Yamaha YP250R 2005 Manuals

Manuals and User Guides for Yamaha YP250R 2005. We have 1 Yamaha YP250R 2005 manual available for free PDF download: Service Manual

Yamaha YP250R 2005 Service Manual

Yamaha YP250R 2005 Service Manual (370 pages)

Brand: Yamaha | Category: Scooter | Size: 15.85 MB

Table of Contents

Table of Contents

6
- Periodic Checks and
  4
- Chassis
  5
  - Table of Contents
    6
- General Information
  5
- Periodic Checks and Adjustments
  5
- Specifications
  5
- Chapter 1 General Information
  8
- Identification
  8
  - Vehicle Identification Number
    8
  - Model Label
    8
- Multi-Function Display
  9
- Important Information
  12
  - Preparation for Removal and Disassembly
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking the Connections
  14
- Special Tools
  15
Table of Contents

20
- Chapter 2 Specifications
  21
- General Specifications
  21
- Engine
  22
  - Engine Specifications
    22
- Cooling System
  23
- Spec
  30
Chapter 3 Periodic Checks and Adjustments

61
- Introduction
  63
- Periodic Maintenance and Lubrication Chart
  63
- Covers and Panels
  65
  - Seat and Side Covers
    65
  - Footrest Board
    66
  - Handlebar Covers
    67
  - Storage Compartment
    68
- Air Filter Case
  69
- Engine
  70
- Chassis
  96
- Chk Adj
  107
- Electrical System
  107
  - Checking and Charging the Battery
    107
  - Checking the Fuses
    113
  - Replacing the Headlight Bulbs
    115
  - Adjusting the Headlight Beam
    116
Chapter 4 Chassis

117
- Chas
  117
  - Front Wheel and Brake Disc
    119
- Checking the Front Wheel
  121
- Removing the Front Wheel
  121
- Checking the Brake Disc
  123
- Adjusting the Front Wheel Static Balance
  124
- Installing the Front Wheel
  126
- Rear Wheel and Brake Disc
  127
  - Removing the Rear Wheel
    129
  - Checking the Rear Wheel
    129
  - Adjusting the Rear Wheel Static Balance
    130
  - Installing the Rear Wheel
    130
- Front and Rear Brakes
  131
- Front Fork
  165
  - Removing the Front Fork Legs
    168
  - Disassembling the Front Fork Legs
    168
  - Checking the Front Fork Legs
    170
  - Assembling the Front Fork Legs
    171
  - Installing the Front Fork Legs
    176
- Handlebar
  177
  - Removing the Handlebar
    179
  - Checking the Handlebar
    179
  - Installing the Handlebar
    179
- Steering Head
  182
  - Lower Bracket
    182
  - Removing the Lower Bracket
    184
  - Checking the Steering Head
    185
  - Installing the Steering Head
    186
- Rear Shock Absorber Assemblies and Swingarm
  187
Chapter 5 Engine

192
- Eng
  192
- Engine Removal
  194
  - Leads, Hoses, Exhaust Pipe and Muffler
    194
  - Engine
    196
  - Installing the Engine
    197
- Cylinder Head
  198
  - Removing the Cylinder Head
    200
  - Checking the Cylinder Head
    201
  - Checking the Camshaft Sprocket
    202
  - Checking the Timing Chain Tensioner
    202
  - Installing the Cylinder Head
    202
- Camshaft and Rocker Arms
  206
- Valves and Valve Springs
  212
  - Removing the Valves
    213
  - Checking the Valves and Valve Guides
    214
  - Checking the Valve Seats
    216
  - Checking the Valve Springs
    218
  - Installing the Valves
    219
- Cylinder and Piston
  222
  - Removing the Piston
    223
  - Checking the Cylinder and Piston
    223
  - Checking the Piston Rings
    225
  - Checking the Piston Pin
    226
  - Installing the Piston and Cylinder
    227
- Belt Drive
  229
  - V-Belt Case Cover
    229
  - V-Belt, Primary Sheave and Secondary Sheave
    230
  - Secondary Sheave
    232
  - Removing the Primary Sheave
    233
  - Removing the Secondary Sheave and V-Belt
    233
  - Disassembling the Secondary Sheave
    234
  - Checking the V-Belt
    235
  - Checking the Primary Sheave Weights
    235
  - Checking the Secondary Sheave
    235
  - Checking the Clutch Shoes
    236
  - Assembling the Primary Sheave
    237
  - Assembling the Secondary Sheave
    238
  - Installing the Secondary Sheave, V-Belt, and Primary Sheave
    239
- Starter Clutch and Generator
  242
  - Generator Cover and Stator Coil
    242
  - Starter Clutch
    244
  - Removing the Generator
    245
  - Removing the Starter Clutch
    246
  - Checking the Starter Clutch
    246
  - Installing the Starter Clutch
    247
  - Installing the Generator
    247
- Oil Pump
  249
  - Checking the Oil Pump
    251
  - Assembling the Oil Pump
    252
  - Installing the Oil Pump Assembly
    252
- Transmission
  253
  - Removing the Transmission
    255
  - Checking the Transmission
    255
- Crankshaft
  256
  - Crankshaft Assembly
    256
  - Disassembling the Crankcase
    258
  - Removing the Crankshaft Assembly
    258
  - Checking the Timing Chain and Timing Chain Guide
    259
  - Checking the Crankshaft and Connecting Rod
    260
  - Checking the Crankcase
    261
  - Checking the Bearings
    261
  - Installing the Crankshaft
    261
  - Assembling the Crankcase
    263
Cool

264
- Chapter 6 Cooling System
  265
- Radiator
  265
  - Checking the Radiator
    267
  - Installing the Radiator
    267
- Thermostat
  268
  - Checking the Thermostat
    269
  - Installing the Thermostat
    269
- Water Pump
  270
  - Disassembling the Water Pump
    272
  - Checking the Water Pump
    273
  - Assembling the Water Pump
    273
  - Installing the Water Pump
    275
Carb

277
- Carburetor
  278
- Chapter 7
  282
- Checking the Carburetor
  282
- Disassembling the Carburetor
  282
- Assembling the Carburetor
  283
- Installing the Carburetor
  284
- Checking the Auto Choke Unit
  285
- Air Induction System
  287
  - Checking the Air Induction System
    288
- Fuel Tank
  289
  - Removing the Fuel Sender
    291
  - Checking the Fuel Pump
    291
  - Installing the Fuel Sender
    292
Chapter 8 Electrical System

293
- Elec
  293
- Electrical Components
  295
- Checking Switch Continuity
  296
- Checking the Switches
  297
- Checking the Bulbs and Bulb Sockets
  298
- Ignition System
  301
  - Circuit Diagram
    301
  - Troubleshooting
    302
- Electric Starting System
  306
  - Circuit Diagram
    306
  - Starting Circuit Cut-Off System Operation
    307
  - Troubleshooting
    308
  - Starter Motor
    311
  - Checking the Starter Motor
    313
  - Assembling the Starter Motor
    314
- Charging System
  315
  - Circuit Diagram
    315
  - Troubleshooting
    316
- Lighting System
  318
  - Circuit Diagram
    318
  - Troubleshooting
    319
  - Checking the Lighting System
    321
- Signaling System
  324
  - Circuit Diagram
    324
  - Troubleshooting
    326
  - Checking the Signaling System
    327
- Cooling System
  337
  - Circuit Diagram
    337
  - Troubleshooting
    338
- Fuel Pump System
  341
  - Circuit Diagram
    341
  - Fuel Pump Circuit Operation
    342
  - Troubleshooting
    343
- Auto Choke System
  345
  - Circuit Diagram
    345
  - Troubleshooting
    346
- Immobilizer System
  349
  - System Diagram
    349
  - Circuit Diagram
    350
  - General Information
    351
  - Key Code Registration
    352
  - Self-Diagnosis Malfunction Codes
    355
  - Troubleshooting
    356
  - Checking the Immobilizer System
    357
  - Part Replacement Key Registration Requirements
    359
Trbl Shtg

360
- Troubleshooting Trbl
  360
- Chapter 9 Troubleshooting
  362
- Starting Failure/Hard Starting
  362
  - Engine
    362
  - Fuel System
    362
  - Electrical Systems
    363
- Incorrect Engine Idling Speed
  363
  - Engine
    363
  - Fuel System
    363
- Faulty Clutch
  364
  - Engine Operates but Vehicle will Not Move
    364
  - Clutch Slips
    364
  - Poor Starting Performance
    364
  - Poor Speed Performance
    364
- Poor Medium-And-High-Speed Performance
  364
  - Engine
    364
  - Fuel System
    364
- Overcooling
  365
- Overheating
  365
  - Engine
    365
  - Cooling System
    365
  - Fuel System
    365
  - Chassis
    365
  - Electrical Systems
    365
- Poor Braking Performance
  365
- Faulty Front Fork Legs
  366
  - Leaking Oil
    366
  - Malfunction
    366

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