Yamaha YFM250X 2002 Manual

YFM250X(P)

4XE3-AE3

SUPPLEMENTARY

SERVICE MANUAL

2002

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for

the YFM250X(P) 2002. For complete information on service procedures, it is necessary to use this

Supplementary Service Manual together with the following manual.

YFM250XL’99 SERVICE MANUAL: 4XE3-AE1

YFM250XN 2001 SUPPLEMENTARY SERVICE MANUAL: 4XE3-AE2

YFM250X(P) 2002

SUPPLEMENTARY

SERVICE MANUAL

 2001 by Yamaha Motor Co., Ltd.

First Edition, June 2001

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 machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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.

OTE:

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 machine operator, a bystander or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

TE:

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is a chapter with its symbol on the upper right of each page.

2nd title 2: This title appears on the upper of each page on the left of the chapter sym-

bol. (For the chapter “Periodic inspection and adjustment” the 3rd title

appears.)

3rd title 3: This is a final title.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been compiled to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure 4is placed between a line of asterisks “*” with each proce-

dure preceded by “●”.

IMPORTANT FEATURES

●Data and a special tool are framed in a box preceded by a relevant symbol 5.

●An encircled numeral 6indicates a part name, and an encircled alphabetical letter data or an

alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

●A condition of a faulty component will precede an arrow symbol 9and the course of action will fol-

low it.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section for ease in identifying

correct disassembly and assembly procedures.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 9are printed on the

top right of each page and indicate the subject

of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetion

6Drive train

7Chassis

8Electrical

9Troubleshooting

Illustrated symbols 0to Fare used to identify

the specifications appearing in the text.

0Filling fluid

ALubricant

BSpecial tool

CTorque

DWear limit, clearance

EEngine speed

FΩ, V, A

Illustrated symbols Gto Min the exploded

diagrams indicate the types of lubricants and

lubrication points.

GApply engine oil

HApply gear oil

IApply molybdenum disulfide oil

JApply wheel bearing grease

KApply lightweight lithium soap base grease

LApply molybdenum disulfide grease

MApply silicon grease

Illustrated symbols Nto Oin the exploded

diagrams indicate where to apply a locking

agent Nand when to install a new part O.

NApply the locking agent (LOCTITE)

OReplace

GHI

GEN

INFO SPEC

CHK

ADJ ENG

CARB

DRIV

CHAS

–+

ELEC

TRBL

SHTG

EGM

BLS MS

KLM

LT New

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATION ............................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................3

ELECTRICAL ........................................................................................3

CABLE ROUTING .....................................................................................4

PERIODIC CHECKS AND ADJUSTMENTS ..................................................12

INTRODUCTION .....................................................................................12

PERIODIC MAINTENANCE/LUBRICATION INTERVALS.......................12

CHASSIS .................................................................................................14

ADJUSTING THE FRONT BRAKE .....................................................14

ADJUSTING THE REAR BRAKE LIGHT SWITH ...............................14

ELECTRICAL .................................................................................................15

CHECKING THE SWITCH ......................................................................15

CHECKING THE SWITCH ..................................................................15

CHECKING A SWITCH SHOWN IN THE MANUAL ...........................15

SIGNAL SYSTEM ...................................................................................16

CIRCUIT DIAGRAM ............................................................................16

CHECKING THE SIGNAL SYSTEM ...................................................17

YFM250X(P) 2002 WIRING DIAGRAM

–1 –

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 4XEF (CDN, Europe and Oceania)

Dimensions:

Overall length 1,940 mm (76.4 in)

Overall width 1,080 mm (42.5 in)

Overall height 1,118 mm (44.0 in)

Seat height 780 mm (30.7 in)

Wheelbase 1,170 mm (46.1 in)

Minimum ground clearance 150 mm (5.9 in)

Minimum turning radius 2,900 mm (114.2 in)

Brake:

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Drum brake (fully sealed)

operation Left hand and right foot operation

Electrical:

Ignition system DC.C.D.I.

Generator system A.C. magneto

Battery type YB14A-A2

Battery capacity 12 V 14 AH

Bulb wattage ×quantity:

Headlight 12 V 25 W/25 W ×2

Tail/brake light 12 V 5 W/21 W ×1

Indicator lights:

Neutral 12 V 1.7 W ×1

Reverse 12 V 1.7 W ×1

–2 –

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.03 mm

(0.001 in)

Measuring point Lines indicate straightedge

measurement.

Piston:

Piston to cylinder clearance 0.04 ~ 0.06 mm

(0.0016 ~ 0.0024 in)

0.15 mm

(0.0059 in)

Piston size “D”70.92 ~ 70.97 mm

(2.792 ~ 2.794 in)

----

Measuring point “H”4.0 mm (0.16 in) from bottom line

of piston skirt

----

Oversize 2nd 71.5 mm (2.81 in) ----

Oversize 4th 72 mm (2.83 in) ----

Piston off-set 0.5 mm (0.02 in) ----

Piston off-set direction Intake side ----

Piston pin bore inside diameter 16.002 ~ 16.013 mm

(0.6300 ~ 0.6304 in)

----

Piston pin outside diameter 15.991 ~ 16.000 mm

(0.6296 ~ 0.6299 in)

----

Lubrication system:

Oil filter type Wire mesh ----

Oil pump type Trochoid type ----

Tip clearance “A”or “B”0.15 mm (0.006 in) 0.20 mm

(0.008 in)

Side clearance 0.04 ~ 0.09 mm

(0.002 ~ 0.004 in)

0.09 mm

(0.004 in)

Bypass valve setting pressure 80 ~ 120 kPa

(0.8 ~ 1.2 kg/cm2, 11 ~ 17 psi)

----

Oil pressure (hot) 52 kPa (0.52 kg/cm², 7.5 psi) at

7,500 r/min

----

Pressure check location Element cover ----

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