Yamaha YP250 98 Manual

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 Sup-
plementary 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.

NOTE:
CAUTION:
EB001000 NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha deal-
ersandtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicin
one manual, so it is assumed that anyone who uses this book to perform maintenance and re-
pairsonYamahascooterhasabasicunderstandingofthemechanicalideasandtheprocedures
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 Ya-
maha dealers and will appear in future editions of this manual where applicable.
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 re-
pairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid
damage to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.

1
243
5
6
7
6
8
YP002000 HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-
bols”)
1st title 1: This is the title of the chapter with its symbol on the upper right corner of each
page.
2nd title 2: Thistitleindicatesthesectionofthe chapter and only appears on thefirstpageof
each section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures ac-
companied 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 4is provided for disassembly and assembly jobs.
2. Numbers 5are given in the order of jobs in the exploded diagram. A number that is en-
closed 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 7accompanies 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 8are given in
addition to the exploded diagram and the job instruction chart.

1
3
5
7
9
11
13
15
18
2
4
8
10
12
14
16
6
21
24 25
17
19 20
22 23
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are designed as
thumbtabstoindicatethe chapter’snumber
and content.
1General information
2Specifications
3Periodic inspection and adjustment
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustratedsymbols 10 to 17 are usedtoiden-
tify 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
Illustrated symbols 18 to 23 in the exploded
diagrams indicate the types of lubricants
and lubrication points.
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 lock-
ing 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)

1
SCOOTER IDENTIFICATION GEN
INFO
YP100000
GENERAL INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (for E)
The vehicle identification number 1is
stamped into the right side of the frame.
MODEL LABEL
The model label 1is affixed under the seat.
This information will be needed to order
spare parts.

2
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YP250
Model code: 4UC3 (except for CH, A, AUS)
4UD3 (for CH, A)
4UC4 (for AUS)
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High-speed riding
front
rear
197 kg
0 90 kg
175 kPa (1.75 kg/cm2, 1.75 bar)
200 kPa (2.0 kg/cm2, 2.0 bar)
90 197 kg
200 kPa (2.0 kg/cm2, 2.0 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
200 kPa (2.0 kg/cm2, 2.0 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
Wheel travel:
Front wheel travel
Rear wheel travel 100 mm
90 mm
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
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.

3
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
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
11/2
1.4
ø0.5
ø1.3
27 mm
1,350 1,450 r/min
220 260 mmHg
65 75C
80C




















CHASSIS
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 cm3)
80 mm
Fork oil 15 WT or equivalent


265 mm





0.2 mm

4
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Rear suspension:
Shock absorber stroke
Spring free length
Fitting length
Spring rate (K1)
(K2)
(K3)
Stroke (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







ELECTRICAL
Item Standard limit
Spark plug cap:
Type
Resistance Resin type
10 kΩ


Charging system:
Type
Model/manufacturer
Normal output
Stator coil resistance/color
A.C. magneto
F4T252/MITSUBISHI
14 V 16 A at 5,000 r/min
0.54 0.66 Ωat 20C/
White – White




Rectifire/regulator:
Model/manufacturer
No load regulated voltage
Capacity
Withstand voltage
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 Ωat 20C
10 mm
2 pcs.
570 920 g
28 mm
0.7 mm




4 mm

570 g
27 mm


5
MAINTENANCE SPECIFICATIONS SPEC
Item Standard limit
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
MS5F-471JIDECO
100 A
4.2 4.6 Ωat 20C



Horn:
Model/manufacturer
Maximum amperage YF-12/NIKKO
3 A


Flasher relay:
Type
Model/manufacturer
Flasher frequency
Full transistor type
FE246BH/DENSO
75 95 cycle/min



Starting circuit cut-off relay:
Model/manufacturer
Coil winding resistance ACA12115-1/MATSUSHITA
72 88 Ω


Thermo unit:
Model/manufacturer 11H/NIPPON SEIKI 

6
CABLE ROUTING SPEC
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.
CABLE ROUTING

7
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.
CABLE ROUTING SPEC

8
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.
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
CABLE ROUTING SPEC
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.

9
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
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
CABLE ROUTING SPEC
A Install the positive (+) lead
between the battery and the
starterrelaytothestarterrelay
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.

10
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
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
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.

11
Install the damper assembly to the
body with its rod side backward and
labels upward.
Reverse the removal procedure for
installation.
Order Job name/Part name Q’ty Remarks
1
2
3
4
5
6
7
8
Side panel and seat removal
Rear panel
Side panel (left)
Side panel (right)
Rivet
Front panel
Clip
Damper assembly
Seat
1
1
1
2
1
2
1
1
Remove the parts in order.
NOTE:
COVER AND PANEL INSP
ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
COVER AND PANEL
SIDE PANEL AND SEAT

12
3Main switch
4Battery
5Main 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
SIGNAL SYSTEM ELEC

 
 