User Guide

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1. GENERAL INFORMATION

1-0

YUP 25 0

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GENERAL INFORMATION

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ENGINE SERIAL NUMBER--------------------------------------------- 1-1

SPECIFICATION---------------------------------------------------------- 1-2

SERVICE PRECAUTIONS----------------------------------------------- 1-3

TORQUE VALUES ------------------------------------------------------- 1-7

SPECIAL TOOLS --------------------------------------------------------- 1-8

LUBRICATION POINTS------------------------------------------------- 1-9

CABLE & HARNESS ROUTING-----------------------------------------1-11

WIRING DIAGRAM-------------------------------------------------------------------1-17

TROUBLESHOOTING --------------------------------------------------1-18

Summary of content (29 pages)

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. GENERAL INFORMATION YUP 250 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION _________________________________
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1. GENERAL INFORMATION YUP 250 Cooling Type SPECIFICATIONS Displacement Fuel Used 1° 0.1 0.1 1450±50rpm Forced pressure & wet sump Inner/outer rotor type Full-flow filtration 1.1 liters Spark plug gap Battery Capacity Clutch Type NGK DPR7EA-9 0.7mm 12V10AH Dry multi-disc clutch Type Non-stage transmission Operation Automatic centrifugal Type Reduction Gear 13.34/7000 2.0/5500 42° -8° 33° Spark plug Transmission Gear 16.
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1. GENERAL INFORMATION SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. YUP 250 n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
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1. GENERAL INFORMATION n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity YUP 250 n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire. n After operation, terminal caps shall be installed securely. n Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
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1. GENERAL INFORMATION n After clamping, check each wire to make sure it is secure. YUP 250 n Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tightð n Do not squeeze wires against the weld or its clamp. n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
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1. GENERAL INFORMATION n After routing, check that the wire harnesses are not twisted or kinked. n Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. YUP 250 n Symbols: The following symbols represent the servicing methods and cautions included in this service manual.
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1. GENERAL INFORMATION YUP 250 TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut Torque (N-m) 4.5_ 6 8_ 12 18_ 25 30_ 40 50_ 60 Item 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut Torque (N-m) 3.5_ 5 8.8 10_ 14 24_ 30 35_ 45 Torque specifications listed below are for important fasteners.
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1. GENERAL INFORMATION YUP 250 FRAME Item Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt (frame side) Engine hanger bolt (ENG. side) Front caliper holder bolt Rear caliper holder bolt Brake oil bolt Master cylinder holder bolt Exhaust muffler pipe nut Exhaust muffler bolt Rear fork bolt Q‘ty Thread dia.
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1. GENERAL INFORMATION YUP 250 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
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1. GENERAL INFORMATION YUP 250 Fuse Box Luggage Box Light Switch Coupler Earth Wire (To Frame) Heater Control Unit A.C.
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1. GENERAL INFORMATION Throttle Cable YUP 250 Radiator Air Vent Tube Rear Brake Fluid Tube Harness Wire Side Stand Switch Prepared Wire Coupler Side Stand Switch Coupler Fuel Unit Wire Fuel Filter Secondary Air Vacuum Tube Ignition Unit Fuel Pump Vacuum Tube Harness Wire (to Luggage Box Light) Start Relay Battery (+) Cable Fuel Pump Ignition Unit Regulator/ Rectifier Heater Control Unit A.C.
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1. GENERAL INFORMATION YUP 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Correct timing Incorrect timing Correctly adjusted Incorrectly adjusted ÅFaulty ignition unit ÇFaulty A.C.
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1. GENERAL INFORMATION YUP 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty ignition unit ÇFaulty A.C.
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1. GENERAL INFORMATION YUP 250 STARTER MOTOR 1.
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1. GENERAL INFORMATION YUP 250 FUEL GAUGE 1.
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