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Yamaha 2010 XMAX YP125R Service Manual

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Table of Contents
2010
SERVICE MANUAL
YP125R/YP250R
37P-F8197-E0

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Table of Contents

   Summary of Contents for Yamaha 2010 XMAX YP125R

  • Page 1 2010 SERVICE MANUAL YP125R/YP250R 37P-F8197-E0...
  • Page 2 EAS20060 YP125R/YP250R 2010 SERVICE MANUAL ©2009 by Yamaha Motor España, S.A. First edition, November 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited.
  • Page 3 EAS20071 IMPORTANT This manual was produced by Yamaha Motor España, S.A. primarily for use by Yamaha and MBK deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS................1-4 IMPORTANT INFORMATION ................. 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS................1-8 GASKETS, OIL SEALS AND O-RINGS ............
  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the location shown. This information will be needed to order spare parts.
  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS37P1140 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
  • Page 12: Fi System

    FEATURES EAS37P1141 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.50 kgf/cm², 36.3 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 13 INSTRUMENT FUNCTIONS • a fuel reserve tripmeter (which shows the dis- EAS37P1080 INSTRUMENT FUNCTIONS tance traveled since the bottom segment of the fuel meter and fuel level warning indicator Multi-function display started flashing) EWA37P1016 • a self-diagnosis device WARNING • a clock Be sure to stop the vehicle before making •...
  • Page 14: Oil Change Indicator

    This indicator flashes at the initial 1000 km (600 mi), then at 6000 km (3500 mi) and every 6000 km (3500 mi) thereafter for YP125R, or at 4000 To reset a tripmeter, select it by pushing the “SE- km (2500 mi) and every 3000 km (1800 mi) LECT”...
  • Page 15 This indicator flashes every 18000 km (10500 light will flash and the multi-function display will mi) for the YP125R, or every 20000 km (12500 indicate a fault code when the key is turned to mi) for the YP250R, when the V-belt needs to be “ON”.
  • Page 16: Instrument Functions

    INSTRUMENT FUNCTIONS Immobilizer system keys may cause signal inter- “SELECT” button for at least two seconds ference, which may prevent the engine from switches the ambient temperature display to the starting. clock display. 2. If the engine starts, turn it off, and try starting •...
  • Page 17: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
  • Page 18: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
  • Page 19: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...
  • Page 20: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 21 T-handle 3/8" drive 60 cm long YM-01326 Fork seal driver weight 4-54 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø38) 4-54 90890-01372 Replacement 38 mm YM-A5142-1 Yamaha bond No. 1215 5-12, 5-43, 90890-85505 5-59, 5-103, (Three Bond No.1215®) 5-120, 6-15 1-12...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-19, 5-24, 90890-04019 5-78, 5-83 YM-04019 Valve spring compressor attachment 5-19, 5-24, 90890-04108 5-78, 5-83 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø4.5) 5-20 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø4.5) 5-20...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Locknut wrench 5-33, 5-37, 90890-01348 5-93, 5-97 YM-01348 Clutch spring holder 5-34, 5-37, 90890-01337 5-94, 5-97 Clutch spring holder arm 5-34, 5-37, 90890-01464 5-94, 5-97 Oil seal guide (ø41) 5-36, 5-96 90890-01396 Flywheel puller 5-41, 5-101 90890-01362...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-56, 5-117 90890-01135 Crankcase separator YU-01135-B Crankshaft installer pot 5-58, 5-59, 90890-01274 5-119, 5-120 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-58, 5-59, 90890-01275 5-119, 5-120 Bolt YU-90060 Adapter (M14) 5-58, 5-59, 90890-01478 5-119...
  • Page 25 YM-04064-A Valve guide installer (ø6) 5-79 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 5-79 90890-04066 Valve guide reamer (6.0 mm) YM-04066 Yamaha grease G 5-91 90793-40016 Spacer (crankshaft installer) 5-119 90890-04081 Pot spacer YM-91044 YM-91044 1-16...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Adapter (M16) 5-120 90890-01280 Adapter #7 YM-90067 Spacer 5-120 90890-01288 Mechanical seal installer 90890-04145 ø30 ø10 Middle driven shaft bearing driver 6-6, 6-15 90890-04058 Bearing driver 40 mm YM-04058 Mechanical seal installer 6-15 90890-04132 Water pump seal installer...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness-lean angle sensor (6P) 8-84 90890-03209 Test harness 8-89 90890-03204 1-18...
  • Page 28 SPECIAL TOOLS 1-19...
  • Page 29: Specifications

    TIGHTENING TORQUES (YP125R) ............. 2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES (YP125R)....2-21 ENGINE....................2-21 CHASSIS....................2-23 LUBRICATION SYSTEM DIAGRAMS (YP125R) ......... 2-25 COOLING SYSTEM DIAGRAMS (YP125R) ..........2-27 CABLE ROUTING (YP125R) ................
  • Page 30 COOLING SYSTEM DIAGRAMS (YP250R) ..........2-73 CABLE ROUTING (YP250R) ................ 2-75...
  • Page 32: General Specifications (yp125r)

    GENERAL SPECIFICATIONS (YP125R) EAS37P1117 GENERAL SPECIFICATIONS (YP125R) Model Model 39D1 (YAMAHA) 39D3 (MBK) Dimensions Overall length 2201 mm (86.7 in) Overall width 776 mm (30.6 in) Overall height 1337 mm (52.6 in) Seat height 792 mm (31.2 in) Wheelbase 1545 mm (60.8 in) Ground clearance 134 mm (5.30 in)
  • Page 33: Engine Specifications (yp125r)

    ENGINE SPECIFICATIONS (YP125R) EAS37P1118 ENGINE SPECIFICATIONS (YP125R) Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 124 cm³ Cylinder arrangement Forward-inclined single cylinder Bore × stroke 52.0 × 58.6 mm (2.05 × 2.31 in) Compression ratio 11.20 :1 Standard compression pressure (at sea level) 550 kPa/680 r/min (5.5 kgf/cm²/680 r/min, 78.2...
  • Page 34 ENGINE SPECIFICATIONS (YP125R) Radiator cap opening pressure 100.0–120.0 kPa (1.00–1.20 kgf/cm², 14.5–17.4 psi) Thermostat Valve opening temperature 70.5–73.5 °C (158.9–164.3 °F) Valve full open temperature 85.0 °C (185.0 °F) Valve lift (full open) 3.0 mm (0.12 in) Radiator core Width 244.0 mm (9.61 in)
  • Page 35 ENGINE SPECIFICATIONS (YP125R) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in) Limit 10.015 mm (0.3943 in) Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in) Limit 9.940 mm (0.3913 in)
  • Page 36 ENGINE SPECIFICATIONS (YP125R) Limit 0.5 mm (0.02 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.445 mm (0.1750 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) Limit 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.550 mm (0.1791 in)
  • Page 37 ENGINE SPECIFICATIONS (YP125R) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 52.000–52.010 mm (2.0472–2.0476 in) Wear limit 52.110 mm (2.0516 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.005 mm (0.0002 in) Warp limit 0.05 mm (0.0020 in)
  • Page 38 ENGINE SPECIFICATIONS (YP125R) Limit 0.60 mm (0.0236 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.120 mm (0.0047 in) Oil ring Dimensions (B × T) 1.50 × 1.95 mm (0.06 × 0.08 in) End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) Ring side clearance 0.060–0.150 mm (0.0024–0.0059 in)
  • Page 39 ENGINE SPECIFICATIONS (YP125R) Secondary reduction ratio 44/13 (3.385) Operation Centrifugal automatic type Gear ratio 2.645–0.824 :1 Decompression device Device type Auto decomp Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Output pressure 250.0 kPa (2.50 kgf/cm², 36.3 psi)
  • Page 40: Chassis Specifications (yp125r)

    CHASSIS SPECIFICATIONS (YP125R) EAS37P1119 CHASSIS SPECIFICATIONS (YP125R) Chassis Frame type Steel tube underbone Caster angle 28.00° Trail 100.0 mm (3.94 in) Front wheel Wheel type Cast wheel 15 × MT3.5 Rim size Rim material Aluminum Wheel travel 110.0 mm (4.33 in) Radial wheel runout limit 1.0 mm (0.04 in)
  • Page 41 CHASSIS SPECIFICATIONS (YP125R) Front disc brake Disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 5.0 mm (0.20 in)
  • Page 42 CHASSIS SPECIFICATIONS (YP125R) Rear suspension Type Unit swing Spring/shock absorber type Coil spring/oil damper Rear shock absorber assembly travel 95.0 mm (3.74 in) Spring free length 274.0 mm (10.79 in) Installed length 241.3 mm (9.50 in) Spring rate K1 8.00 N/mm (0.82 kgf/mm, 45.68 lb/in) Spring rate K2 17.30 N/mm (1.76 kgf/mm, 98.78 lb/in)
  • Page 43: Electrical Specifications (yp125r)

    ELECTRICAL SPECIFICATIONS (YP125R) EAS37P1120 ELECTRICAL SPECIFICATIONS (YP125R) Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Advancer type Digital Ignition timing (B.T.D.C.) 8.0°/1700 r/min Engine control unit Model/manufacturer 39D0/YAMAHA Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 44 ELECTRICAL SPECIFICATIONS (YP125R) Indicator lights 12 V, 1.4 W × 2 Turn signal indicator light 12 V, 1.4 W × 1 High beam indicator light 12 V, 1.4 W × 1 Engine trouble warning light Immobilizer system indicator light Electric starting system...
  • Page 45 ELECTRICAL SPECIFICATIONS (YP125R) Spare fuse 15.0 A Spare fuse 10.0 A Spare fuse 5.0 A Spare fuse 7.5 A 2-14...
  • Page 46: Tightening Torques (yp125r)

    TIGHTENING TORQUES (YP125R) EAS37P1121 TIGHTENING TORQUES (YP125R) EAS37P1123 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual.
  • Page 47: Engine Tightening Torques

    TIGHTENING TORQUES (YP125R) EAS37P1122 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt 53 Nm (5.3 m·kgf, 38 ft·lbf) Muffler joint bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) sensor 45 Nm (4.5 m·kgf, 32 ft·lbf)
  • Page 48 TIGHTENING TORQUES (YP125R) Thread Item Q’ty Tightening torque Remarks size Engine oil drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Final transmission oil drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Crankcase bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Timing chain guide bolt (intake 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 49: Chassis Tightening Torques

    TIGHTENING TORQUES (YP125R) EAS37P1124 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket nut 59 Nm (5.9 m·kgf, 43 ft·lbf) Engine bracket rod nut 64 Nm (6.4 m·kgf, 46 ft·lbf) Engine mounting nut 43 Nm (4.3 m·kgf, 31 ft·lbf) Radiator bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 50 TIGHTENING TORQUES (YP125R) Thread Item Q’ty Tightening torque Remarks size Front brake hose holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front brake pad pin cap 3 Nm (0.3 m·kgf, 2.2 ft·lbf) Front brake pad pin 18 Nm (1.8 m·kgf, 13 ft·lbf)
  • Page 51 TIGHTENING TORQUES (YP125R) Lower ring nut 1. Tighten the lower ring nut 38 Nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower ring nut 22 Nm (2.2 m·kgf, 16 ft·lbf) with a torque wrench and the steering nut wrench.
  • Page 52: Lubrication Points And Lubricant Types (yp125r)

    LUBRICATION POINTS AND LUBRICANT TYPES (YP125R) EAS37P1125 LUBRICATION POINTS AND LUBRICANT TYPES (YP125R) EAS37P1126 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nut mounting surface Crankshaft pin Connecting rod big end thrust surface Oil pump drive gear inner surface...
  • Page 53 LUBRICATION POINTS AND LUBRICANT TYPES (YP125R) Lubrication point Lubricant Yamaha bond Timing chain tensioner bolt No.1215® 2-22...
  • Page 54: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES (YP125R) EAS37P1127 CHASSIS Lubrication point Lubricant Drive axle Swingarm oil seal lips Steering bearings (upper and lower) Seat hinge pin Front wheel oil seal lip and front wheel axle Speed sensor oil seal lip Brake lever pivoting point and metal-to-metal moving parts...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES (YP125R) 2-24...
  • Page 56: Lubrication System Diagrams (yp125r)

    LUBRICATION SYSTEM DIAGRAMS (YP125R) EAS37P1139 LUBRICATION SYSTEM DIAGRAMS (YP125R) 2-25...
  • Page 57 LUBRICATION SYSTEM DIAGRAMS (YP125R) 1. Camshaft 2. Crankshaft 3. Oil pump 4. Oil filter 5. Oil strainer 2-26...
  • Page 58: Cooling System Diagrams (yp125r)

    COOLING SYSTEM DIAGRAMS (YP125R) EAS37P1128 COOLING SYSTEM DIAGRAMS (YP125R) 2-27...
  • Page 59 COOLING SYSTEM DIAGRAMS (YP125R) 1. Coolant reservoir 2. Coolant reservoir hose 3. Radiator cap 4. Radiator filler hose 5. Radiator 6. Radiator inlet hose 7. Radiator outlet hose 2-28...
  • Page 60: Cable Routing (yp125r)

    CABLE ROUTING (YP125R) EAS37P1129 CABLE ROUTING (YP125R) Battery (front view) 2-29...
  • Page 61 CABLE ROUTING (YP125R) 1. Positive battery lead 2. Meter assembly lead 3. Self-diagnosis signal lead 4. Fuse box 1 5. Air temperature sensor lead 6. Fuse box 2 7. Starter relay lead 8. Negative battery lead 9. Headlight lead 10. Wire harness 11.
  • Page 62 CABLE ROUTING (YP125R) Front fork (front view) 2-31...
  • Page 63 CABLE ROUTING (YP125R) 1. Speed sensor lead 2. Front brake hose 3. Rectifier/regulator 4. Left front turn signal light coupler 5. Wire harness 6. Horn 7. Right front turn signal light coupler A. Point the end of the plastic locking tie forward, and –...
  • Page 64 CABLE ROUTING (YP125R) Front brake hose (right side view) 2-33...
  • Page 65 CABLE ROUTING (YP125R) 1. Front brake hose 2. Radiator fan motor relay 3. Starting circuit cut-off relay 4. Speed sensor lead 5. Right front turn signal light 6. Radiator fan motor 7. Radiator fan motor lead 8. Wire harness 9. Rear brake pipe 10.
  • Page 66 CABLE ROUTING (YP125R) Engine (right side view) 2-35...
  • Page 67 CABLE ROUTING (YP125R) 1. Seat lock cable 2. Wire harness 3. Ignition coil lead 4. Spark plug cap 5. O sensor 6. Starter motor lead 7. Rear brake hose A. Point the end of the plastic locking tie to the right, –...
  • Page 68 CABLE ROUTING (YP125R) Throttle cables (left side view) 2-37...
  • Page 69 CABLE ROUTING (YP125R) 1. Meter assembly 2. ECU (engine control unit) 3. Seat lock cable 4. Immobilizer unit coupler 5. Throttle cables 6. Wire harness 7. Sidestand switch lead 8. Rear brake hose 9. Front brake hose 10. Left front turn signal light lead 11.
  • Page 70 CABLE ROUTING (YP125R) Engine (left side view) 2-39...
  • Page 71 CABLE ROUTING (YP125R) 1. Wire harness 2. Intake air temperature sensor 3. Seat lock cable 4. Left tail/brake light assembly A. Point the end of the plastic locking tie to the left, – and then cut off the excess end of the tie to 0 –...
  • Page 72 CABLE ROUTING (YP125R) Handlebar (top view) 2-41...
  • Page 73 CABLE ROUTING (YP125R) 1. Radiator fan motor relay 2. Starting circuit cut-off relay 3. Headlight relay 4. Right handlebar switch lead 5. Front brake hose 6. Fuel pump coupler 7. Fuel sender coupler 8. Fuel hose 9. Left handlebar switch lead 10.
  • Page 74 CABLE ROUTING (YP125R) Throttle body (top view) 2-43...
  • Page 75 CABLE ROUTING (YP125R) 1. Rear brake pipe 2. Crankshaft position sensor/stator assembly lead 3. Wire harness 4. ISC (idle speed control) unit coupler 5. Ground lead 6. Intake air temperature sensor coupler 7. Intake air pressure sensor coupler 8. Seat lock cable 9.
  • Page 76 CABLE ROUTING (YP125R) Tail/brake light (top view) 2-45...
  • Page 77 CABLE ROUTING (YP125R) 1. Wire harness 2. Rear brake hose 3. License plate light lead 4. Right tail/brake light assembly coupler 5. Left tail/brake light assembly coupler 6. Seat lock cable A. Point the end of the plastic locking tie to the right, –...
  • Page 78: General Specifications (yp250r)

    GENERAL SPECIFICATIONS (YP250R) EAS20280 GENERAL SPECIFICATIONS (YP250R) Model Model 37P1 (YAMAHA) Dimensions Overall length 2201 mm (86.7 in) Overall width 776 mm (30.6 in) Overall height 1337 mm (52.6 in) Seat height 792 mm (31.2 in) Wheelbase 1545 mm (60.8 in) Ground clearance 134 mm (5.30 in)
  • Page 79: Engine Specifications (yp250r)

    ENGINE SPECIFICATIONS (YP250R) EAS20290 ENGINE SPECIFICATIONS (YP250R) Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 249 cm³ Cylinder arrangement Forward-inclined single cylinder Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) Compression ratio 10.00 :1 Standard compression pressure (at sea level) 1400 kPa/500 r/min (14.0 kgf/cm²/500 r/min, 199.1 psi/500 r/min) Minimum–maximum...
  • Page 80 ENGINE SPECIFICATIONS (YP250R) Thermostat Valve opening temperature 80.5–83.5 °C (176.9–182.3 °F) Valve full open temperature 93.0–97.0 °C (199.4–206.6 °F) Valve lift (full open) 3.0 mm (0.12 in) Radiator core Width 244.0 mm (9.61 in) Height 128.9 mm (5.07 in) Depth 22.0 mm (0.87 in) Water pump Water pump type...
  • Page 81 ENGINE SPECIFICATIONS (YP250R) Timing chain Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Limit 12.030 mm (0.4736 in) Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Limit 11.950 mm (0.4705 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0031 in)
  • Page 82 ENGINE SPECIFICATIONS (YP250R) Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit...
  • Page 83 ENGINE SPECIFICATIONS (YP250R) Spring rate K1 (intake) 23.18 N/mm (2.36 kgf/mm, 132.36 lb/in) Spring rate K2 (intake) 31.66 N/mm (3.23 kgf/mm, 180.78 lb/in) Spring rate K1 (exhaust) 23.18 N/mm (2.36 kgf/mm, 132.36 lb/in) Spring rate K2 (exhaust) 31.66 N/mm (3.23 kgf/mm, 180.78 lb/in) Installed compression spring force (intake) 115–133 N (11.73–13.56 kgf, 25.85–29.90 lbf) Installed compression spring force (exhaust)
  • Page 84 ENGINE SPECIFICATIONS (YP250R) Dimensions (B × T) 1.00 × 2.60 mm (0.04 × 0.10 in) End gap (installed) 0.15–0.30 mm (0.0059–0.0118 in) Limit 0.55 mm (0.0217 in) Ring side clearance 0.040–0.080 mm (0.0016–0.0031 in) Limit 0.130 mm (0.0051 in) 2nd ring Ring type Taper Dimensions (B ×...
  • Page 85 ENGINE SPECIFICATIONS (YP250R) Clutch shoe spring free length 40.5 mm (1.59 in) Clutch housing inside diameter 145.0 mm (5.71 in) Limit 145.5 mm (5.73 in) Compression spring free length 102.4 mm (4.03 in) Limit 90.0 mm (3.54 in) Weight outside diameter 20.0 mm (0.79 in) Limit 19.5 mm (0.77 in)
  • Page 86 ENGINE SPECIFICATIONS (YP250R) Water temperature 85.0–95.0 °C (185.00–203.00 °F) Oil temperature 75.0–85.0 °C (167.00–185.00 °F) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 2-55...
  • Page 87: Chassis Specifications (yp250r)

    CHASSIS SPECIFICATIONS (YP250R) EAS20300 CHASSIS SPECIFICATIONS (YP250R) Chassis Frame type Steel tube underbone Caster angle 28.00° Trail 100.0 mm (3.94 in) Front wheel Wheel type Cast wheel 15 × MT3.5 Rim size Rim material Aluminum Wheel travel 110.0 mm (4.33 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit...
  • Page 88 CHASSIS SPECIFICATIONS (YP250R) Front disc brake Disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 5.0 mm (0.20 in) Limit 1.5 mm (0.06 in)
  • Page 89 CHASSIS SPECIFICATIONS (YP250R) Rear suspension Type Unit swing Spring/shock absorber type Coil spring/oil damper Rear shock absorber assembly travel 95.0 mm (3.74 in) Spring free length 274.0 mm (10.79 in) Installed length 241.3 mm (9.50 in) Spring rate K1 8.00 N/mm (0.82 kgf/mm, 45.68 lb/in) Spring rate K2 17.30 N/mm (1.76 kgf/mm, 98.78 lb/in) Spring stroke K1...
  • Page 90: Electrical Specifications (yp250r)

    TCI (digital) Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1550 r/min Engine control unit Model/manufacturer 37P0/YAMAHA Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω at 20 °C (68 °F) Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ at 20 °C (68 °F)
  • Page 91 ELECTRICAL SPECIFICATIONS (YP250R) Indicator lights 12 V, 1.4 W × 2 Turn signal indicator light 12 V, 1.4 W × 1 High beam indicator light 12 V, 1.4 W × 1 Engine trouble warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor...
  • Page 92 ELECTRICAL SPECIFICATIONS (YP250R) Spare fuse 15.0 A Spare fuse 10.0 A Spare fuse 5.0 A Spare fuse 7.5 A 2-61...
  • Page 93: Tightening Torques (yp250r)

    TIGHTENING TORQUES (YP250R) EAS20320 TIGHTENING TORQUES (YP250R) EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual.
  • Page 94: Engine Tightening Torques

    TIGHTENING TORQUES (YP250R) EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt 53 Nm (5.3 m·kgf, 38 ft·lbf) Muffler joint bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) sensor 45 Nm (4.5 m·kgf, 32 ft·lbf) Oil check bolt...
  • Page 95 TIGHTENING TORQUES (YP250R) Thread Item Q’ty Tightening torque Remarks size Oil pump assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Transmission case cover bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Oil strainer cover 32 Nm (3.2 m·kgf, 23 ft·lbf) Engine oil drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Final transmission oil drain bolt 22 Nm (2.2 m·kgf, 16 ft·lbf)
  • Page 96 TIGHTENING TORQUES (YP250R) Cylinder head tightening sequence: Muffler tightening sequence: 2-65...
  • Page 97: Chassis Tightening Torques

    TIGHTENING TORQUES (YP250R) EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket nut 59 Nm (5.9 m·kgf, 43 ft·lbf) Engine bracket rod nut 64 Nm (6.4 m·kgf, 46 ft·lbf) Engine mounting nut 43 Nm (4.3 m·kgf, 31 ft·lbf) Radiator bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Filler neck bolt...
  • Page 98 TIGHTENING TORQUES (YP250R) Thread Item Q’ty Tightening torque Remarks size Front brake hose holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front brake pad pin cap 3 Nm (0.3 m·kgf, 2.2 ft·lbf) Front brake pad pin 18 Nm (1.8 m·kgf, 13 ft·lbf) Front brake caliper retaining pin...
  • Page 99 TIGHTENING TORQUES (YP250R) Lower ring nut 1. Tighten the lower ring nut 38 Nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower ring nut 22 Nm (2.2 m·kgf, 16 ft·lbf) with a torque wrench and the steering nut wrench.
  • Page 100: Lubrication Points And Lubricant Types (yp250r)

    Starter clutch gear thrust surface Starter clutch gear inner surface Main axle thrust surfaces Main axle serration Drive axle serration BEL-RAY assembly Oil seal (secondary sliding sheave) lube® BEL-RAY assembly O-ring and collar (clutch housing) lube® Yamaha bond Crankcase mating surfaces No.1215 2-69...
  • Page 101 LUBRICATION POINTS AND LUBRICANT TYPES (YP250R) Lubrication point Lubricant Yamaha bond No. Crankshaft position sensor/stator assembly lead grommet 1215 2-70...
  • Page 102: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES (YP250R) EAS20380 CHASSIS Lubrication point Lubricant Drive axle Swingarm oil seal lips Steering bearings (upper and lower) Seat hinge pin Front wheel oil seal lip and front wheel axle Speed sensor oil seal lip Brake lever pivoting point and metal-to-metal moving parts Rear brake caliper retaining bolt Throttle cable end Throttle grip inner surface and throttle cables...
  • Page 103 LUBRICATION POINTS AND LUBRICANT TYPES (YP250R) 2-72...
  • Page 104 COOLING SYSTEM DIAGRAMS (YP250R) EAS20420 COOLING SYSTEM DIAGRAMS (YP250R) 2-73...
  • Page 105 COOLING SYSTEM DIAGRAMS (YP250R) 1. Coolant reservoir 2. Coolant reservoir hose 3. Radiator cap 4. Radiator filler hose 5. Radiator 6. Radiator inlet hose 7. Radiator outlet hose 2-74...
  • Page 106 CABLE ROUTING (YP250R) EAS20430 CABLE ROUTING (YP250R) Battery (front view) 2-75...
  • Page 107 CABLE ROUTING (YP250R) 1. Positive battery lead 2. Meter assembly lead 3. Self-diagnosis signal lead 4. Fuse box 1 5. Air temperature sensor lead 6. Fuse box 2 7. Starter relay lead 8. Negative battery lead 9. Headlight lead 10. Wire harness 11.
  • Page 108 CABLE ROUTING (YP250R) Front fork (front view) 2-77...
  • Page 109 CABLE ROUTING (YP250R) 1. Speed sensor lead 2. Front brake hose 3. Rectifier/regulator 4. Left front turn signal light coupler 5. Wire harness 6. Horn 7. Right front turn signal light coupler A. Point the end of the plastic locking tie forward, and –...
  • Page 110 CABLE ROUTING (YP250R) Front brake hose (right side view) 2-79...
  • Page 111 CABLE ROUTING (YP250R) 1. Front brake hose 2. Radiator fan motor relay 3. Starting circuit cut-off relay 4. Speed sensor lead 5. Right front turn signal light 6. Radiator fan motor 7. Radiator fan motor lead 8. Wire harness 9. Rear brake pipe 10.
  • Page 112 CABLE ROUTING (YP250R) Engine (right side view) 2-81...
  • Page 113 CABLE ROUTING (YP250R) 1. Seat lock cable 2. Wire harness 3. Ignition coil lead 4. Spark plug cap 5. Coolant temperature sensor lead 6. O sensor 7. Starter motor lead 8. Rear brake hose A. Fasten the wire harness, starter motor lead, crankshaft position sensor/stator assembly lead, and O sensor lead with a plastic locking tie.
  • Page 114 CABLE ROUTING (YP250R) Throttle cables (left side view) 2-83...
  • Page 115 CABLE ROUTING (YP250R) 1. Meter assembly 2. ECU (engine control unit) 3. Seat lock cable 4. Immobilizer unit coupler 5. Throttle cables 6. Wire harness 7. Sidestand switch lead 8. Rear brake hose 9. Front brake hose 10. Left front turn signal light lead 11.
  • Page 116 CABLE ROUTING (YP250R) Engine (left side view) 2-85...
  • Page 117 CABLE ROUTING (YP250R) 1. Wire harness 2. Intake air temperature sensor 3. Seat lock cable 4. Left tail/brake light assembly 5. Safety protector 6. O sensor 7. Spark plug cap A. Route the left tail/brake light assembly lead and right tail/brake light assembly lead over the safety protector.
  • Page 118 CABLE ROUTING (YP250R) Handlebar (top view) 2-87...
  • Page 119 CABLE ROUTING (YP250R) 1. Radiator fan motor relay 2. Starting circuit cut-off relay 3. Headlight relay 4. Right handlebar switch lead 5. Front brake hose 6. Fuel pump coupler 7. Fuel sender coupler 8. Fuel hose 9. Left handlebar switch lead 10.
  • Page 120 CABLE ROUTING (YP250R) Throttle body (top view) 2-89...
  • Page 121 CABLE ROUTING (YP250R) 1. Rear brake pipe 2. Intake air pressure sensor coupler 3. Wire harness 4. Starter motor lead 5. Ground lead 6. Breather hose (air filter case to throttle body) 7. Intake air temperature sensor coupler 8. Fuel injector lead 9.
  • Page 122 CABLE ROUTING (YP250R) Tail/brake light (top view) 2-91...
  • Page 123 CABLE ROUTING (YP250R) 1. Wire harness 2. Rear brake hose 3. License plate light lead 4. Right tail/brake light assembly coupler 5. Left tail/brake light assembly coupler 6. Seat lock cable 7. Cylinder head breather hose 8. Intake air temperature sensor coupler A.
  • Page 124 CABLE ROUTING (YP250R) 2-93...
  • Page 125: Periodic Checks And Adjustments

    INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (YP125R) .................. 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART (YP125R) ..3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (YP250R) .................. 3-3 GENERAL MAINTENANCE AND LUBRICATION CHART (YP250R) ..3-3 ENGINE (YP125R)...................
  • Page 126 CHASSIS ....................... 3-35 CHECKING THE BRAKE FLUID LEVEL..........3-35 CHECKING THE FRONT BRAKE PADS ..........3-35 CHECKING THE REAR BRAKE PADS (YP125R)........3-35 CHECKING THE REAR BRAKE PADS (YP250R)........3-36 CHECKING THE FRONT BRAKE HOSE..........3-36 CHECKING THE REAR BRAKE HOSE ..........3-36 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........
  • Page 128: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 129 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 6000 km 12000 km 18000 km 24000 km (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi) √ √ √ √ √ • Check for cracks or damage. 5 * Brake hoses •...
  • Page 130: Periodic Maintenance Chart For The Emission Control System (yp250r)

    UK, a milage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 131 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level √ √ √ √ √ √...
  • Page 132 PERIODIC MAINTENANCE EAU38262 • Engine air filter and V-belt air filters • This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The engine air filter element needs to be replaced and the V-belt air filter element needs to be ser- viced more frequently when riding in unusually wet or dusty areas.
  • Page 133: Engine (yp125r)

    ENGINE (YP125R) EAS37P1087 ENGINE (YP125R) EAS37P1088 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 4.
  • Page 134 ENGINE (YP125R) c. Turn the adjusting screw “3” in direction “a” or “b” with the tappet adjusting tool “4” until the specified valve clearance is obtained. Direction “a” Valve clearance is increased. Direction “b” Valve clearance is decreased. Tappet adjusting tool c.
  • Page 135: Adjusting The Exhaust Gas Volume

    ENGINE (YP125R) 8. Install: • V-belt case air filter element • V-belt case air duct FI Diagnostic Tool • V-belt case cover DIAG V-belt case air duct bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) V-belt case cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 9.
  • Page 136: Adjusting The Throttle Cable Free Play

    ENGINE (YP125R) 15.Install: EWA12910 WARNING • Upper panel After adjusting the throttle cable free play, Refer to “GENERAL CHASSIS” on page 4-1. start the engine and turn the handlebar to the EAS37P1090 right and to the left to ensure that this does ADJUSTING THE THROTTLE CABLE FREE not cause the engine idling speed to change.
  • Page 137: Checking The Ignition Timing

    ENGINE (YP125R) 7. Install: 4. Check: • Spark plug • Ignition timing M MMM M MMM M MMM M MMM M MMM Spark plug a. Start the engine, warm it up for several min- 13 Nm (1.3 m·kgf, 9.4 ft·lbf) utes, and then let it run at the specified en- gine idling speed.
  • Page 138: Measuring The Compression Pressure

    ENGINE (YP125R) EAS37P1093 MEASURING THE COMPRESSION Standard compression pressure PRESSURE (at sea level) 550 kPa/680 r/min (5.5 kgf/cm²/680 r/min, 78.2 psi/680 Insufficient compression pressure will result in a r/min) loss of performance. Minimum–maximum 1. Remove: 480–620 kPa (4.8–6.2 kgf/cm², 68.3–88.2 psi) •...
  • Page 139: Checking The Engine Oil Level

    ENGINE (YP125R) EAS37P1134 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 140 ENGINE (YP125R) 5. If the oil filter element is also to be replaced, c. Install the oil strainer cover. perform the following procedure. Oil strainer cover M MMM M MMM M MMM M MMM M MMM 32 Nm (3.2 m·kgf, 23 ft·lbf) a.
  • Page 141: Changing The Final Transmission Oil

    Check the engine oil passages and the oil 4. Remove: pump for damage or leakage. Refer to “OIL • Oil filler cap “1” PUMP (YP125R)” on page 5-48. • O-ring “2” d. Start the engine after solving the problem(s) and check the engine oil pressure again.
  • Page 142: Replacing The Air Filter Element

    ENGINE (YP125R) 9. Start the engine, warm it up for several min- EAS37P1097 CLEANING THE V-BELT CASE AIR FILTER utes, turn it off, and then check for oil leak- ELEMENT age. 1. Remove: • V-belt case cover “1” EAS37P1096 REPLACING THE AIR FILTER ELEMENT •...
  • Page 143: Checking The Throttle Body Joint

    ENGINE (YP125R) EAS37P1099 CHECKING THE FUEL HOSE 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Fuel hose “1” Cracks/damage → Replace the fuel injector assembly. Loose connection → Connect properly. 3. Check: • V-belt case air filter element Damage →...
  • Page 144: Checking The Exhaust System

    ENGINE (YP125R) 3. Install: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. EAS37P1101 CHECKING THE EXHAUST SYSTEM 1. Check: • Exhaust pipe “1” • Muffler “2” Cracks/damage → Replace. • Exhaust system connection Exhaust gas leaks → Replace the gaskets EAS37P1102 “3”.
  • Page 145: Checking The Cooling System

    • Radiator filler hose “4” • Coolant reservoir hose “5” • Thermostat cover “6” • Thermostat inlet hose “7” Cracks/damage → Replace. Refer to “RADIATOR (YP125R)” on page 6-1 4. Drain: and “THERMOSTAT (YP125R)” on page 6-3. • Coolant (from the coolant reservoir) 5.
  • Page 146 ENGINE (YP125R) The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the air bleed bolt hole “1”. 6. Remove: • Coolant drain bolt (from the cylinder) “1” (along with the copper washer)
  • Page 147 ENGINE (YP125R) 13.Install: • Coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then turn it off. 15.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.
  • Page 148: Engine (yp250r)

    ENGINE (YP250R) EAS20470 ENGINE (YP250R) EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 5.
  • Page 149 ENGINE (YP250R) Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 d. Measure the valve clearance with a thickness gauge “1”. Out of specification → Adjust. d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion.
  • Page 150: Adjusting The Exhaust Gas Volume

    ENGINE (YP250R) 6. Press the “UP” button to select the CO adjust- EAS20600 ADJUSTING THE EXHAUST GAS VOLUME ment mode “CO” or the diagnostic mode “DI- AG”. Be sure to set the CO density level to standard, 7. After selecting “CO”, press the “MODE” but- and then adjust the exhaust gas volume.
  • Page 151: Checking The Spark Plug

    ENGINE (YP250R) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 2. Remove: • Spark plug ECA13330 NOTICE 2. Adjust: Before removing the spark plug, blow away • Throttle cable free play any dirt accumulated in the spark plug well M MMM M MMM M MMM M MMM...
  • Page 152: Checking The Ignition Timing

    ENGINE (YP250R) 4. Check: Spark plug • Ignition timing 18 Nm (1.8 m·kgf, 13 ft·lbf) M MMM M MMM M MMM M MMM M MMM a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.
  • Page 153: Checking The Engine Oil Level

    ENGINE (YP250R) 3. Start the engine, warm it up for several min- c. If the compression pressure is above the utes, and then turn it off. maximum specification, check the cylinder 4. Disconnect: head, valve surfaces and piston crown for •...
  • Page 154: Changing The Engine Oil

    ENGINE (YP250R) EAS20780 CHANGING THE ENGINE OIL • Before checking the engine oil level, wait a few 1. Start the engine, warm it up for several min- minutes until the oil has settled. utes, and then turn it off. • Do not screw the dipstick in when inspecting 2.
  • Page 155: Changing The Final Transmission Oil

    ENGINE (YP250R) c. Check the engine oil passages and the oil Oil strainer cover pump for damage or leakage. Refer to “OIL 32 Nm (3.2 m·kgf, 23 ft·lbf) PUMP (YP250R)” on page 5-108. d. Start the engine after solving the problem(s) L LLL L LLL L LLL...
  • Page 156: Replacing The Air Filter Element

    ENGINE (YP250R) 9. Start the engine, warm it up for several min- utes, turn it off, and then check for oil leak- age. EAS20960 REPLACING THE AIR FILTER ELEMENT Check hoses are located on the bottom of the air filter case. If dust or water or both collects in a hose, remove the clamp from the hose, and then remove the plug to drain the hose.
  • Page 157: Cleaning The V-belt Case Air Filter Element

    ENGINE (YP250R) EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • V-belt case air filter cover “1” • V-belt case air filter element 3. Install: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. EAS21030 CHECKING THE FUEL HOSE 1.
  • Page 158: Checking The Exhaust System

    ENGINE (YP250R) 3. Install: • Storage box EAS21110 CHECKING THE COOLANT LEVEL Refer to “GENERAL CHASSIS” on page 4-1. 1. Stand the vehicle on a level surface. EAS21080 CHECKING THE EXHAUST SYSTEM • Place the vehicle on the centerstand. 1. Check: •...
  • Page 159: Checking The Cooling System

    ENGINE (YP250R) 3. Start the engine, warm it up for several min- 3. Install: utes, and then turn it off. • Footrest board 4. Check: • Bottom cover • Coolant level • Storage box Refer to “GENERAL CHASSIS” on page 4-1. Before checking the coolant level, wait a few EAS21130 minutes until it settles.
  • Page 160 ENGINE (YP250R) The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the air bleed bolt hole “1”. 6. Remove: • Coolant drain bolt (water pump) “1” (along with the copper washer) Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
  • Page 161 ENGINE (YP250R) 13.Install: • Coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then turn it off. 15.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-31. Before checking the coolant level, wait a few minutes until the coolant has settled.
  • Page 162: Chassis

    → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-17. EAS37P1130 CHECKING THE REAR BRAKE PADS (YP125R) The following procedure applies to all of the A. Front brake brake pads. B. Rear brake 1. Operate the brake.
  • Page 163: Checking The Rear Brake Pads (yp250r)

    • Rear brake pad Wear indicator groove “a” has almost disap- peared → Replace the brake pads as a set. Refer to “REAR BRAKE” on page 4-29. A. YP125R B. YP250R 3. Hold the vehicle upright and apply the rear brake several times.
  • Page 164: Checking And Adjusting The Steering Head

    Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: A. Front brake caliper • Steering head B. Rear brake caliper (YP125R) Grasp the bottom of the front fork legs and C. Rear brake caliper (YP250R) gently rock the front fork. 3-37...
  • Page 165 CHASSIS Binding/looseness → Adjust the steering EWA13140 WARNING head. Do not overtighten the lower ring nut. 3. Remove: • Lower handlebar holder Refer to “STEERING HEAD” on page 4-57. Lower ring nut (final tightening torque) 4. Adjust: 22 Nm (2.2 m·kgf, 16 ft·lbf) •...
  • Page 166: Checking The Front Fork

    CHASSIS 5. Install: Spring preload • Lower handlebar holder ECA13590 NOTICE Refer to “STEERING HEAD” on page 4-57. Never go beyond the maximum or minimum EAS21530 adjustment positions. CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. 1.
  • Page 167 CHASSIS Wear limit (front) 1.6 mm (0.06 in) Wear limit (rear) 1.6 mm (0.06 in) EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must 1.
  • Page 168: Checking The Wheels

    After a tire or wheel has been changed or re- proved by Yamaha is used on this vehicle. placed, always balance the wheel. Front tire EAS21690...
  • Page 169: Lubricating The Centerstand

    CHASSIS EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium-soap-based grease 3-42...
  • Page 170: Electrical System

    ELECTRICAL SYSTEM 5. Install: EAS21750 ELECTRICAL SYSTEM • Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 NOTICE page 8-71. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES...
  • Page 171: Adjusting The Headlight Beam

    ELECTRICAL SYSTEM 6. Install: c. Install the adjusting screw accessing cap. L LLL L LLL L LLL L LLL L LLL • Headlight bulb ECA13690 NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 172 ELECTRICAL SYSTEM 3-45...
  • Page 173 REPLACING THE REAR BRAKE PADS (YP250R)........ 4-38 REMOVING THE REAR BRAKE CALIPER ..........4-39 DISASSEMBLING THE REAR BRAKE CALIPER (YP250R only) ..4-39 CHECKING THE REAR BRAKE CALIPER (YP125R) ......4-40 CHECKING THE REAR BRAKE CALIPER (YP250R) ......4-40 ASSEMBLING THE REAR BRAKE CALIPER ........4-41 INSTALLING THE REAR BRAKE CALIPER (YP125R) ......
  • Page 174 HANDLEBAR ....................4-46 REMOVING THE HANDLEBAR.............. 4-48 CHECKING THE HANDLEBAR .............. 4-48 INSTALLING THE HANDLEBAR ............4-48 FRONT FORK....................4-50 REMOVING THE FRONT FORK LEGS..........4-52 DISASSEMBLING THE FRONT FORK LEGS ........4-52 CHECKING THE FRONT FORK LEGS ..........4-53 ASSEMBLING THE FRONT FORK LEGS ..........
  • Page 176: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and storage box 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 177: Removing The Storage Box

    GENERAL CHASSIS M MMM M MMM M MMM M MMM M MMM EAS37P1079 REMOVING THE STORAGE BOX a. Fold the tabs on the safety protector so that 1. Remove: the holes in each tab are aligned, and then • Storage box bolts “1” fasten the tabs to the storage box with the quick fastener screws at the locations “a”...
  • Page 178 GENERAL CHASSIS When tightening the mudguard bolts, tighten the center bolt “a” first, and then tighten the side bolts “b”. 3. Install: • Seat Seat nut 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the seat nuts in the proper tightening se- quence as shown.
  • Page 179 GENERAL CHASSIS Removing the headlight assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 180 GENERAL CHASSIS Removing the meter assembly Order Job/Parts to remove Q’ty Remarks Windshield Refer to “Removing the headlight assembly”. Rearview mirror Center handlebar cover Upper handlebar cover Lower handlebar cover Storage compartment molding Meter assembly coupler Disconnect. Meter assembly cover Meter assembly For installation, reverse the removal proce- dure.
  • Page 181 GENERAL CHASSIS Removing the radiator cover Order Job/Parts to remove Q’ty Remarks Refer to “Removing the seat and storage Storage box box”. Front cowling assembly Refer to “Removing the headlight assembly”. Front turn signal light coupler Disconnect. Front upper panel Front turn signal light Footrest board mat Front lower panel...
  • Page 182 GENERAL CHASSIS Removing the storage compartment 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Radiator cover...
  • Page 183 Cylinder head breather hose Disconnect. Disconnect. Breather hose (air filter case to throttle body) YP250R only Air filter case joint screw clamp YP125R Air filter case joint screw clamp YP250R Air filter case For installation, reverse the removal proce- dure.
  • Page 184: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc 23 Nm (2.3 m kgf, 17 ft Ibf) • • 70 Nm (7.0 m kgf, 50 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 185 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-10...
  • Page 186: Removing The Front Wheel

    FRONT WHEEL EAS21890 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Wheel axle EWA13120 WARNING Roll the wheel axle on a flat surface. Bends → Replace. Securely support the vehicle so that there is no danger of it falling over.
  • Page 187: Assembling The Front Wheel

    FRONT WHEEL L LLL L LLL L LLL L LLL L LLL EAS21960 ASSEMBLING THE FRONT WHEEL EAS21970 1. Install: ADJUSTING THE FRONT WHEEL STATIC BALANCE • Wheel bearings M MMM M MMM M MMM M MMM M MMM a. Install the new wheel bearing (right side). •...
  • Page 188: Installing The Front Wheel (front Brake Disc)

    FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 189 FRONT WHEEL 2. Check: Wheel axle • Front brake disc 70 Nm (7.0 m·kgf, 50 ft·lbf) Refer to “CHECKING THE FRONT BRAKE Wheel axle pinch bolt DISC” on page 4-22. 23 Nm (2.3 m·kgf, 17 ft·lbf) 3. Lubricate: • Oil seal lips ECA37P1030 •...
  • Page 190: Rear Wheel

    17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “ENGINE REMOVAL (YP125R)” on Muffler page 5-1 and “ENGINE REMOVAL (YP250R)” on page 5-61. Refer to “REAR SHOCK ABSORBER AS- Swingarm SEMBLIES AND SWINGARM” on page 4-61.
  • Page 191: Removing The Rear Wheel

    REAR WHEEL EAS28760 REMOVING THE REAR WHEEL Tighten the brake disc bolts in stages and in a 1. Stand the vehicle on a level surface. crisscross pattern. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.
  • Page 192: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 40 Nm (4.0 m kgf, 29 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 3 Nm (0.3 m kgf, 2.2 ft Ibf)
  • Page 193 FRONT BRAKE Removing the front brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 194 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 195 FRONT BRAKE Removing the front brake caliper 40 Nm (4.0 m kgf, 29 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 196 FRONT BRAKE Disassembling the front brake caliper 23 Nm (2.3 m kgf, 17 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 197: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake L LLL L LLL L LLL...
  • Page 198: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the e. If out of specification, repeat the adjustment bleed screw “2”. Put the other end of the hose steps until the brake disc deflection is within into an open container.
  • Page 199: Removing The Front Brake Caliper

    FRONT BRAKE 5. Check: EWA13550 WARNING • Brake lever operation Soft or spongy feeling → Bleed the brake sys- • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- tem. ton is expelled from the brake caliper. Refer to “BLEEDING THE HYDRAULIC •...
  • Page 200: Assembling The Front Brake Caliper

    • Use only the designated brake fluid. Other sure safe vehicle operation. Refer to “CABLE brake fluids may cause the rubber seals to ROUTING (YP125R)” on page 2-29 and “CA- deteriorate, causing leakage and poor BLE ROUTING (YP250R)” on page 2-75.
  • Page 201: Removing The Front Brake Master Cylinder

    FRONT BRAKE • When refilling, be careful that water does not enter the brake master cylinder reser- To collect any remaining brake fluid, place a voir. Water will significantly lower the boil- container under the master cylinder and the end ing point of the brake fluid and could cause of the brake hose.
  • Page 202: Installing The Front Brake Master Cylinder

    Proper brake hose routing is essential to in- NOTICE sure safe vehicle operation. Refer to “CABLE Brake fluid may damage painted surfaces ROUTING (YP125R)” on page 2-29 and “CA- and plastic parts. Therefore, always clean up BLE ROUTING (YP250R)” on page 2-75. any spilt brake fluid immediately.
  • Page 203 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-36. 4-28...
  • Page 204: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads (YP125R) 14 Nm (1.4 m kgf, 10 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 205 REAR BRAKE Removing the rear brake pads (YP250R) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt...
  • Page 206 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 207 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32...
  • Page 208 REAR BRAKE Removing the rear brake caliper (YP125R) 28 Nm (2.8 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 209 REAR BRAKE Removing the rear brake caliper (YP250R) 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “ENGINE REMOVAL (YP250R)”...
  • Page 210 REAR BRAKE Disassembling the rear brake caliper (YP125R) 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Rear brake pad Brake pad spring Bleed screw/cap For assembly, reverse the disassembly pro- cedure.
  • Page 211 REAR BRAKE Disassembling the rear brake caliper (YP250R) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Brake caliper bracket Rear brake pad Brake pad shim Brake pad support...
  • Page 212: Introduction

    Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-22. Brake disc deflection limit 0.25 mm (0.0098 in) (YP125R) 0.15 mm (0.0059 in) (YP250R) 4. Measure: • Brake disc thickness Measure the brake disc thickness at a few dif- 2.