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2014
SERVICE MANUAL
YP250R
YP250RA
2DL-F8197-E0

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Table of Contents
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Summarization of Contents

General Information
Identification
Details on how to identify the vehicle model and VIN.
Features
Overview of the motorcycle's key features, including FI and ABS systems.
Instrument Functions
Description of the multi-function meter unit functions and displays.
Important Information
Crucial guidelines for preparation, parts, and component handling.
Basic Service Information
Information on quick fasteners and electrical system handling.
Special Tools
List of necessary special tools for maintenance and assembly.
Specifications
General Specifications
Basic dimensions, weight, and load capacity of the vehicle.
Engine Specifications
Detailed technical specifications for the engine and its components.
Chassis Specifications
Specifications related to the chassis, wheels, tires, and suspension.
Electrical Specifications
Electrical system parameters, including voltage, components, and fuses.
Tightening Torques
Specifies torque values for critical fasteners across various assemblies.
Periodic Checks and Adjustments
Periodic Maintenance
Outlines recommended maintenance tasks based on mileage or time intervals.
Adjusting the Valve Clearance
Detailed procedure for measuring and adjusting valve clearance.
Bleeding the Hydraulic Brake System (for YP250R)
Procedure for removing air from the hydraulic brake system.
Checking the Engine Oil Level
Procedure for checking the engine oil level using the dipstick.
Replacing the V-belt
Steps for replacing the V-belt and resetting the indicator.
Chassis
Front Wheel
Procedures for removing, disassembling, checking, and installing the front wheel.
Rear Wheel
Procedures for removing, checking, and installing the rear wheel.
ABS (Anti-lock Brake System) (for YP250RA)
Detailed explanation of the ABS system, its components, and operation.
Handlebar
Procedures for removing, checking, and installing handlebar components.
Front Fork
Steps for removing, disassembling, checking, and assembling the front fork legs.
Front Brake
Removing the Front Brake Pads
Steps for removing and replacing front brake pads without disconnecting the brake hose.
Checking the Front Brake Disc
Procedure for checking brake disc thickness and deflection.
Installing the Front Brake Caliper
Steps for installing the front brake caliper, including brake hose routing.
Rear Brake
Removing the Rear Brake Pads (for YP250R)
Steps for replacing rear brake pads without disconnecting the brake hose.
Checking the Rear Brake Disc
Inspecting the rear brake disc for damage, thickness, and runout.
Installing the Rear Brake Caliper (for YP250R)
Steps for installing the rear brake caliper, including hose routing and bleeding.
ABS (Anti-lock Brake System) (for YP250RA)
Removing the Hydraulic Unit Assembly
Steps for safely removing the ABS hydraulic unit assembly and related components.
Hydraulic Unit Operation Tests
Procedures for testing ABS hydraulic unit operation and reaction force.
Basic Process for Troubleshooting
Outlines the systematic approach to diagnosing ABS malfunctions.
Engine
Engine Inspection
Procedures for checking engine health, including compression testing.
Engine Removal
Detailed steps for safely removing the engine from the vehicle.
Cylinder Head
Procedures for removing, checking, and installing cylinder head components.
Camshaft
Steps for removing, checking, and installing the camshaft and rocker arms.
Valves and Valve Springs
Procedures for removing, checking, and installing valves, springs, and guides.
Cylinder and Piston
Steps for removing, checking, and installing the cylinder, piston, and rings.
V-Belt Automatic Transmission
Procedures for servicing the V-belt, sheaves, and clutch components.
Starter Clutch and Generator
Covers removal, checking, and installation of starter clutch and generator.
Electric Starter
Procedures for removing, disassembling, checking, and assembling the starter motor.
Oil Pump
Steps for removing, checking, and assembling the oil pump.
Transmission
Procedures for removing, checking, and installing the transmission assembly.
Crankshaft
Steps for removing, disassembling, checking, and installing the crankshaft.
Cooling System
Radiator
Procedures for removing, checking, and installing the radiator.
Thermostat
Steps for checking and installing the thermostat.
Water Pump
Procedures for removing, disassembling, checking, assembling, and installing the water pump.
Fuel System
Fuel Tank
Procedures for removing, checking, and installing the fuel tank and pump.
Throttle Body
Steps for removing, checking, and installing the throttle body and related sensors.
Electrical System
Ignition System
Covers the ignition system circuit diagram and troubleshooting steps.
Electric Starting System
Details the circuit diagram, operation, and troubleshooting for the electric starting system.
Charging System
Includes circuit diagram and troubleshooting for the battery charging system.
Lighting System
Circuit diagram and troubleshooting for the vehicle's lighting components.
Signaling System
Circuit diagram and troubleshooting for turn signals, brake lights, and horn.
Cooling System
Circuit diagram and troubleshooting for the cooling fan motor.
Fuel Injection System
Detailed circuit diagrams, ECU self-diagnostics, and troubleshooting for the FI system.
Fuel Pump System
Circuit diagram and troubleshooting procedures for the fuel pump system.
Immobilizer System
Information on the immobilizer system, key registration, and troubleshooting.
ABS (Anti-lock Brake System) (for YP250RA)
Comprehensive guide to the ABS system, including circuit diagrams and troubleshooting.
Electrical Components
Identification and checking procedures for various electrical components.
Checking the Switches
How to check the continuity and operation of various switches.
Checking the Bulbs and Bulb Sockets
Procedures for checking bulb and socket condition and continuity.
Checking the Fuses
Steps for checking fuse continuity and replacing blown fuses.
Checking and Charging the Battery
Guide to checking battery voltage and proper charging methods.
Checking the Relays
Procedures for checking the continuity and operation of various relays.
Checking the Diodes
Steps for checking diode continuity.
Checking the Spark Plug Cap
Procedure for checking the resistance of the spark plug cap.
Checking the Ignition Coil
Steps for checking the primary and secondary coil resistance.
Checking the Ignition Spark Gap
Procedure for checking and adjusting the ignition spark gap.
Checking the Crankshaft Position Sensor
Steps for checking the resistance of the crankshaft position sensor.
Checking the Lean Angle Sensor
Procedure for checking the lean angle sensor output voltage.
Checking the Starter Motor Operation
How to check the starter motor operation.
Checking the Stator Coil
Procedure for checking stator coil resistance.
Checking the Rectifier/Regulator
Steps for checking the charging voltage.
Checking the Fuel Sender
Procedure for checking the fuel sender resistance.
Checking the Speed Sensor (for YP250R)
Steps for checking the speed sensor output voltage.
Checking the Radiator Fan Motor
Procedure for checking the radiator fan motor.
Checking the Coolant Temperature Sensor
Steps for checking the coolant temperature sensor resistance.
Checking the Throttle Position Sensor
Procedure for checking the throttle position sensor voltage.
Checking the Intake Air Pressure Sensor
Steps for checking the intake air pressure sensor output voltage.
Checking the Intake Air Temperature Sensor
Procedure for checking the intake air temperature sensor resistance.
Checking the Air Temperature Sensor
Procedure for checking the air temperature sensor resistance.
Checking the Fuel Injector
Steps for checking the fuel injector resistance.
Checking the ISC (Idle Speed Control) Unit
Procedure for checking the ISC unit resistance.
Troubleshooting
General Information
General guidance for troubleshooting common issues.
Starting Failure/Hard Starting
Common causes and checks for engine starting problems.
Incorrect Engine Idling Speed
Potential causes for abnormal engine idling speed.
Poor Medium-and-High-Speed Performance
Troubleshooting steps for issues affecting mid to high-speed engine performance.
Faulty Clutch
Diagnosis and solutions for clutch-related problems causing the vehicle not to move.
Overheating
Potential causes and checks for engine overheating issues.
Poor Braking Performance
Common issues leading to reduced braking performance.
Faulty Front Fork Legs
Troubleshooting for issues related to front fork legs, including oil leaks and damage.
Unstable Handling
Factors contributing to unstable vehicle handling and steering issues.
Faulty Lighting or Signaling System
Troubleshooting for issues with headlights, taillights, and turn signals.
Self-diagnostic Function and Diagnostic Code Table
Self-diagnostic Function Table
Table mapping fault codes to items, symptoms, and reference pages for diagnosis.
Communication Error with the Meter
Troubleshooting steps for communication errors between ECU and multi-function meter.
Diagnostic Code: Sensor Operation Table
Procedures for checking sensor operation using diagnostic codes.

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