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.

EAS00002
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.
EAS00005
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:

EAS00007
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.

EAS00008
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

EAS00010
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
EAS00015
GENERAL INFORMATION
IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the frame.
1
EAS00018
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

1 - 4
GEN
INFO
Ambient temperature display
This display shows the ambient temperature
from -30 °C to 50 °C.
The frost warning indicator “*”automatically
comes on if the temperature is lower than 3 °C.
1Frost warning indicator
2Negative symbol
3Ambient temperature
Oil change indicator “OIL”
The engine oil should be changed when this
indicator comes on. The indicator stays on
until it is reset. After changing the engine oil,
reset the indicator as follows.
1Oil change indicator “OIL”
To reset the oil change indicator:
1. Set the main switch to “ON”while holding
the “MODE”and “SET”buttons pushed for
two to five seconds.
2. Release the buttons, and the oil change
indicator will go off.
NOTE:
•The oil change indicator will come on at the
initial 1000 km and every 3000 km thereafter.
•If the engine oil is changed before the oil
change indicator comes on, the indicator
must be reset after the oil change for the
next periodic oil change to be indicated at
correct time.
MULTI-FUNCTION DISPLAY

1 - 5
GEN
INFO
IMPORTANT INFORMATION
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated”through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

1 - 6
GEN
INFO
IMPORTANT INFORMATION
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’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 appro-
priate.
1Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
2Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft

1 - 7
GEN
INFO
CHECKING THE CONNECTIONS
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
•lead
•coupler
•connector
2. Check:
•lead
•coupler
•connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect sev-
eral times.
3. Check:
•all connections
Loose connection →Connect properly.
NOTE:
_
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
•lead
•coupler
•connector
NOTE:
_
Make sure all connections are tight.
5. Check:
•continuity
(with the pocket tester)
NOTE:
_
•If there is no continuity, clean the terminals.
•When checking the wire harness, perform
steps (1) to (3).
•As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
90890-03112

1 - 8
GEN
INFO
SPECIAL TOOLS
EAS00027
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 inappropri-
ate 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.
Tool No. Tool name/Function Illustration
90890-01083
90890-01084
Slide hammer bolt
Weight
These tools are used to remove or install
the rocker arm shafts.
90890-01135
Crankshaft separating tool
This tool is used to remove the crank-
shaft.
90890-01235
Rotor holding tool
This tool is used to hold the primary fixed
sheave.
90890-01274
Crankshaft installer pot
This tool is used to install the crankshaft.
90890-01275
Crankshaft installer bolt
This tool is used to install the crankshaft.
90890-01294
Damper rod holder
This tool is used to hold the damper rod
when removing or installing the damper
rod.
90890-01304
Piston pin puller set
This tool is used to remove the piston
pins.

1 - 9
GEN
INFO
SPECIAL TOOLS
90890-01311
Tappet adjusting tool
This tool is used to adjust valve clear-
ance.
90890-01326
T-handle
This tool is used to hold the damper rod
when removing or installing the damper
rod.
90890-01337
Clutch spring holder
This tool is used to disassembly and
assembly the secondary sheave.
90890-01348
Locknut wrench
This tool is used to remove or install the
clutch carrier nut.
90890-01362
Flywheel puller
This tool is used to remove the generator
rotor.
90890-01367
Fork seal driver weight
This tool is used to install the oil seal,
dust seal, and the outer tube bushing of a
front fork leg.
90890-01370
Fork seal driver attachment (ø36)
This tool is used to install the oil seal and
the outer tube bushing of the front fork
leg.
90890-01396
Oil seal guide (ø41)
This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
Tool No. Tool name/Function Illustration

1 - 10
GEN
INFO
SPECIAL TOOLS
90890-01403
Steering nut wrench
This tool is used to loosen or tighten the
steering ring nuts.
90890-01464
Clutch spring holder arm
This tool is used to disassembly and
assembly the secondary sheave.
90890-01478
Adapter (M14)
This tool is used to install the crankshaft.
90890-01701
Sheave holder
This tool is used to hold the generator
rotor, clutch housing, and clutch carrier.
90890-03081
Compression gauge
This tool is used to measure the engine
compression.
90890-03112
Pocket tester
This tool is used to check the electrical
system.
90890-03134
Exhaust attachment
This tool is used to measure the CO den-
sity.
90890-03141
Timing light
This tool is used to check the ignition tim-
ing.
Tool No. Tool name/Function Illustration

1 - 11
GEN
INFO
SPECIAL TOOLS
90890-04019
Valve spring compressor
This tool is used to remove or install the
valve assemblies.
90890-04058
Middle driven shaft bearing driver
This tool is used to install the water pump
seal.
90890-04064
Valve guide remover (ø6)
This tool is used to remove or install the
valve guides.
90890-04065
Valve guide installer (ø6)
This tool is used to install the valve
guides.
90890-04066
Valve guide reamer (ø6)
This tool is used to rebore the new valve
guides.
90890-04081
Spacer (crankshaft installer)
This tool is used to install the crankshaft.
90890-04108
Valve spring compressor attachment
This tool is used to remove or install the
valve assemblies.
90890-04132
Mechanical seal installer
This tool is used to install the water pump
seal.
Tool No. Tool name/Function Illustration

1 - 12
GEN
INFO
SPECIAL TOOLS
90890-06754
Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-06756
Vacuum/pressure pump gauge set
This tool is used to check the air cut-off
valve.
90890-11098
Fuel sender removal tool
This tool are used to remove the fuel
sender.
90890-85505
Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
Tool No. Tool name/Function Illustration

SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-15
CONVERSION TABLE ..................................................................................2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-18
TIGHTENING TORQUES ..............................................................................2-19
ENGINE TIGHTENING TORQUES.........................................................2-19
CHASSIS TIGHTENING TORQUES.......................................................2-21
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ................2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ..............2-24
COOLING SYSTEM DIAGRAMS ..................................................................2-25
CABLE ROUTING .........................................................................................2-26