KYMCO YUP 250 User manual

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
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YUP 250
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO YUP 250.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 5 through 13 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 14 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL SYSTEM/CARBURETOR/FUEL
PUMP FUEL TANK
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS EQUIPMENT
ENGINE
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1. GENERAL INFORMATION
1-0
YUP 250
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
1
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1. GENERAL INFORMATION
1-1
YUP 250
SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
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1. GENERAL INFORMATION
1-2
YUP 250
SPECIFICATIONS
Name & Model No.
SH50AA
Motorcycle Name & Type
YUP 250
Overall length
2060mm
Overall width
740mm
Overall height
1165mm
Wheel base
1435mm
Engine type
Water cooled 4-stroke,
OHC engine
Displacement
249.1/251cc
Fuel Used
92# nonleaded gasoline
Front wheel
65
Net weight (kg)
Rear wheel
93
Total
158
1 Person
Front wheel
86
55kg
Rear wheel
127
Gross weight(kg)
Total
213
Front wheel
120/70-12 58P
Rear wheel
140/70-12 65P
Ground clearance
135mm
Perform
-
Braking distance (m)
4m/30km/hr
ance
Min. turning radius
2350mm
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
72.7 x 60/60.4
Compression ratio
10.3:1
Compression pressure
(kg/cm_-rpm)
16.5±2
Max. output (kw/rpm)
13.34/7000
Max. torque (kg.m/rpm)
2.0/5500
BDC
42°
Port
Intake
TDC
-8°
timin
g
BDC
33°
Exhaust
TDC
1°
Valve
Intake
0.1
clearance (cold)
Exhaust
0.1
Idle speed (rpm)
1450±50rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
1.1 liters
Cooling Type
Water cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
10.5 liters
Type
CVK
Piston dia.
30
Venturi dia.
30 equivalent
Throttle type
Butterfly type
Type
Full transistor igniter
Ignition timing
repeatedly
Contact breaker
Non-contact point
type
Spark plug
NGK
DPR7EA-9
Spark plug gap
0.7mm
Battery
Capacity
12V10AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
Type
Type
Two-stage reduction
Reduction
1st
0.83~2.2
ratio
2nd
6.98
Front
Caster angle
Axle
Connecting rod
Tire pressure
Front
1.75
(kgf/cm_)
Rear
2.25
Turning
Left
45°
angle
Right
45°
Brake system
Front
Disk brake
type
Rear
Disk brake
Suspension
Front
Telescope
type
Rear
Double swing
Shock absorber
Front
Telescope
type
Rear
Double swing
Frame type
Under bone
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
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1. GENERAL INFORMATION
1-3
YUP 250
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
nUse genuine parts and lubricants.
nWhen servicing the motorcycle, be sure to
use special tools for removal and
installation.
nAfter disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
nApply or add designated greases and
lubricants to the specified lubrication
points.
nAfter reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, pay
attention to the mutual working safety.
nDisconnect the battery negative (-) terminal
before operation.
nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
nAfter operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
nWhen connecting the battery, the positive
(+) terminal must be connected first.
nAfter connection, apply grease to the
battery terminals.
nTerminal caps shall be installed securely.
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1. GENERAL INFORMATION
1-4
YUP 250
nIf the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
nAfter operation, terminal caps shall be
installed securely.
nWhen taking out the connector, the lock on
the connector shall be released before
operation.
nHold the connector body when connecting
or disconnecting it.
nDo not pull the connector wire.
nCheck if any connector terminal is bending,
protruding or loose.
nThe connector shall be inserted
completely.
nIf the double connector has a lock, lock
it at the correct position.
nCheck if there is any loose wire.
nBefore connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
nCheck the double connector cover for
proper coverage and installation.
nInsert the terminal completely.
nCheck the terminal cover for proper
coverage.
nDo not make the terminal cover opening
face up.
nSecure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Confirm
Capacity
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1. GENERAL INFORMATION
1-5
YUP 250
nAfter clamping, check each wire to make
sure it is secure.
nDo not squeeze wires against the weld or
its clamp.
nAfter clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
nRoute wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
nRoute wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
nRoute harnesses so they are neither
pulled tight nor have excessive slack.
nProtect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
nWhen rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
nDo not break the sheath of wire.
nIf a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
nWhen installing other parts, do not press or
squeeze the wires.
Do not pull
too tightð
No Contact
Do not press
or squeeze the
wire
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1. GENERAL INFORMATION
1-6
YUP 250
nAfter routing, check that the wire harnesses
are not twisted or kinked.
nWire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
nWhen a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
nBe careful not to drop any parts.
nWhen rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
nSymbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
:Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
:Apply grease for lubrication.
:Transmission Gear Oil (90#)
:Use special tool.
: Caution
:Warning
Special
Engine Oil
Grease
Gear Oil
＊
Do you
understand the
instrument？
Remove
Rustð
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1. GENERAL INFORMATION
1-7
YUP 250
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (N-m)
Item
Torque (N-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
4.5_6
8_12
18_25
30_40
50_60
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
3.5_5
8.8
10_14
24_30
35_45
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (N-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Cylinder head cap nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Flywheel nut
Oil pump bolt
Cylinder head cover bolt
Spark plug
Cam chain tensioner bolt
Water pump impeller
Drive face nut
Transmission case cover bolt
Gear oil check bolt
2
2
1
4
2
1
1
1
1
1
2
4
1
1
1
1
9
1
8
8
30
8
5
6
12
12
12
14
5
6
10
6
8
12
8
8
8.9
8.9
12.7
24.5
8.8
8.8
14.7
53.9
53.9
58.8
3.9
11.8
17.2
11.8
11.8
93
20
10
Double end bolt
Double end bolt
Apply oil to
threads
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1. GENERAL INFORMATION
1-8
YUP 250
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (N-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Front shock absorber lock bolt
Engine hanger bolt (frame side)
Engine hanger bolt (ENG. side)
Front caliper holder bolt
Rear caliper holder bolt
Brake oil bolt
Master cylinder holder bolt
Exhaust muffler pipe nut
Exhaust muffler bolt
Rear fork bolt
1
1
1
2
2
4
2
1
2
2
4
4
2
3
2
10
12
16
10
10
8
12
10
8
8
10
6
8
8
8
40_50
50_70
110_130
35_45
35_45
29_35
45_55
45_55
29_35
29_35
30_40
10_14
18_22
32_38
29_35
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
Clutch spring compressor
E034
Clutch disassembly
Bearing puller 10,12,15,18mm
E037
Bearing removal
Valve spring compressor
E040
Valve removal
Oil seal & bearing installer
E014
Oil seal & bearing install
Tappet adjuster
E036
Tappet adjustment
Flywheel puller
E003
A.C. generator flywheel removal
Universal holder
E017
Holding clutch for removal
Flywheel holder
E021
A.C. generator flywheel holding
Lock nut socket wrench
F002
Steering stem removal or install
Float level gauge
Carburetor fuel level check
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1. GENERAL INFORMATION
1-9
YUP 250
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Cranksahft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYM CO Engine Oil (SAE15W-40)
•API SJ Engine Oil
Starter idle gear
Friction springmovable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads
Thread locking agent
A.C. generator connector
Transmission case breather tubee
Adhesive
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1. GENERAL INFORMATION
1-10
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.
Seat Lock
Rear Wheel Bearing
Grease
Speedometer Cable
Throttle Cable
Speedometer Gear/
Front Wheel Bearing
Engine Oil
Grease
Grease
Grease
Front Brake Lever Pivot
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1. GENERAL INFORMATION
1-11
YUP 250
CABLE & HARNESS ROUTING
Throttle Cable
Radiator Air
Ventilated Tube
Ignition Switch Wire
Reserve Water
Tank
Front Brake Fluid Tube
Meter Wire
EMI Filter Wire
Water Hose (Hot Water)
Water Hose (Cool Water)
Fan Motor Wire
Thermostatic Switch
Harness Wire (to Horn)
Harness Wire (to
Front Right Winker)
Earth Wire (to Filler Cap)
Rear Brake Fluid Tube
Harness Wire
Harness Wire (to
Front Left Winker)
Rear Brake Fluid Tube
Radiator Air
Vent Tube
Radiator Overflow
Tube
Water Fill Hose
Ignition Switch
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1. GENERAL INFORMATION
1-12
YUP 250
Front Brake Fluid Tube
Fuel Unit Wire
Speedometer Cable
Rear Brake Fluid Tube
Radiator Air
Ventilated Tube
Throttle Cable
Ignition Coil Wire
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1. GENERAL INFORMATION
1-13
YUP 250
Fuel Pump
Rear Brake
Fluid Tube
Fuel Filter
Fuse Box
Ignition Unit
Regulator/
Rectifier
A.C.Generator/
Regulator/Recti
fier/
Start Relay
coupler
Earth Wire (To Frame)
Heater Control Unit
Ignition Unit Wire
Heat Control Unit
Wire Coupler
Ignition Coil
Ignition Coil Wire
Water Duct
Start Relay
Harness
Wire (To
Tail Light)
Luggage Box
Light Switch
Coupler
Fuel Pump
Vacuum
Tube
Secondary Air
Cleaner
Secondary Air
Vacuum Tube
Fuel Tube (between
Fuel Pump and Fuel
Tank)
Fuel Tube (between
Fuel Pump and
Caburetor)
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1. GENERAL INFORMATION
1-14
YUP 250
Battery (+) Cable
Battery (-) Cable
Ignition Unit
Carburetor
Regulator/
Rectifier
Fuse Box
Wire Harness
Side Stand Switch
Start Relay
Resister
Heater Control Unit
Ignition Coil
Spark Plug Cap
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1. GENERAL INFORMATION
1-15
YUP 250
Harness Wire
Throttle Cable
Oil Pressure
Control Unit
Speedometer Cable
Meter Wire
Reserve Water
Tank
Horn
Fuel Level
Indicator
Rear Brake
Fluid Tube
Fuel Filter
Side Stand Switch Prepared
Wire Coupler
Front Brake
Fluid Tube
EMI Filter
Radiator Air
Vent Tube
Radiator Overflow
Tube
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1. GENERAL INFORMATION
1-16
YUP 250
Fuel Filter
Radiator Air Vent Tube
Start Relay
Resister
Ignition Unit
Rear Brake Fluid Tube
Battery (+) Cable
Battery (-) Cable
Secondary Air
Vacuum Tube
Fuel Pump
Vacuum Tube
Fuel Pump
Regulator/
Rectifier
A.C.Generator/Reg
ulator/Rectifier/
Start Relay
coupler
Harness Wire (to Tail
Light)
Luggage Box
Light Switch
Coupler
Fuse Box
Earth Wire (to Frame)
Heater Control
Unit
Ignition Unit
Harness Wire (to
Luggage Box Light)
Fuel Unit Wire
Side Stand
Switch Coupler
Side Stand Switch
Prepared
Wire Coupler
Throttle Cable
Harness Wire
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1. GENERAL INFORMATION
1-17
YUP 250
WIRING DIAGRAM
SIDE STAND SW PREPARED WIRE COUPLER
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