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5. ENGINE REMOVAL/INSTALLATION

5-0

YUP 25 0

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ENGINE REMOVAL/INSTALLATION

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SERVICE INFORMATION -------------------------------------------- 5-1

ENGINE HANGER REMOVAL --------------------------------------- 5-2

ENGINE REMOVAL --------------------------------------------------- 5-3

Summary of content (8 pages)

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5.
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5. ENGINE REMOVAL/INSTALLATION YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. • Drain the coolant before removing the engine. • After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the water jacket.
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5. ENGINE REMOVAL/INSTALLATION YUP 250 ENGINE HANGER REMOVAL Remove rear carrier (!2-6), met-in box (!26), center cover (!2-7), rear fender A (!28), and rear body cover. (!2-8) Remove two bolts on air cleaner. Bolts Air Cleaner Tube Band Disconnect the oil vapor recovery tube and loosen air cleaner tube band. Oil Vapor Recovery Tube Disconnect the transmission case breather hose, then remove air cleaner.
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5. ENGINE REMOVAL/INSTALLATION YUP 250 Starter Motor Remove two bolts, then remove the starter motor. Bolts Remove the engine hanger nut, then remove the engine hanger bolt (engine side). Engine Hanger Bolts (frame side) Remove the engine hanger bolts (frame side) and collar, then remove the engine hanger. Nut Bolt Engine Hanger Bolts (engine side) Engine Hanger Inspect the engine hanger bushings and stopper rubber for wear or damage. Install the engine hanger in the reverse order of remove.
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. ENGINE REMOVAL/INSTALLATION Open the rubber sheath and remove the nut, then disconnect the starter motor lead. Disconnect rear brake fluid tube from clamps. Remove the bolt on right crankcase cover for disconnect ground wire lead. YUP 250 Rubber Sheath Nut Rear Brake Fluid Tube Clamps Ground Wire Lead on Engine Bolts Bolts Remove the two exhaust muffler joint lock nuts. Remove the three exhaust muffler lock bolts to remove the exhaust muffler.
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5. ENGINE REMOVAL/INSTALLATION YUP 250 Rear Fender C Remove three screws, then remove rear fender C. Screws Screw Remove the right rear shock absorber lower bolt, rear axle nut, collar and two rear fork bolt. Remove the rear fork. Right Rear Shock Absorber Lower Bolt Rear Axle Nut Rear Fork Bolts Disconnect two water hoses from water ducts. Disconnect oil pressure switch lead. Water Hose Disconnect secondary air vacuum tube and fuel pump vacuum tube from intake manifold.
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5. ENGINE REMOVAL/INSTALLATION Loosen band screw, then disconnect carburetor. Screw YUP 250 Carburetor Remove the left rear shock absorber lower bolt. Bolt Remove engine hanger nut and bolt (engine side). Nut Bolt Remove and pull the engine assembly to back of the machine. Put the engine assembly to below of the machine.
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5. ENGINE REMOVAL/INSTALLATION YUP 250 Move the engine assembly by rear wheel. ENGINE ASSEMBLY INSTALLATION Bushes Install the engine assembly in the reverse order of removal. ＊ • Apply grease onto the bushes before install the engine assembly.