Yamaha YP250D 98 Manual

FOREWORD

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

YP250D ’98. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

YP250 SERVICE MANUAL: 4UC-AE1

YP250 (J) SUPPLEMENTARY SERVICE MANUAL: 4UC-AE2

YP250D ’98

SUPPLEMENTARY

SERVICE MANUAL

1997 by Yamaha Motor Co., Ltd.

First Edition, December 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 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

scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Re-

pairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for

use.

YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha 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!

FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathto

thescooter operator, abystander ora personinspectingorrepairingthescoot-

er.

ACAUTION indicatesspecialprecautionsthatmust betakentoavoiddamage

to the scooter.

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

243

YP002000 HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

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

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

2nd title 2: This title indicates the section of the chapter and only appears on the first page of 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 accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

Tohepsidentifypartsandclarifyproceduresteps,thereareexplodeddiagramsatstartofeachremov-

al and disassembly section.

1. An easy-to-see exploded diagram 4is provided for disassembly and assembly jobs.

2. Numbers 5aregivenintheorderofjobs intheexplodeddiagram.Anumberthatisenclosedbya

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. Forjobsrequiring more information,thestep-by-step format supplements 8aregiven inaddition

to the exploded diagram and the job instruction chart.

24 25

19 20

22 23

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 9are designed as

thumb tabs to indicate the chapter’s number

and content.

1General information

2Specifications

3Periodic inspection and adjustment

4Engine

5Cooling system

6Carburetion

7Chassis

8Electrical

9Troubleshooting

Illustrated symbols 10 to 17 are used to identify

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

Illustratedsymbols 18 to 23 in theexplodeddia-

grams indicate the types of lubricants and lu-

brication 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

Illustratedsymbols 24 to 25 in theexplodeddia-

gramsindicatethewheretoapplylockingagent

24 and when to install new parts 25 .

24 Apply locking agent (LOCTITE)

25 Use new one

CONTENTS

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

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

MAINTENANCE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHASSIS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

PERIODIC INSPECTION AND ADJUSTMENTS 10. . . . . . . . . . . . . . . . . . .

INTRODUCTION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 10. . . . . . . . .

COVER AND PANEL 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE PANEL AND SEAT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE REAR BRAKE FLUID 13. . . . . . . . . . . . . . . . . . . . . .

CHECKING THE REAR BRAKE PADS 14. . . . . . . . . . . . . . . . . . . . . .

BLEEDING THE HYDRAULIC BRAKE SYSTEM 14. . . . . . . . . . . . . .

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 16. .

CHASSIS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL AND BRAKE DISC 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BRAKE DISC 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR BRAKE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE PAD 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING THE BRAKE PADS 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

CALIPER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CALIPER DISASSEMBLY 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE REAR BRAKE CALIPER 23. . . . . . . . . . . . . . . . . .

MASTER CYLINDER 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MASTER CYLINDER DISASSEMBLY 25. . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER AND SWINGARM 26. . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YP250D

Model code: 5DF1 (except for CH, A, AUS)

5DF2 (for CH, A)

Basic weight:

With oil and full fuel tank 164 kg

Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Transmission type

Operation

Single speed automatic

Helical gear

38/15 (2.533)

Sper gear

37/16 (2.312)

Single speed automatic (V-belt type)

Centrifugal automatic type

2.34 0.82 : 1

Tire pressure (cold tire):

Maximum load-except motorcycle

Loading condition A*

front

rear

Loading condition B*

front

rear

High-speed riding

front

rear

191 kg

0 90 kg

175 kPa (1.75 kg/cm2, 1.75 bar)

200 kPa (2.0 kg/cm2, 2.0 bar)

90 191 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)

Brake:

Front brake type

operation

Rear brake type

operation

Single disc brake

Right hand operation

Single disc brake

Left hand operation

Wheel travel:

Front wheel travel

Rear wheel travel 85 mm

90 mm

Electrical:

Ignition system

Generator system

Battery type

Battery capacity

T.C.I. (Digital)

A.C. magneto

GT7B-4

12 V 6.5 AH

*Load is the total weight of cargo, rider, passenger, and accessories.

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Automatic centrifugal clutch:

Clutch shoe thickness

Clutch housing inside diameter

Clutch shoe spring free length

Weight outside diameter

Clutch - in revolution

Clutch - stall revolution

3.0 mm

135 mm

28.1 mm

20 mm

2,250 2,850 r/min

3,700 4,700 r/min

2.0 mm

135.5 mm



19.5 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-1A

4UC 02 [4UD 00 (CH)]

ø28

#130

ø0.9

5D32-3/5

11

ø1.2

#85

ø0.8

#44

0.7 3

1 7/8 [1 5/8 (CH)]

1.4

ø0.45 [ø0.47 (CH)]

ø0.5

27 mm

1,350 1,450 r/min

220 260 mmHg

65 75C

80C



CHASSIS

Item Standard Limit

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

268.5 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



263.5 mm



0.2 mm

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