys
. DRIVE AND DRIVEN PULLEYS YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3 DRIVE PULLEY -------------------------------------------------------- 8- 4 CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8 www.PlanDeGraissage.org...
Page 93: Drive And Driven Pulleys
. DRIVE AND DRIVEN PULLEYS YUP 250 SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 94: Service Information
. DRIVE AND DRIVEN PULLEYS YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 95: Left Crankcase Cover
. DRIVE AND DRIVEN PULLEYS YUP 250 LEFT CRANKCASE COVER REMOVAL Remove the four bolts on the left crankcase surface cover. Cover Air Tube Band Bolts Remove the left crankcase cover bolts and left crankcase covers. Remove the seal rubber and dowel pins.
Page 96: Drive Pulley
. DRIVE AND DRIVEN PULLEYS YUP 250 Universal Holder DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer. Remove the drive pulley face. Special Universal Holder...
Page 97 . DRIVE AND DRIVEN PULLEYS YUP 250 Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Remove the weight rollers. Weight Roller INSPECTION Check each weight roller for wear or damage.
Page 98 . DRIVE AND DRIVEN PULLEYS YUP 250 Measure the movable drive face bushing assembly I.D. Service Limit: 27.13mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
Page 99 . DRIVE AND DRIVEN PULLEYS YUP 250 Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Driven Pulley Drive Pulley Collar Lay the drive belt on the driven pulley.
Page 100: Clutch/Driven Pulley
. DRIVE AND DRIVEN PULLEYS YUP 250 Drive Pulley Face Install the drive pulley face, washer and drive face nut. Drive Face Nut Washer Universal Holder Hold the drive pulley with the universal holder and tighten the drive face nut.
Page 101 . DRIVE AND DRIVEN PULLEYS YUP 250 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.
Page 102 . DRIVE AND DRIVEN PULLEYS YUP 250 Guide Roller Pin Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face O-ring Remove the oil seal from the movable driven Oil Seal face.
Page 103 . DRIVE AND DRIVEN PULLEYS YUP 250 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 40.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.
Page 104 . DRIVE AND DRIVEN PULLEYS YUP 250 Press a new needle bearing into the driven face. Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. ＊ Keep grease off the clutch • linings. Retainer Plate Clutch Lining 8-12 www.PlanDeGraissage.org...
Page 105 . DRIVE AND DRIVEN PULLEYS YUP 250 CLUTCH ASS EMBLY Circlips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
Page 106 . DRIVE AND DRIVEN PULLEYS YUP 250 Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
Page 107 . DRIVE AND DRIVEN PULLEYS YUP 250 Clutch Outer Install washer and the clutch outer nut. Hold the clutch outer with the universal holder to tighten clutch outer nut. Torque: 49.0_ 58.8kg-m Special Universal Holder E017 8-15 www.PlanDeGraissage.org...
Page 108 . FINAL REDUCTION YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 9-1 SERVICE INFORMATION -------------------------------------------- 9-2 TROUBLESHOOTING ------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY------------------------------- 9-3 FINAL REDUCTION INSPECTION---------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ----------------------------------- 9-6 www.PlanDeGraissage.org...
Page 109 . FINAL REDUCTION YUP 250 SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 110 . FINAL REDUCTION YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
Page 111 . FINAL REDUCTION YUP 250 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. ( 2-10) Remove the rear brake caliper. ( 15-3) Remove the right rear shock absorber. ( 15-5) Remove the rear fork. ( 15-4) Remove the rear wheel. ( 15-4) Remove the left crankcase cover.
Page 112: Final Reduction
. FINAL REDUCTION YUP 250 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Final Shaft Bearing...
Page 113 . FINAL REDUCTION YUP 250 Bearing Remover, 15mm BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Drive Shaft Bearing Pilot, 15mm Drive new bearings into the transmission case cover.
Page 114 . FINAL REDUCTION YUP 250 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the left crankcase.
Page 115 . FINAL REDUCTION YUP 250 Install the countershaft and gear into the left crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Countershaft Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case Bolts cover bolts.
Page 116 . FINAL REDUCTION YUP 250 Oil Check Bolt Hole/Oil Filler After installation, fill the transmission case with the specified oil. ＊ • Place the motorcycle on its main stand on level ground. • Check the oil-sealing washer for wear or damage.
Page 117 . A.C. GENERATOR/STARTER CLUTCH YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 10-1 SERVICE INFORMATION -------------------------------------------- 10-2 TROUBLESHOOTING ------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3 STATOR REMOVAL --------------------------------------------------- 10-3 FLYWHEEL REMOVAL----------------------------------------------- 10-3 STARTER CLUTCH ---------------------------------------------------- 10-4...
Page 118: Schematic Drawing
. A.C. GENERATOR/STARTER CLUTCH YUP 250 SCHEMATIC DRAWING 10-1 www.PlanDeGraissage.org...
Page 119: Service Information
. A.C. GENERATOR/STARTER CLUTCH YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
Page 120: . A.c. Generator/Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH YUP 250 Bolts Water Inlet Hose RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover. Water Outlet Hose A.C. Generator Stator...
Page 121: Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH YUP 250 Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter driven gear. Starter Driven Gear Remove the starter idle gear and shaft. Starter Idle Gear INSPECTION Inspect the starter driven gear for wear or damage.
Page 122: Flywheel Installation
. A.C. GENERATOR/STARTER CLUTCH YUP 250 Remove the starter one-way clutch rollers, plungers and springs. INSTALLATION Starter Idle Gear Shaft Install the starter driven gear onto the crankshaft. Install the starter idle gear and shaft. Starter Driven Gear FLYWHEEL INSTALLATION...
Page 123: Stator Installation
. A.C. GENERATOR/STARTER CLUTCH YUP 250 A.C. Generator Stator Screws STATOR INSTALLATION Install the A.C. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws.
Page 124 . CRANKCASE/CRANKSHAFT YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT INSPECTION----------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5 11-0 www.PlanDeGraissage.org...
Page 125: Schematic Drawing
. CRANKCASE/CRANKSHAFT YUP 250 SCHEMATIC DRAWING 11-1 www.PlanDeGraissage.org...
Page 126: Service Information
. CRANKCASE/CRANKSHAFT YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
Page 127: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT YUP 250 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the three right crankcase attaching bolts. Bolt Cam Chain Remove the left crankcase.
Page 128: Crankshaft Inspection
. CRANKCASE/CRANKSHAFT YUP 250 Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over 11-4 www.PlanDeGraissage.org...
Page 129: Crankcase Assembly
. CRANKCASE/CRANKSHAFT YUP 250 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
Page 130 . CRANKCASE/CRANKSHAFT YUP 250 Place the left crankcase down and install the crankshaft into the left crankcase. ＊ Avoid damaging the oil seal. • Apply grease to the lip of the oil • seal. Gasket Install the two dowel pins and a new gasket.
Page 131 . CRANKCASE/CRANKSHAFT YUP 250 Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 7.8_ 11.8N-m Bolt 11-7 www.PlanDeGraissage.org...
Page 132 . COOLING SYSTEM YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------- 12- 2 TROUBLESHOOTING ------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------- 12- 4 RADIATOR -------------------------------------------------------------- 12- 5 WATER PUMP ---------------------------------------------------------- 12- 9...
Page 133 . COOLING SYSTEM YUP 250 SCHEMATIC DRAWING 12-1 www.PlanDeGraissage.org...
Page 134: Cooling System
. COOLING SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system.
Page 135 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water -9℃ -15℃ 425cc 975cc -25℃...
Page 136: Cooling System Testing
. COOLING SYSTEM YUP 250 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the cap sealing surface before testing.
Page 137: Radiator
. COOLING SYSTEM YUP 250 RADIATOR RADIATOR INSPECTION Remove the front cover. ( 2-4) Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off.
Page 138 . COOLING SYSTEM YUP 250 Fan Motor Wire Coupler Disconnect the thermostatic switch wire lead. Disconnect the fan motor wire coupler. Thermostatic Switch Nuts Bolts Remove the three bolts and two nuts on the radiator, then remove the radiator. Fan/Shroud...
Page 139 . COOLING SYSTEM YUP 250 Battery Check fan motor by battery. Fan Motor Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85~90℃ the thermostatic switch OFF. When coolant temperature over 85~90℃ the thermostatic switch ON. Fan/Shroud Install the fan shroud on the radiator with the three bolts.
Page 140 . COOLING SYSTEM YUP 250 Nuts Bolts RADIATOR INSTALLATION Install the radiator on the radiator bracket with the three bolts and two nuts. Fan Motor Wire Coupler Connect the thermostatic switch lead and fan motor wire couplers. Thermostatic Switch Upper Hose Connect the upper and lower hoses and secure them with hose bands.
Page 141: Water Pump
. COOLING SYSTEM YUP 250 Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
Page 142 . COOLING SYSTEM YUP 250 Bolts Water Pump Cover Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Impeller (Left Hand Remove the water pump impeller. Threads) ＊ The impeller has left hand threads. Mechanical Seal Inspect the mechanical (water) seal and seal washer for wear or damage.
Page 143 . COOLING SYSTEM YUP 250 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the eight bolts attaching the right crankcase cover. Water Pump Assembly Water Pump Assembly Inner Bearing Remove the water pump bearing snap ring from the water pump assembly.
Page 144 . COOLING SYSTEM YUP 250 Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver.
Page 145 . COOLING SYSTEM YUP 250 Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Bolts Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.
Page 146 . COOLING SYSTEM YUP 250 Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 9.8_ 13.7N-m ＊ The impeller has left hand threads. Dowel Pins Install the two dowel pins and a new gasket. Water Pump Cover Install the water pump cover and tighten the 4 bolts.
Page 147: Thermosensor
. COOLING SYSTEM YUP 250 THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire Thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water Thermosensor over a burner and measure the resistance through the sensor as the water heats up.
Page 148: Thermostat
. COOLING SYSTEM YUP 250 Thermostat Water Hose Bolt THERMOSTAT THERMOSTAT REMOVAL Remove the the met-in box and center cover. ( 2-6) Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing.
Page 149 . COOLING SYSTEM YUP 250 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80±2℃ Full-open 90℃ Valve lift 3.5_...
Page 150 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM --------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ---------------------------------------------- 13- 2 OPERATION OF CARBURETOR JETS------------------------------ 13- 3 SERVICE INFORMATION -------------------------------------------- 13- 5 CARBURETOR REMOVAL ------------------------------------------- 13- 7...
Page 151 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 FUEL SYSTEM 13-1 www.PlanDeGraissage.org...
Page 152 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 SCHEMATIC DRAWING 13-2 www.PlanDeGraissage.org...
Page 153: Fuel System/Carburetor/Fuel Pump Fuel Tank
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 OPERATION OF CARBURETOR JETS LOW SPEED Venturi (slightly opened throttle valve) ※ Air Bleed Holes‡ Mixture……. Low Speed Air Inlet Fuel in Float Chamber‡ Slow Jet ※ -------------------- Low Speed Small Jet Holes 2.MIDDLE SPEED...
Page 154 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 FUEL PUMP CONSTRUCTION: The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.
Page 155: Service Information
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly.
Page 156 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly • No fuel in tank • Incorrect idle speed • Restricted fuel line • Rich mixture • Too much fuel getting to cylinder •...
Page 157: Carburetor Removal
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Auto Fuel Tube Bystarter/T.P.S/ Heater Wire CARBURETOR REMOVAL Remove the met-in box. ( 2-6) Disconnect the fuel tube and vacuum tube at the carburetor. Disconnect the auto bystarter, heater and T.P.S wire.
Page 158 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Diaphragm Vacuum Piston Remove the needle holder, spring and jet needle from the piston.
Page 159: Float Chamber Disassembly
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Valve Float Pin Float Valve...
Page 160 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 JETS/SCREWS REMOVAL ＊ • Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns. Do not force the pilot screw against its seat to avoid seat damage.
Page 161: Auto Bystarter Inspection/Removal
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10W (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.
Page 162: Air Cut-Off Valve (A.c.v.)
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle...
Page 163 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body. ＊ • Make sure that no fuel jet is clogged. O-ring Install the O-ring onto the air-cut-off valve body securely.
Page 164 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Screws ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. Diaphragm Cover INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration.
Page 165: Float Chamber Assembly
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Main Jet Slow Jet FLOAT CHAMBER ASSEMBLY Install the main jet. Install the slow jet. Install the pilot screw. ＊ • Be sure to record the rotating turns when it is removed.
Page 166: Float Level Inspection
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet (just contacting the float valve). Float Level: 18.5±1.0mm Replace the float if the level is incorrect. Check the operation of the float and then reinstall the float chamber.
Page 167: Carburetor Installation
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Heater Air Cleaner Connecting Intake Manifold Band Tube Band CARBURETOR INSTALLATION Tighten the drain screw.
Page 168: Fuel Pump Removal/Disassembly
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Bolts Outlet Tube Vacuum Tube FUEL PUMP REMOVAL Remove the frame rear body cover. ( 2-8) Disconnect the fuel pump inlet, outlet and vacuum tubes. Remove the two fuel pump attaching bolts and the fuel pump.
Page 169: Fuel Pump Inspection
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Relief Valve Outlet Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.
Page 170: Fuel Pump Installation
. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Bolts Outlet Tube Vacuum Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts. Connect the fuel pump inlet, outlet and vacuum tubes. Inlet Tube Fuel Pump Measure the fuel pump output.
Page 171 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK YUP 250 Remove the fuel tank. The installation sequence is the reverse of removal. Fuel Strainer FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tubes. Fuel Tube INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air.
Page 172: Steering Handlebar/Front Wheel/Front Brake/Front
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 14- 1 SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 STEERING HANDLEBAR--------------------------------------------- 14- 4...
Page 173: Schematic Drawing
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1 www.PlanDeGraissage.org...
Page 174: Service Information
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 175: Troubleshooting
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate • Insufficient tire pressure •...
Page 176: Steering Handlebar
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 2-3) Remove the front and rear brake master cylinder attaching bolts. Remove the front cover. ( 2-4) Remove the front body cover.
Page 177: Front Wheel
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
Page 178 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
Page 179 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ Do not allow the bearings to tilt •...
Page 180: Front Brake
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Fluid Bolts Holder FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. ( 2-3) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
Page 181 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear.
Page 182 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Connect the front stop switch wire connector. Install the handlebar covers. ( 2-3) BRAKE FLUID REFILLING Stop Switch Wire Connector Keep the handlebar upright and remove the brake reservoir cover and diaphragm.
Page 183 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
Page 184 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore.
Page 185 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 24.5_ 34.3N-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.
Page 186: Front Shock Absorber
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Shock Absorber Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front cover. ( 2-4) Remove the front body cover. ( 2-4) Remove the front wheel. ( 14-5) Remove the front brake caliper. ( 14-11) Remove the front shock absorber upper mount bolts.
Page 187 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending, damage or wear •Weak front shock absorber spring •Damper and damper rod bending •Oil seal damage or wear 14-15 www.PlanDeGraissage.org...
Page 188: Front Fork
14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube. Set the front shock absorber tube in a vise and then tighten the lock nut.
Page 189 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. ( 2-3) Remove the front cover. ( 2-4) Remove the front body cover. ( 2-4) Remove the front wheel. ( 14-5) Remove the front brake caliper.
Page 190 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT YUP 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Outer Driver Drive in new ball races. ＊ Be sure to drive the ball races into place completely. Bottom Ball Race INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.
Page 191: Rear Brake/Rear Fork/Rear
. REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 REAR BRAKE ----------------------------------------------------------- 15-3 REAR FORK ------------------------------------------------------------- 15-4...
Page 192 . REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1 www.PlanDeGraissage.org...
Page 193: Wheel/Rear Shock Absorber
. REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk.
Page 194: Rear Brake
. REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. ( 2-10) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove the two bolts attaching the rear brake caliper.
Page 195: Rear Fork
. REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER REAR FORK Shock Absorber Lower Mount Bolt REMOVAL Remove the exhaust muffler. ( 2-10) Remove the rear brake caliper. ( 15-3) Remove the right rear shock absorber lower mount bolt. Remove the rear axle nut and remove the collar.
Page 196: Rear Shock Absorber
. REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER Shock Absorber Lower Mount Bolt INSTALLATION The installation sequence is the reverse of removal. Torque: Rear shock absorber lower mount bolt: 45N-m Rear axle nut: 110_ 130N-m Brake Caliper Bolts Axle Nut...
Page 197 . REAR BRAKE/REAR FORK/REAR YUP 250 WHEEL/REAR SHOCK ABSORBER Spring Rubber INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Damper Rod ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly.
Page 198 . BATTERY/CHARGING SYSTEM YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6 16-0...
Page 199 . BATTERY/CHARGING SYSTEM YUP 250 CHARGING SYSTEM LAYOUT Battery (in the met-in box) Fuse Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 16-1 www.PlanDeGraissage.org...
Page 200: Battery/Charging System
. BATTERY/CHARGING SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention •...
Page 201: Troubleshooting
. BATTERY/CHARGING SYSTEM YUP 250 SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in ignition system •...
Page 202: Battery
. BATTERY/CHARGING SYSTEM YUP 250 Battery Cover Battery BATTERY Open the seat with key. Remove the battery cover screw and the battery cover. Remove the battery. First disconnect the battery negative (-) cable and then the positive (+) cable. ＊...
Page 203: Charging System
. BATTERY/CHARGING SYSTEM YUP 250 Red Wire CHARGING SYSTEM CURRENT TEST ＊ Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.
Page 204: Regulator/Rectifier Inspection
. BATTERY/CHARGING SYSTEM YUP 250 A.C. Generator Stator Pulser Coil A.C. GENERATOR REMOVAL A.C. generator removal ( 10-3) A.C. generator installation ( 10-6) Right Crankcase Cover Bolts Regulator/Rectifier REGULATOR/RECTIFIER INSPECTION Remove the met-in box. ( 2-6) Remove the regulator/rectifier wire coupler.
Page 205 . IGNITION SYSTEM YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4 IGNITION UNIT RESISTANCE INSPECTION--------------------- 17-4 17-0 www.PlanDeGraissage.org...
Page 206 . IGNITION SYSTEM YUP 250 IGNITION SYSTEM LAYOUT Ignition Switch Ignition Unit Ignition Coil Pulser Coil A.C. Generator IGNITION CIRCUIT IGNITION UNIT 17-1 www.PlanDeGraissage.org...
Page 207: Ignition System
. IGNITION SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 1-28) • The ignition system adopts ignition unit and the ignition timing cannot be adjusted. • If the timing is incorrect, inspect the ignition unit and A.C. generator and replace any faulty parts.
Page 208: Spark Plug
. IGNITION SYSTEM YUP 250 Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the met-in box. ( 2-6) Remove the center cover. ( 2-7) Remove the ignition coil Ignition Coil...
Page 209: A .C. Generator Inspection
. IGNITION SYSTEM YUP 250 A .C. GENERATOR INSPECTION EXCITER COIL/PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the met-in box. ( 2-6) Disconnect the A.C. generator connector. Measure the exciter coil resistance between the black/red wire terminal and ground.
Page 210 . IGNITION SYSTEM YUP 250 ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester in an improper range may give false readings. • Use Electric tester: YF-3501.
Page 211 . STARTING SYSTEM YUP 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION----------------------------------- 18-5 STARTER RELAY INSPECTION ------------------------------------ 18-6 18-0 www.PlanDeGraissage.org...
Page 212: Starting System
. STARTING SYSTEM YUP 250 STARTING SYSTEM LAYOUT Starter Button Starter Relay Stop Switches Starter Motor STARTING CIRCUIT Relay 18-1 www.PlanDeGraissage.org...
Page 213: Service Information
. STARTING SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 10-3. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 214 . STARTING SYSTEM YUP 250 STARTER MOTOR Starter Motor Cable Rubber Sheath REMOVAL ＊ • Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
Page 215 . STARTING SYSTEM YUP 250 DISASSEMBLY Front Cover Motor Case Remove the two starter motor case screws, front cover, rear cover, motor case and other parts. Case Screws Commutator INSPECTION Inspect the removed parts for wear, damage or discoloration. Replace if necessary.
Page 216 . STARTING SYSTEM YUP 250 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.
Page 217: Starter Clutch Inspection
. STARTING SYSTEM YUP 250 ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.
Page 218: Starter Relay Inspection
. STARTING SYSTEM YUP 250 Starter Relay Wire STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
Page 219: Switches/Horn/Fuel Unit
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5...
Page 220 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Starter Button Engine Stop Switch Headlight Stop Switches Switch Passing Ignition Switch Dimmer Switch Turn Signal Switch Horn Button Thermostati Fuel Unit c Switch Horn Heater Control Unit 19-1...
Page 221: Service Information
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS • After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT...
Page 222: Switches
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SWITCHES IGNITION SWITCH INSPECTION Remove the frame front body covers. ( 2-4) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/Wh Green Black Position PARK LOCK ○...
Page 223 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN BUTTON INSPECTION Remove the handlebar front covers. ( 2-3) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Br/L Color Light Green Brown/Blue...
Page 224: Horn Inspection
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN INSPECTION Remove the front body cover. ( 2-4) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
Page 225: Thermostatic Switch
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS THERMOSTATIC SWITCH INSPECTION Remove the front body covers. ( 2-4) Start and run the engine to make the water temperature reaches 85℃_ 90℃ and check if the cooling fan motor operates. Lower the water temperature to 85℃...
Page 226: Instruments
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS THROTTLE POSTTION SENSOR Unit:KW ∞ 0~5±1 0~5±1 ∞ T.P.S. INSTRUMENTS Screws REMOVAL Remove the handlebar rear cover. ( 2-3) Remove the three screws under instruments. Remove the instruments from the handlebar rear cover.
Page 227: Side Stand Switch
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Rubber Boot FRONT POSITION LIGHT /HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover. ( 2-3) Remove the position bulb socket by turning them counterclockwise. Remove the bulb and replace with new one.
Page 228: Heater Wiring Diagram
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH YUP 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HEATER WIRING DIAGRAM 19-9 www.PlanDeGraissage.org...

KYMCO YUP 250 Manual

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