Yamaha YP250R 2014 Manuals

Manuals and User Guides for Yamaha YP250R 2014. We have 1 Yamaha YP250R 2014 manual available for free PDF download: Service Manual

Yamaha YP250R 2014 Service Manual

Yamaha YP250R 2014 Service Manual (486 pages)

Brand: Yamaha | Category: Scooter | Size: 16.16 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Outline of the Fi System
  11
- Fi System
  12
- OUTLINE of the ABS (for YP250RA)
  13
- Abs Component Functions
  17
- Abs Operation
  23
- Abs Warning Light and Operation
  26
- Instrument Functions
  27
- Important Information
  33
- Preparation for Removal and Disassembly
  33
- Replacement Parts
  33
- Gaskets, Oil Seals and O-Rings
  33
- Lock Washers/Plates and Cotter Pins
  33
- Bearings and Oil Seals
  34
- Circlips
  34
- Rubber Parts
  34
- Quick Fasteners
  35
- Basic Service Information
  35
- Electrical System
  36
- Special Tools
  40
Specifications

49
- General Specifications
  50
- Engine Specifications
  51
- Chassis Specifications
  57
- Electrical Specifications
  60
- General Tightening Torque Specifications
  63
- Tightening Torques
  63
- Engine Tightening Torques
  64
- Chassis Tightening Torques
  67
- Engine
  71
- Lubrication Points and Lubricant Types
  71
- Chassis
  73
- Cooling System Diagrams
  74
- Cable Routing
  78
Periodic Checks and Adjustments

113
- General Maintenance and Lubrication Chart
  116
- Introduction
  116
- Periodic Maintenance
  116
- Periodic Maintenance Chart for the Emission Control System
  116
- Adjusting the Valve Clearance
  119
- Checking the Fuel Line
  119
- Checking the Spark Plug
  119
- Checking the Throttle Body Joint and Intake Manifold
  121
- Adjusting the Exhaust Gas Volume
  122
- Checking the Breather Hose
  122
- Checking the Exhaust System
  122
- Replacing the Air Filter Element
  123
- Checking the Brake Fluid Level
  124
- Checking the Brake Operation
  124
- Cleaning the V-Belt Case Air Filter Element
  124
- BLEEDING the HYDRAULIC BRAKE SYSTEM (for YP250R)
  125
- BLEEDING the HYDRAULIC BRAKE SYSTEM (ABS) (for YP250RA)
  126
- Checking the Front Brake Hoses
  127
- Checking the Front Brake Pads
  127
- CHECKING the REAR BRAKE PADS (for YP250R)
  127
- CHECKING the REAR BRAKE PADS (for YP250RA)
  127
- Checking the Rear Brake Hose
  128
- Checking the Tires
  128
- Checking the Wheels
  128
- Checking and Adjusting the Steering Head
  130
- Checking the Wheel Bearings
  130
- Checking the Centerstand
  131
- Checking the Chassis Fasteners
  131
- Checking the Sidestand
  131
- Checking the Sidestand Switch
  131
- Lubricating the Centerstand
  131
- Lubricating the Levers
  131
- Lubricating the Sidestand
  131
- Adjusting the Rear Shock Absorber Assemblies
  132
- Checking the Front Fork
  132
- Checking the Rear Suspension
  132
- Changing the Engine Oil
  133
- Checking the Engine Oil Level
  133
- Checking the Coolant Level
  134
- Changing the Coolant
  135
- Checking the Cooling System
  135
- Changing the Final Transmission Oil
  137
- Replacing the V-Belt
  137
- Checking and Lubricating the Cables
  138
- Checking the Brake Light Switches
  138
- Lubricating the Rear Suspension
  138
Chassis

141
- General Chassis
  144
- Installing the Center Panels
  153
- Installing the Storage Box
  153
- Removing the Center Panels
  153
- Installing the Rear Upper Cover
  154
- Removing the Rear Panels
  154
- Removing the Rear Upper Cover
  154
- Installing the Rear Panels
  155
- Installing the Upper Panel and Front Cowling Cover
  155
- Removing the Front Cowling Cover and Upper Panel
  155
- Installing the Front Upper Panel
  156
- Removing the Front Cowling
  156
- Removing the Front Upper Panel
  156
- Installing the Front Cowling
  157
- Removing the Main Switch Cover
  157
- Installing the Footrest Board
  158
- Installing the Main Switch Cover
  158
- Removing the Footrest Board
  158
- Disposing of a Seat Hinge Damper
  159
- Handling the Seat Hinge Damper
  159
- Front Wheel
  160
- Checking the Front Wheel
  163
- Disassembling the Front Wheel
  163
- REMOVING the FRONT WHEEL (for YP250R)
  163
- REMOVING the FRONT WHEEL (for YP250RA)
  163
- MAINTENANCE of the FRONT WHEEL SENSOR and SENSOR ROTOR (for YP250RA)
  164
- Assembling the Front Wheel
  165
- Adjusting the Front Wheel Static Balance
  166
- INSTALLING the FRONT WHEEL (FRONT BRAKE DISC) (for YP250R)
  167
- INSTALLING the FRONT WHEEL (FRONT BRAKE DISCS) (for YP250RA)
  168
- Rear Wheel
  170
- Adjusting the Rear Wheel Static Balance
  172
- Checking the Rear Wheel
  172
- Installing the Rear Wheel (Rear Brake Disc)
  172
- MAINTENANCE of the REAR WHEEL SENSOR ROTOR (for YP250RA)
  172
- REMOVING the REAR WHEEL (DISC) (for YP250R)
  172
- REMOVING the REAR WHEEL (DISC) (for YP250RA)
  172
- Checking the Front Brake Disc
  180
- Front Brake
  180
- Introduction
  180
- Replacing the Front Brake Pads
  181
- Checking the Front Brake Caliper
  182
- Disassembling the Front Brake Caliper
  182
- Removing the Front Brake Caliper
  182
- Assembling the Front Brake Caliper
  183
- Installing the Front Brake Caliper
  183
- Assembling the Front Brake Master Cylinder
  184
- Checking the Front Brake Master Cylinder
  184
- Removing the Front Brake Master Cylinder
  184
- Installing the Front Brake Master Cylinder
  185
- Rear Brake
  187
- Checking the Rear Brake Disc
  196
- Introduction
  196
- REPLACING the REAR BRAKE PADS (for YP250R)
  196
- REPLACING the REAR BRAKE PADS (for YP250RA)
  197
- Removing the Rear Brake Caliper
  198
- Checking the Rear Brake Caliper
  199
- DISASSEMBLING the REAR BRAKE CALIPER (for YP250R)
  199
- DISASSEMBLING the REAR BRAKE CALIPER (for YP250RA)
  199
- Assembling the Rear Brake Caliper
  200
- CHECKING the REAR BRAKE CALIPER (for YP250RA)
  200
- INSTALLING the REAR BRAKE CALIPER (for YP250R)
  201
- INSTALLING the REAR BRAKE CALIPER (for YP250RA)
  202
- Assembling the Rear Brake Master Cylinder
  203
- Checking the Rear Brake Master Cylinder
  203
- Installing the Rear Brake Master Cylinder
  203
- Removing the Rear Brake Master Cylinder
  203
- ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA)
  205
- Checking the Hydraulic Unit Assembly
  206
- Installing the Hydraulic Unit Assembly
  206
- Removing the Hydraulic Unit Assembly
  206
- Hydraulic Unit Operation Tests
  208
- Checking the Abs Warning Light
  211
- Handlebar
  212
- Checking the Handlebar
  214
- Installing the Handlebar
  214
- Removing the Handlebar
  214
- Front Fork
  217
- Disassembling the Front Fork Legs
  219
- Removing the Front Fork Legs
  219
- Assembling the Front Fork Legs
  220
- Checking the Front Fork Legs
  220
- Installing the Front Fork Legs
  222
- Steering Head
  224
- Checking the Steering Head
  226
- Installing the Steering Head
  226
- Removing the Lower Bracket
  226
- Rear Shock Absorber Assemblies and Swingarm
  228
- (For YP250RA)
  230
- Checking the Rear Shock Absorber Assembly
  230
- Checking the Swingarm
  230
- Maintenance of the Rear Wheel Sensor
  230
- Removing the Rear Shock Absorber Assemblies
  230
- Removing the Swingarm
  230
- Installing the Swingarm
  231
Engine

233
- Engine Inspection
  236
- Measuring the Compression Pressure
  236
- Engine Removal
  237
- Installing the Engine
  241
- Cylinder Head
  243
- Checking the Cylinder Head
  245
- Removing the Cylinder Head
  245
- Checking the Camshaft Sprocket
  246
- Checking the Timing Chain Tensioner
  246
- Installing the Cylinder Head
  247
- Camshaft
  249
- Checking the Camshaft
  250
- Removing the Rocker Arms and Camshaft
  250
- Checking the Rocker Arms and Rocker Arm Shafts
  251
- Checking the Valves and Valve Guides
  254
- Removing the Valves
  254
- Valves and Valve Springs
  254
- Checking the Valve Seats
  256
- Checking the Valve Springs
  257
- Installing the Valves
  258
- Cylinder and Piston
  260
- Checking the Cylinder and Piston
  261
- Removing the Piston
  261
- Checking the Piston Rings
  262
- Checking the Piston Pin
  263
- Checking the Timing Chain Guide
  263
- Installing the Piston and Cylinder
  263
- V-Belt Automatic Transmission
  265
- Removing the Primary Sheave
  269
- Removing the Secondary Sheave
  269
- Checking the Clutch Housing
  270
- Checking the Clutch Shoes
  270
- Checking the V-Belt
  270
- Disassembling the Secondary Sheave
  270
- Assembling the Primary Sheave
  271
- Checking the Primary Sheave
  271
- Checking the Primary Sheave Sliders
  271
- Checking the Primary Sheave Weights
  271
- Checking the Secondary Sheave
  271
- Assembling the Secondary Sheave
  272
- Installing the V-Belt
  273
- Starter Clutch and Generator
  275
- Checking the Starter Clutch
  277
- Removing the Generator
  277
- Removing the Starter Clutch
  277
- Installing the Generator
  278
- Installing the Starter Clutch
  278
- Electric Starter
  280
- Checking the Starter Motor
  282
- Assembling the Starter Motor
  283
- Oil Pump
  284
- Assembling the Oil Pump
  286
- Checking the Oil Pump
  286
- Installing the Oil Pump
  287
- Transmission
  288
- Checking the Transmission
  290
- Installing the Transmission
  290
- Removing the Transmission
  290
- Crankshaft
  291
- Disassembling the Crankcase
  293
- Removing the Crankshaft Assembly
  293
- Checking the Crankshaft and Connecting Rod
  294
- Checking the Timing Chain and Timing Chain Guide
  294
- Checking the Bearing and Oil Seal
  295
- Checking the Crankcase
  295
- Checking the Oil Strainers
  295
- Installing the Crankshaft
  295
- Assembling the Crankcase
  296
Cooling System

297
- Checking the Radiator
  299
- Installing the Radiator
  299
- Radiator
  299
- Thermostat
  301
- Checking the Thermostat
  302
- Installing the Thermostat
  302
- Water Pump
  303
- Assembling the Water Pump
  305
- Checking the Water Pump
  305
- Disassembling the Water Pump
  305
- Installing the Water Pump
  306
Fuel System

307
- Fuel Tank
  308
- Checking the Fuel Pump Body
  309
- Installing the Fuel Pump
  309
- Installing the Fuel Tank
  309
- Removing the Fuel Pump
  309
- Removing the Fuel Tank
  309
- Checking the Fuel Pressure
  310
- Throttle Body
  311
- Checking the Fuel Injector
  313
- Checking the Throttle Body
  313
- Installing the Fuel Hose
  313
- Installing the Intake Manifold
  313
- Removing the Fuel Hose
  313
- Checking the Isc (Idle Speed Control) Unit
  314
- Checking the Throttle Position Sensor
  314
- Installing the Throttle Body
  314
Electrical System

315
- Circuit Diagram
  318
- Ignition System
  318
- Troubleshooting
  320
- CIRCUIT DIAGRAM (for YP250R)
  322
- Electric Starting System
  322
- CIRCUIT DIAGRAM (for YP250RA)
  324
- STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250R)
  326
- STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250RA)
  328
- Troubleshooting
  330
- Charging System
  332
- Circuit Diagram
  332
- Troubleshooting
  334
- Circuit Diagram
  336
- Lighting System
  336
- Troubleshooting
  338
- CIRCUIT DIAGRAM (for YP250R)
  340
- Signaling System
  340
- CIRCUIT DIAGRAM (for YP250RA)
  342
- Troubleshooting
  344
- Circuit Diagram
  350
- Cooling System
  350
- Troubleshooting
  352
- CIRCUIT DIAGRAM (for YP250R)
  354
- Fuel Injection System
  354
- CIRCUIT DIAGRAM (for YP250RA)
  356
- Ecu Self-Diagnostic Function
  358
- Diagnostic Mode
  359
- Troubleshooting Method
  359
- Troubleshooting Details
  362
- CIRCUIT DIAGRAM (for YP250R)
  390
- Fuel Pump System
  390
- CIRCUIT DIAGRAM (for YP250RA)
  392
- Troubleshooting
  394
- Circuit Diagram
  396
- Immobilizer System
  396
- General Information
  398
- Part Replacement and Key Code Registration Requirements
  398
- Self-Diagnosis Fault Code Indication
  402
- Troubleshooting
  402
- ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA)
  406
- Circuit Diagram
  406
- Abs Components Chart
  408
- Abs Coupler Location Chart
  410
- Abs Troubleshooting Outline
  412
- Maintenance of the Abs Ecu
  412
- Basic Instructions for Troubleshooting
  413
- Basic Process for Troubleshooting
  414
- [A-1] Only the Abs Warning Light Fails to Come on
  415
- [A-2] the Abs Warning Light and All Other Indicator Lights Fail to Come on
  415
- [A-3] the Abs Warning Light Comes on
  415
- [A] Checking the Abs Warning Light
  415
- [B-1] Malfunction Are Currently Detected
  416
- [B-2] Diagnosis Using the Fault Codes
  416
- [B-3] Deleting the Fault Codes
  442
- Electrical Components
  444
- Checking the Switches
  448
- Checking the Bulbs and Bulb Sockets
  451
- Checking the Fuses
  452
- Checking and Charging the Battery
  453
- Checking the Relays
  456
- Checking the Turn Signal/Hazard Relay
  457
- Checking the Diodes
  458
- Checking the Ignition Coil
  459
- Checking the Spark Plug Cap
  459
- Checking the Crankshaft Position Sensor
  460
- Checking the Ignition Spark Gap
  460
- Checking the Lean Angle Sensor
  461
- Checking the Starter Motor Operation
  461
- Checking the Fuel Sender
  462
- Checking the Rectifier/Regulator
  462
- Checking the Stator Coil
  462
- Checking the Radiator Fan Motor
  463
- CHECKING the SPEED SENSOR (for YP250R)
  463
- Checking the Coolant Temperature Sensor
  464
- Checking the Throttle Position Sensor
  464
- Checking the Intake Air Pressure Sensor
  465
- Checking the Intake Air Temperature Sensor
  465
- Checking the Air Temperature Sensor
  466
- Checking the Fuel Injector
  466
- Checking the Isc (Idle Speed Control) Unit
  467
Troubleshooting

469
- General Information
  470
- Incorrect Engine Idling Speed
  470
- Starting Failure/Hard Starting
  470
- Troubleshooting
  470
- Faulty Clutch
  471
- Overheating
  471
- Poor Medium-And-High-Speed Performance
  471
- Faulty Front Fork Legs
  472
- Faulty Lighting or Signaling System
  472
- Overcooling
  472
- Poor Braking Performance
  472
- Unstable Handling
  472
- Self-Diagnostic Function and Diagnostic Code Table
  475

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