Service manual

ManualsBrandsYamaha ManualsAutomotiveYFM250BT

LIT-11616-18-41 4XE-F8197-13

YFM250BT

SUPPLEMENTARY

SERVICE MANUAL

Summary of content (34 pages)

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YFM250BT SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-41 4XE-F8197-13
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FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM250BT. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
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EBS00002 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.
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EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in 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.
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1 EBS00005 2 GEN INFO SYMBOLS The following symbols are not relevant to every machine. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting ENG 5 6 CARB DRIV 7 8 CHAS – ELEC 9 + 0 TRBL SHTG A Symbols 0 to F indicate the following.
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CONTENTS SPECIFICATIONS .............................................................................................1 GENERAL SPECIFICATIONS ....................................................................1 MAINTENANCE SPECIFICATIONS ...........................................................2 ENGINE ................................................................................................2 CHASSIS ..............................................................................................
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ELECTRICAL ..................................................................................................37 ELECTRICAL COMPONENTS ..................................................................
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GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Carburetor: Type/quantity Manufacturer Tire: Type Size front rear Manufacturer front rear Type front rear Electrical: Ignition system Generator system Battery type Battery capacity Bulb wattage × quantity: Headlight Tail/brake light Indicator lights: Neutral
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MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum Standard (M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (V.S) (G.S.1) (G.S.2) (Th.V) (F.H) (F.L) Limit 1P01 00 #93.
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MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Brake lever and brake pedal: Front brake lever free play (at lever pivot) Rear brake lever free play (at lever pivot) Brake pedal free play Throttle lever free play Limit 0 mm (0 in) 5 ~ 7 mm (0.20 ~ 0.28 in) 20 ~ 30 mm (0.79 ~ 1.18 in) 3 ~ 5 mm (0.12 ~ 0.
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MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item C.D.I.: Magneto model/manufacturer Pickup coil resistance/color Standard Limit F4T259/MITSUBISHI 189 ~ 231 Ω at 20 °C (68 °F)/ White/Green – White/Red 0.065 ~ 0.080 Ω at 20 °C (68 °F)/ Red – White/Blue F8T38683/MITSUBISHI ---- Constant mesh type ------------- Brush overall length 5XG/MORIC TAIWAN 0.4 kW 0.0144 ~ 0.0176 Ω at 20 °C (68 °F) 10 mm (0.4 in) Spring force Commutator diameter 563 ~ 844 g (5.52 ~ 8.28 N) 22 mm (0.
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CABLE ROUTING SPEC CABLE ROUTING 1 Rear brake light switch lead 2 Starter cable 3 Rear brake cable 4 Lower bracket cable guide 5 Front brake hose 6 Front brake light switch lead 7 Throttle cable 8 Reverse indicator light 9 Neutral indicator light 0 Fuel tank breather hose A Handlebar switch assembly lead B Rectifier/regulator –5–
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CABLE ROUTING È Do not route the handlebar switch assembly lead through the lower bracket cable guide. É Fasten the front brake light switch lead to the handlebar with the plastic band. Ê Faster the front brake light switch lead and front brake hose to the handlebar with the plastic band. Ë Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar (below the handlebar, not over it). Then, pass the hose through the cable guide.
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CABLE ROUTING 1 Headlight lead 2 Lower bracket cable guide 3 Indicator light lead 4 Main switch lead 5 Indicator light 6 Main switch 7 Fuel tank breather hose 8 Carburetor overflow hose 9 Reverse switch lead 0 Neutral switch lead A Negative battery lead B A.C.
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CABLE ROUTING È Fasten the headlight lead to the front bumper with the plastic band. É Route the main switch lead and indicator light lead to the side of the lower bracket cable guide. Ê Fasten the starter cable to the frame with the plastic locking tie. Ë Insert the carburetor air vent hose, rear brake breather hose, and final gear case breather hose into the air duct after routing them through the fuel tank grommet.
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CABLE ROUTING 1 A.C. magneto lead couplers 2 Wire harness 3 Starter motor lead 4 Tail/brake light lead 5 Battery breather hose 6 Final gear case breather hose 7 Negative battery lead 8 Ground lead 9 Carburetor air vent hose 0 Rear brake breather hose SPEC A Rear brake light switch lead B Rear brake cable C A.C. magneto lead È Make sure that the starter motor lead has no slack. É 0 mm (0 in) Ê Fasten the starter motor lead and wire harness to the frame with the plastic band.
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CABLE ROUTING Ë Fasten the negative battery lead with the plastic clamp. Ì Fasten the tail/brake light lead and negative battery lead with the plastic locking tie. Í Fasten the negative battery lead with the plastic clamp. Î 40 ~ 50 mm (1.6 ~ 2.0 in) Ï Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ð Route the rear brake cable and rear brake breather hose through the cable guide. SPEC Ñ 100 mm (4.0 in) Ò Route the rear brake breather hose through the cable guide.
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CABLE ROUTING 1 Battery breather hose 2 Rear brake cable 3 Select lever control cable 4 Spark plug cap 5 Ignition coil 6 Ignition coil leads 7 Starter motor lead 8 Rear brake light switch 9 Rear brake breather hose SPEC È Fasten the battery breather hose to the frame with the plastic band. É Fasten the starter motor lead to the frame with the plastic clamps. Ê 50 ~ 60 mm (2.0 ~ 2.4 in) Ë Fasten the battery breather hose to the frame with the plastic clamps.
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CABLE ROUTING 1 Positive battery lead 2 Battery 3 Tail/brake light lead 4 Negative battery lead 5 CDI unit 6 Starter relay 7 Wire harness 8 Starter motor lead 9 Carburetor air vent hose 0 Final gear case breather hose A Rear brake breather hose SPEC È Fasten the wire harness, starter motor lead, and select lever control cable to the frame with the plastic band. É 5 mm (0.2 in) Ê Fasten the positive battery lead to the rear fender with the plastic clamps.
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CABLE ROUTING 1 Headlight leads 2 Wire harness 3 Starter motor lead 4 Rear brake cable 5 Throttle cable 6 Starter cable 7 Select lever control cable 8 Rectifier/regulator È Fasten the wire harness to the frame with the plastic clamps. SPEC É Make sure the starter motor lead and wire harness do not contact the ignition coil. Ê 50 mm (2.0 in) Ë Route the throttle cable, select lever control cable and rear brake cable through the cable guide.
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INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION CHK ADJ EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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PERIODIC MAINTENANCE/LUBRICATION CHK ADJ INITIAL ITEM ROUTINE Whichever comes first EVERY month 1 3 6 6 12 km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 2,400 (1,500) 4,800 (3,000) hours 20 75 150 150 300 Wheels* • Check balance/damage/runout. • Repair if necessary. Wheel bearings* • Check bearing assemblies for looseness/damage. • Replace if damaged. Front and rear suspension* • Check operation. • Correct if necessary. Steering system* • Check operation./Replace if damaged.
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SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) 2 10 9 1 7 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 8 11 (6) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) (6) 6 4 R. T. R. Order T. 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) 34 Nm (3.
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SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) 2 10 9 1 7 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 8 11 (6) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) (6) 6 4 R. T. R. Order 11 T. 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) 34 Nm (3.4 m • kg, 24 ft • Ib) Job/Part Front fender Q’ty 1 Remarks For installation, reverse the removal procedure.
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SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ REAR CARRIER AND REAR FENDER T. R. 2 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. T. 3 34 Nm (3.4 m • kg, 24 ft • Ib) R. 34 Nm (3.4 m • kg, 24 ft • Ib) 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 4 5 12 11 7 14 10 6 8 13 9 15 (6) (6) T. R. Order 1 2 3 4 Job/Part Removing the rear carrier and rear fender Seat and fuel tank cover Rear carrier Battery cover Battery holding bracket Battery lead Q’ty 7 Nm (0.7 m • kg, 5.
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SEAT, CARRIERS, FENDERS AND FUEL TANK T. R. 2 34 Nm (3.4 m • kg, 24 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. T. 3 CHK ADJ R. 34 Nm (3.4 m • kg, 24 ft • Ib) 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 4 5 12 11 7 14 10 6 8 13 9 15 (6) (6) T. R.
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SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ FUEL TANK T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 1 Order Job/Part Removing the fuel tank Seat and fuel tank cover Q’ty Remarks Remove the parts in the order listed. Refer to “SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”. 1 Fuel hose 1 NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.
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FOOTREST BOARDS CHK ADJ FOOTREST BOARDS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 R. R. 65 Nm (6.5 m • kg, 47 ft • Ib) T. T. 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 5 (12) (12) T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) 4 2 T. R. Order 1 2 3 4 5 Job/Part Removing the footrest boards Footrest Left footrest board Right footrest board Left footrest bracket Right footrest bracket Q’ty 65 Nm (6.5 m • kg, 47 ft • Ib) Remarks Remove the parts in the order listed.
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ADJUSTING THE STARTER CABLE 1 CHK ADJ ENGINE ADJUSTING THE STARTER CABLE 1. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable. b. Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position. If the distance is out of specification adjust it as described below. Starter plunger stroke distance 15 mm (0.
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ADJUSTING THE REAR BRAKE CHK ADJ CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1. Remove: • right footrest board Refer to “FOOTREST BOARDS”. 2. Check: • brake pedal height a • brake pedal free play b • rear brake lever free play c Out of specification → Adjust. Brake pedal height 43 ~ 53 mm (1.69 ~ 2.09 in) Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) Rear brake lever free play 5 ~ 7 mm (0.20 ~ 0.28 in) 3.
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ADJUSTING THE REAR BRAKE CHK ADJ d. Loosen the locknut 3 and fully screw in the brake lever cable adjusting bolt 4. e. Fully loosen the brake lever cable adjusting nut 5. f. Turn the brake pedal adjusting nut 6 until the brake pedal free play is within the specified limits. g. Turn the brake lever cable adjusting nut 5 clockwise until the gap a is within the specified limits. Gap 0 ~ 1 mm (0 ~ 0.04 in) h. Checking the brake pedal free play to see whether or not it is within the specified limits.
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ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD CHK ADJ ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 2 1 FORWARD 2 REVERSE 3 Control cable 4 Select lever shift rod WARNING Before moving the select lever, bring the machine to a complete stop and return the throttle lever to its closed position. Otherwise the transmission may be damaged. 3 4 1. Adjust: • brake pedal free play Refer to “ADJUSTING THE REAR BRAKE”. 2.
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ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ADJUSTING THE HEADLIGHT BEAM/ REPLACING A HEADLIGHT BULB e. Check that locknuts 2 are tightened correctly. f. If the operation of the select lever is incorrect, adjust the select lever control cable 3 with the adjuster 4. 3 4 2 1 2 3 4 CHK ADJ Select lever shift rod: a. Make sure the select lever 1 is in FORWARD. b. Loosen the locknuts 2. c.
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REPLACING A HEADLIGHT BULB CHK ADJ 2. Remove: • bulb holder 1 • bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb by unhooking the headlight bulb holder tabs 2. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down. 3. Install: • bulb New Secure the new bulb with the headlight unit. CAUTION: Avoid touching the glass part of the bulb.