Yamaha YP250R 2005 User manual

YP250R
SERVICE MANUAL
2005
1C0-F8197-E0

EAS00000
YP250R 2005
SERVICE MANUAL
©2007 by Yamaha Motor España, S.A.
First edition, February 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor España, S.A.
is expressly prohibited.

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NOTICE
This manual was produced by the Yamaha Motor España S.A. 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. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor España S.A. is continually striving to improve all of its models. Modifications and sig-
nificant 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.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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 vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

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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.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

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SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetor
8Electrical system
9Troubleshooting
Symbols 0to Gindicate the following.
0Serviceable with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTightening torque
EWear limit, clearance
FEngine speed
GElectrical data
Symbols Hto Min the exploded diagrams
indicate the types of lubricants and lubrication
points.
HEngine oil
IGear oil
JMolybdenum-disulfide oil
KWheel-bearing grease
LLithium-soap- based grease
MMolybdenum-disulfide grease
Symbols Nto Oin the exploded diagrams
indicate the following.
NApply locking agent (LOCTITE®)
OReplace the part
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
CARB
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

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TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS 4
ENGINE ENG 5
COOLING SYSTEM COOL 6
CARBURETOR CARB 7
ELECTRICAL SYSTEM ELEC 8
TROUBLESHOOTING TRBL
SHTG 9
–+

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
MULTI-FUNCTION DISPLAY..........................................................................1-2
IMPORTANT INFORMATION .........................................................................1-5
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-5
REPLACEMENT PARTS...........................................................................1-5
GASKETS, OIL SEALS AND O-RINGS ....................................................1-5
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-6
BEARINGS AND OIL SEALS....................................................................1-6
CIRCLIPS..................................................................................................1-6
CHECKING THE CONNECTIONS ..................................................................1-7
SPECIAL TOOLS ............................................................................................1-8

1 - 1
GEN
INFO
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GENERAL INFORMATION
IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the frame.
1
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MODEL LABEL
The model label 1is affixed underneath the
seat. This information will be needed when
ordering spare parts.
1
IDENTIFICATION

1 - 2
GEN
INFO
MULTI-FUNCTION DISPLAY
The multi-function display is equipped with the
following:
•an odometer (which shows the total dis-
tance traveled)
•two tripmeters (which show the distance
traveled since they were last set to zero, the
time passed since the tripmeters were set
to zero, and the average speed traveled
during this time)
1“MODE”button
2Multi-function display
3“SET”button
•a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warn-
ing light came on)
•a clock
•an ambient temperature display
•an oil change indicator (which comes on
when the engine oil should be changed)
NOTE:
•For the UK, the distance traveled is dis-
played in miles and the temperature reading
is displayed in °F.
•For other countries, the distance traveled is
displayed in kilometers and the temperature
reading is displayed in °C.
1Total
2Trip 1
3Trip 2
4Trip/Fuel
Odometer and tripmeter modes
Pushing the “MODE”button switches the dis-
play between the odometer mode “Total”and
the tripmeter modes “Trip”in the following
order:
1Distance
2Time
3Average speed
NOTE:
•The Trip/fuel odometer is only activated if the
fuel level warning light comes on.
•The Trip 2 odometer is automatically reset
after turning the key to “OFF”and two hours
have passed.
Total →Trip 1 →Trip 2 →Trip/fuel →Total
MULTI-FUNCTION DISPLAY

1 - 3
GEN
INFO
Pushing the “SET”button when in the tripme-
ter mode switches the display between the dif-
ferent tripmeter functions in the following
order:
Distance →Time →Average speed →Dis-
tance
If the fuel level warning light comes on, the dis-
play will automatically change to the fuel
reserve tripmeter mode “Trip/fuel”and start
counting the distance traveled from that point.
In that case, pushing the “MODE”button
switches the display between the various trip-
meter and odometer modes in the following
order:
To reset a tripmeter, select it by pushing the
“MODE”button, and then push the “SET”but-
ton for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically and the display will return
to the prior mode after refueling and traveling 5
km.
Trip/Fuel →Trip 1 →Trip 2 →Total →Trip/
fuel
Clock mode
To set the clock:
1. When the display is in the “To t a l ”mode,
push the “SET”button for at least two sec-
onds.
2. When the hour digits start flashing, push
the “SET”button to set the hours.
3. Push the “MODE”button, and the minute
digits will start flashing.
4. Push the “SET”button to set the minutes.
5. Push the “MODE”button and then release it
to start the clock. The display will return to
the “Total ”mode.
MULTI-FUNCTION DISPLAY