FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YP250 (J) 98. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YP250 SERVICE MANUAL: 4UC-AE1 YP250 (J) 98 SUPPLEMENTARY SERVICE MANUAL 1997 by Yamaha Motor Co., Ltd. First Edition, June 1997 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person inspecting or repairing the scooter. CAUTION: NOTE: A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. A NOTE provides key information to make procedures easier or clearer.
YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See Illustrated symbols ) 1st title 1 : 2nd title 2 : 3rd title 3 : This is the title of the chapter with its symbol on the upper right corner of each page. This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. EXPLODED DIAGRAMS To heps identify parts and clarify procedure steps, there are exploded diagrams at start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs. 2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. 1 2 4 3 5 8 6 6 7
1 3 5 7 2 4 6 8 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting 9 11 13 10 12 14 Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 Possible to maintain with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit, clearance 16 Engine speed 17 Ω, V, A 15 16 17 Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 18 19 20 21 22 23 24 25 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight lithium-soap base grease 23 Apply molybdenum disulfide grease Illustrated symbols 24 to 25 in the exploded diagrams indicate the where to apply locking agent 24 and when to install new parts 25. 24 Apply locking agent (LOCTITE ) 25 Use new one
CONTENS GENERAL INFORMATION...................................... 1 SCOOTER IDENTIFICATION................................. 1 VEHICLE IDENTIFICATION NUMBER....................... 1 MODEL LABEL........................................... 1 SPECIFICATIONS.............................................. 2 GENERAL SPECIFICATIONS................................. 2 MAINTENANCE SPECIFICATIONS........................... 3 ENGINE................................................. 3 CHASSIS................................................ 3 ELECTRICAL............................................. 4 CABLE ROUTING.......................................... 6 PERIODIC INSPECTION AND ADJUSTMENTS................... 11 COVER AND PANEL........................................ 11 SIDE PANEL AND SEAT.................................. 11 ELECTRICAL.................................................. 12 SIGNAL SYSTEM.......................................... 12 CIRCUIT DIAGRAM...................................... 12 SIGNAL SYSTEM CHECK................................. 13 YP250 98 WIRING DIAGRAM (FOR EUROPE) YP250J WIRING DIAGRAM (FOR OCEANIA)
SCOOTER IDENTIFICATION GEN INFO YP100000 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame. MODEL LABEL The model label 1 is affixed under the seat. This information will be needed to order spare parts. 1
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model code: Model Tire pressure (cold tire): Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear High-speed riding front rear Wheel travel: Front wheel travel Rear wheel travel Bulb wattage quantity: Headlight Marker light Tail/brake light Flasher light Meter light High beam indicator light Oil indicator light Turn indicator light License light YP250 4UC3 (except for CH, A, AUS) 4UD3 (for CH, A) 4UC4 (for AUS) 197 kg 0 90 kg 175 kpa (1.75 kg/cm 2, 1.75 bar) 200 kpa (2.0 kg/cm 2, 2.0 bar) 90 197 kg 200 kpa (2.0 kg/cm 2, 2.0 bar) 225 kpa (2.25 kg/cm 2, 2.25 bar) 200 kpa (2.0 kg/cm 2, 2.0 bar) 250 kpa (2.5 kg/cm 2, 2.5 bar) 100 mm 90 mm 12V 60 W/55 W 1 12V 5 W 1 12V 5 W/21 W 1 12V 21W 4 12V 1.7W 4 12V 1.7 W 1 12V 1.7 W 1 12V 3.4 W 2 12V 5 W 1 *Load is the total weight of cargo, rider, passenger, and accessories. 2
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit V-belt: V-belt width 23.0 mm 21.0 mm Carburetor: Type I.D. mark Ventuly outside diameter Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Throttle valve size (Th.V) Pilot air jet (P.A.J.1) Needle jet (N.J) Pilot outlet (P.O) Pilot jet (P.J) Bypass (B.P) Pilot screw (P.S) Valve seat size (V.S) Starter jet 1 (G.S.1) Starter jet 2 (G.S.2) Float height (F.H) Engine idle speed Intake vacuum Oil temperature Cooling water temperature CHASSIS Y28V-1B-1 4UC 00 [4UD 00 (CH, A)] ø28 #130 ø0.9 5D32-3/5 11 ø1.2 #85 ø0.8 #44 0.7 3 1 1/2 1.4 ø0.5 ø1.3 27 mm 1,350 1,450 r/min 220 260 mmhg 65 75 C 80 C Item Standard Limit Steering system: Steering bearing type Ball and angular bearing Front suspension: Front fork travel Fork spring free length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit 100 mm 265.8 mm 5.7 N/mm (0.57 kg/mm) 0 100 mm 0.142 L (142 cm 3 ) 80 mm Fork oil 15 WT or equivalent 265 mm 0.2 mm 3
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Rear suspension: Shock absorber stroke Spring free length Fitting length Spring rate Stroke ELECTRICAL (K1) (K2) (K3) (K1) (K2) (K3) 106 mm 265 mm 317 mm 7.7 N/mm (0.77 kg/mm) 12.6 N/mm (1.26 kg/mm) 25.8 N/mm (2.58 kg/mm) 0 40 mm 40 75 mm 75 106 mm 260 mm Item Standard limit Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Normal output Stator coil resistance/color Rectifire/regulator: Model/manufacturer No load regulated voltage Capacity Withstand voltage Resin type 10 kω A.C. magneto F4T252/MITSUBISHI 14 V 16 A at 5,000 r/min 0.54 0.66 Ω at 20 C/ White White SH640D-12/SHINDENGEN 14.7 V 14 A 200 V Battery: Specific gravity 1.320 Electric starter system: Type Starter motor: Model/manufacturer/ID number Operation voltage Output Armature coil resistance Brush overall length Brash quantity Spring force Commutator diameter Mica undercut (depth) Constant mesh type SM-13/MITSUBA/SM-13454 12 V 0.65 kw 0.0012 0.0022 Ω at 20 C 10 mm 2 pcs. 570 920 g 28 mm 0.7 mm 4 mm 570 g 27 mm 4
MAINTENANCE SPECIFICATIONS SPEC Item Standard limit Starter relay: Model/manufacturer Amperage rating Coil winding resistance Horn: Model/manufacturer Maximum amperage Flasher relay: Type Model/manufacturer Flasher frequency Starting circuit cut-off relay: Model/manufacturer Coil winding resistance MS5F-471JIDECO 100 A 4.2 4.6 Ω at 20 C YF-12/NIKKO 3 A Full transistor type FE246BH/DENSO 75 95 cycle/min ACA12115-1/MATSUSHITA 72 88 Ω Thermo unit: Model/manufacturer 11H/NIPPON SEIKI 5
CABLE ROUTING SPEC CABLE ROUTING 1 Box light 2 Rectifier/ regulator 3 Fuel sender 4 Roll over valve 5 Fuse 6 Seat lock cable 7 Handlebar switch lead (right) 8 Front brake switch lead 9 Brake hose 10 Speedometer cable 11 Pipe 12 Starter relay 13 Battery 14 Flasher relay 15 Reservoir tank 16 Battery negative ( ) lead 17 Battery positive (+) lead 18 Ignition coil 19 Breather hose 20 Air filter 21 Mudguard 22 Seat lock cable 23 Down tube 24 Wireharness 25 Ground lead 26 Engine bracket 27 AC magnet leads 28 Starter motor lead A Pass the box light lead from outside of frame through inside of protector. B Clamp the fuel sender lead to the pipe. C Clamp the fuel sender lead and auto choke lead to the frame. D Pass the box switch lead through under the fuel tank hinge projection. E Align the mark on seat lock cable to the protector end. F Clamp the wireharness (white tape) to frame. 6
CABLE ROUTING SPEC G Install the meter cable with its sheaved side facing to the meter gear. H Install the brake hose to the brake caliper with its marking facing to the tire side. I Pass the overflow hose form the reservoir tank through the clamp inside the frame. J Clamp the mainharness, battery (+) lead and ( ) lead to clamp of the frame. K Keep the clamping clearance over 3 mm. 7
CABLE ROUTING SPEC 1 Throttle cable (pull side) 2 Throttle cable (push side) 3 Carburetor drain hose 4 Carburetor coolant drain hose 5 Air vent hose 6 Steering head 7 Rear brake cable 8 Steering head 9 Wireharness 10 Down tube 11 Throttle cables 12 Radiator 13 Throttle cables 14 Wireharness 15 Stay A Pass the air vent hose, coolant drain hose, and fuel drain hose through the U clamp on the holder. B Pass the drain hose through the clamp (spring hook). C Clamp the brake cable 2 to the frame. (Up and down) Align the locating mark of the brake cable 2 with the under clamp. D Pass the overflow hose from the tank through the clamp inside the frame pipe. 8
CABLE ROUTING SPEC 1 Air filter 2 Chain tensioner 3 Fuel tank breather hose 4 Vacuum hose 5 Fuel hose 6 Fuel hose 7 Vacuum hose 8 Sidestand switch lead 9 Fan motor lead 10 Thermo switch lead 11 Fuel hose 12 Vacuum hose 13 Fuel cock 14 Fuel tank 15 Over flow hose 16 Starting circuit cutoff relay 17 Auto choke unit lead 18 Protector 19 Seat lock cable 20 Seat lock 21 Ground lead 22 Starter motor lead 23 AC magneto leads A Install the positive (+) lead between the battery and the starter relay to the starter relay along the chassis. B Put the coupler of the A.C. magneto lead and the auto choke lead along the frame pipe after connection. C Clamp the wireharness, A.C. magneto leads, starter motor lead and grand lead to the frame. D Clamp the AC magneto leads, starter motor lead and ground lead to the engine bracket. 9
CABLE ROUTING SPEC 1 Front flasher light (right) 2 Front flasher light (left) 3 Rear brake cable 4 Throttle cable 5 Speedometer cable 6 Brake hose 7 Horn 8 Stay 9 Mark 10 Brake hose stopper 11 Grip heater lead 12 Ararm terminal 13 Handlebar switch (right) 14 Front brake switch 15 Seat lock cable 16 Throttle cable 17 Brake hose 18 Handlebar switch (left) 19 Rear brake switch 20 Rear brake cable 21 Under handlebar cover 22 Speedometer cable 23 Stay A Install the brake hose with its marking facing to the stopper side. B Pass the speedometer cable and the brake hose through the clamps on the frame. (Front: Speedometer cable Rear: Brake hose) C Do not interfere each other after installing the handlebar upper cover. 10
COVER AND PANEL INSP ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS COVER AND PANEL SIDE PANEL AND SEAT Order Job name/part name Q ty Remarks 1 2 3 4 5 6 7 Side panel and seat removal Rear panel Side panel (left) Side panel (right) Rivet Front panel Clip Damper assembly 1 1 1 2 1 2 1 Remove the parts in order. NOTE: Install the damper assembly to the body with its rod side backward and labels upward. 8 Seat 1 Reverse the removal procedure for installation. 11
SIGNAL SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 24 Rear brake switch 25 Front brake switch 26 Flasher relay 27 Horn 28 Turn switch 29 Horn switch 33 Tail/ Brake light 35 Rear flasher lights 36 Front flasher lights 39 Turn indicator lights 44 Fuel gauge 50 Fuel sender 52 Box light 53 Box light switch 12
SIGNAL SYSTEM ELEC SIGNAL SYSTEM CHECK If the box light fails to come on. 1. Bulb and bulb socket. Disconnect the bulb socket connector. Connect the pocket tester (Ω 1) to the bulb socket connector. NO CONTINUITY Check the bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2. Box light switch Disconnect the box light switch coupler. Connect the pocket tester (Ω 1) to the box light switch. Tester (+) lead Read 1 terminal. Tester ( ) lead Blue/Green 2 terminal. Check the box light switch for continuity. CONTINUITY NO CONTINUITY 1 2 3. Wiring connection Wiring circuit from the main switch to the bulb socket connector is faulty. Repair. Refer to SIGNAL SYSTEM WIRING DIA- GRAM. Replace the box light switch. 13
YP250 98 WIRING DIAGRAM (FOR EUROPE) COLOR CODE B........ Black Br....... Brown Ch...... Chocolate Dg...... Dark green G....... Green L........ Blue O....... P........ R........ Sb....... W....... Y........ Orange Pink Red Sky blue White Yellow B/R...... Br/W..... G/R..... G/Y...... L/B...... L/G...... Black/Red Brown/White Green/Red Green/Yellow Blue/Black Blue/Green L/R...... L/W..... L/Y...... R/W..... R/Y...... W/G..... Blue/Red Blue/White Blue/Yellow Red/White Red/Yellow White/Green Y/R...... Yellow/Red 1 A.C. magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Alarm (option) 9 Thermo switch (auto choke) 10 Auto choke 11 Ignitor unit 12 Ignition coil 13 Spark plug 14 Pickup coil 15 Sidestand switch 16 Starting circuit cut-off relay 17 Lights switch 18 Starter switch 19 Engine stop switch 20 Handlebar switches (right) 21 Fuse (fan) 22 Thermo switch 23 Fan motor 24 Rear brake switch 25 Front brake switch 26 Flasher relay 27 Horn 28 Turn switch 29 Horn switch 30 Dimmer switch 31 Pass switch 32 Handlebar switches (left) 33 Tail/ Brake light 34 Licence light 35 Rear flasher lights 36 Front flasher lights 37 Head light 38 Auxiliary light 39 Turn indicator lights 40 High beam indicator light 41 Meter lights 42 Oil indicator light 43 Reset switch 44 Fuel gauge 45 Read switch 46 Clock 47 Thermometer 48 Speedometer 49 Meter assembly 50 Fuel sender 51 Thermo unit 52 Box light 53 Box light switch
YP250J WIRING DIAGRAM (FOR OSEANIA) 1 A.C. magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Alarm (option) 9 Thermo switch (auto choke) 10 Auto choke 11 Ignitor unit 12 Ignition coil 13 Spark plug 14 Pickup coil 15 Sidestand switch 16 Starting circuit cut-off relay 17 Starter switch 18 Engine stop switch 19 Handlebar switches (right) 20 Fuse (fan) 21 Thermo switch 22 Fan motor 23 Rear brake switch 24 Front brake switch 25 Flasher relay 26 Horn 27 Turn switch 28 Horn switch 29 Dimmer switch 30 Pass switch 31 Handlebar switches (left) 32 Tail/ Brake light 33 Licence light 34 Rear flasher lights 35 Front flasher lights 36 Head light 37 Turn indicator lights 38 High beam indicator light 39 Meter lights 40 Oil indicator light 41 Reset switch 42 Fuel gauge 43 Read switch 44 Clock 45 Thermometer 46 Speedometer 47 Meter assembly 48 Fuel sender 49 Thermo unit 50 Box light 51 Box light switch COLOR CODE B........ Black Br....... Brown Ch...... Chocolate Dg...... Dark green G....... Green L........ Blue O....... P........ R........ Sb....... W....... Y........ Orange Pink Red Sky blue White Yellow B/R...... Br/W..... G/R..... G/Y...... L/B...... L/G...... Black/Red Brown/White Green/Red Green/Yellow Blue/Black Blue/Green L/W..... L/Y...... R/B...... R/W..... R/Y...... W/G..... Blue/White Blue/Yellow Red/Black Red/White Red/Yellow White/Green Y/R...... Yellow/Red