ELEC
7-27
EBS00518
LIGHTING SYSTEM
CIRCUIT DIAGRAM
A
A
B/Y
B
RBrRBr
ON
OFF
OFF
LO
HI
OFF
ON
OFF
PUSH
R/B
L
Br
R/W
GY
B
R/B
L
Br
L/B
Y
B
RR
L/BY/B
B/Y
B
BB
B/Y
B
Y/BB/Y
R/B
Sb
GY
B
GY
B
GY
B
GY
B
W
WW
WR
W/L
W/R
W
WW
L
Y
BGY
R/B
BWW
O
W/LW/R
W
Br Sb BrSbYBr Y Br
SUB-WIRE HARNESS
A
WIRE HARNESS
RB
WWW
W/R
W/L
W
W
W
W
W
W
B
R
WWW
B
R
Br
B
R
R
R
R
R
R
Br
BY
BY
BY
BY
B
B
B
B
OO
W/R
W/L
R/B
B
Y/B
L/B
B
B
Y/B B/Y
R/B
Sb
BY
B
Br
Sb
Sb
Br
Br
Y
L
Y
Y
Br
L/B
R/B
B
Y
L
B
G
L
YY
G
Y
G
Y
BB
Stator coil
Rectifier/regulator
Main switch
Battery positive lead
Battery
Fuse
Tail/brake light
Light switch
Headlight relay
Headlight
Ground
LIGHTING SYSTEM
-
YFM250RX
1
-
EBS00001
2
-
HOW TO USE THIS MANUAL
4
-
EBS00006
5
-
TABLE OF CONTENTS
7
-
CHAPTER 1
8
-
CHAPTER 2
8
-
CHAPTER 3
9
-
CHAPTER 4
10
-
CHAPTER 5
12
-
CARBURETOR
12
-
CHAPTER 6
12
-
CHAPTER 7
13
-
ELECTRICAL
13
-
CHAPTER 8
14
-
TROUBLESHOOTING
14
-
GENERAL INFORMATION
16
-
IMPORTANT INFORMATION
17
-
SPECIAL TOOLS
20
-
YU-01304
21
-
SPECIFICATIONS
24
-
GENERAL SPECIFICATIONS
25
-
ENGINE SPECIFICATIONS
27
-
CHASSIS SPECIFICATIONS
34
-
ELECTRICAL SPECIFICATIONS
36
-
TIGHTENING TORQUES
38
-
HOW TO USE THE CONVERSION
42
-
GENERAL TIGHTENING TORQUE
42
-
EBS00024
43
-
OIL FLOW DIAGRAMS
45
-
CABLE ROUTING
48
-
INTRODUCTION
62
-
Whenever worn to the limit
63
-
Every 4 years
63
-
7 Nm (0.7 m•kg, 5.2 ft•Ib)
65
-
SEAT, FENDERS AND FUEL TANK
66
-
ADJUSTING THE VALVE CLEARANCE
70
-
14 Nm (1.4 m•kg, 10 ft•lb)
71
-
EBS00051
72
-
EBS00052
73
-
ADJUSTING THE SPEED LIMITER
74
-
CHECKING THE SPARK PLUG
76
-
CHECKING THE IGNITION TIMING
77
-
CHECKING THE ENGINE OIL LEVEL
80
-
CHANGING THE ENGINE OIL
82
-
ADJUSTING THE CLUTCH CABLE/
84
-
CLEANING THE SPARK ARRESTER
86
-
ADJUSTING THE REAR BRAKE/
88
-
ADJUSTING THE PARKING BRAKE
88
-
16 Nm (1.6 m•kg, 11 ft•lb)
89
-
CHECKING THE FRONT BRAKE PADS
90
-
CHECKING THE REAR BRAKE PADS
91
-
CHECKING THE BRAKE HOSES
92
-
CHECKING THE BRAKE HOSES/
93
-
21 Nm (2.1 m•kg, 15 ft•lb)
97
-
ADJUSTING THE TOE-IN
98
-
EBS00111
100
-
42 Nm (4.2 m•kg, 31 ft•lb)
101
-
CHECKING THE TIRES
102
-
LUBRICATING THE CABLES
104
-
EBS00118
105
-
ELECTRICAL SYSTEM
106
-
Charging time (hours)
107
-
CAUTION:
108
-
CHECKING THE FUSES
113
-
CHECKING THE FUSES/
114
-
ADJUSTING THE HEADLIGHT BEAM
114
-
REPLACING A HEADLIGHT BULB
115
-
34 Nm (3.4 m•kg, 25 ft•lb)
117
-
20 Nm (2.0 m•kg, 15 ft•lb)
117
-
8 Nm (0.8 m•kg, 5.9 ft•lb)
117
-
18 Nm (1.8 m•kg, 13 ft•lb)
117
-
ENGINE REMOVAL
118
-
10 Nm (1.0 m•kg, 7.4 ft•lb)
119
-
40 Nm (4.0 m
122
-
CYLINDER HEAD
123
-
ROCKER ARM, CAMSHAFT
131
-
VALVES AND VALVE SPRINGS
137
-
17 Nm (1.7 m•kg, 13 ft•lb)
147
-
CYLINDER AND PISTON
148
-
73 Nm (7.3 m•kg, 54 ft•lb)
155
-
80 Nm (8.0 m•kg, 59 ft•lb)
156
-
75 Nm (7.5 m•kg, 55 ft•lb)
156
-
Lock washer
162
-
6 Nm (0.6 m•kg, 4.4 ft•lb)
166
-
55 Nm (5.5 m•kg, 41 ft•lb)
166
-
7 Nm (0.7 m•kg, 5.0 ft•lb)
168
-
Inner rotor
169
-
Outer rotor
169
-
Oil pump housing
169
-
SHIFT SHAFT
174
-
20 Nm (2.0 m•kg, 14.8 ft•lb)
183
-
CRANKCASE
184
-
CRANKSHAFT ASSEMBLY
188
-
TRANSMISSION
193
-
2 Nm (0.2 m•kg, 1.5 ft•lb)
199
-
3.5 Nm (0.4 m•kg, 2.6 ft•lb)
199
-
28 Nm (2.8 m•kg, 21 ft•lb)
206
-
70 Nm (7.0 m•kg, 52 ft•lb)
206
-
45 Nm (4.5 m•kg, 33 ft•lb)
206
-
120 Nm (12.0 m•kg, 89 ft•lb)
208
-
FRONT AND REAR WHEELS
209
-
7 Nm (0.7 m•kg, 5.2 ft•lb)
213
-
140 Nm (14.0 m•kg, 103 ft•lb)
213
-
REAR AXLE AND REAR AXLE HUB
215
-
FRONT AND REAR BRAKES
220
-
5 Nm (0.5 m•kg, 3.7 ft•lb)
221
-
27 Nm (2.7 m•kg, 20 ft•lb)
224
-
31 Nm (3.1 m•kg, 23 ft•lb)
226
-
2.5 Nm (0.25 m•kg, 1.8 ft•lb)
235
-
15 Nm (1.5 m•kg, 11 ft•lb)
238
-
4 Nm (0.4 m•kg, 3.0 ft•lb)
247
-
STEERING SYSTEM
249
-
23 Nm (2.3 m•kg, 17 ft•lb)
252
-
25 Nm (2.5 m•kg, 18 ft•lb)
252
-
35 Nm (3.5 m•kg, 26 ft•lb)
252
-
ASSEMBLIES
256
-
100 Nm (10.0 m•kg, 74 ft•lb)
260
-
110 Nm (11.0 m•kg, 81 ft•lb)
260
-
DRIVE CHAIN
262
-
CHECKING SWITCH CONTINUITY
269
-
CHECKING THE SWITCHES
270
-
CHECKING THE BULBS AND
272
-
BULB SOCKETS
272
-
IGNITION SYSTEM
275
-
ELECTRIC STARTING SYSTEM
280
-
STARTER MOTOR
287
-
CHARGING SYSTEM
291
-
LIGHTING SYSTEM
294
-
SIGNAL SYSTEM
298
-
Br Sb BrSb
301
-
POOR IDLE SPEED PERFORMANCE
304
-
FAULTY GEAR SHIFTING
305
-
CLUTCH SLIPPING/DRAGGING
305
-
OVERHEATING
306
-
FAULTY BRAKE
306
-
SHOCK ABSORBER MALFUNCTION
306
-
FAULTY BRAKE/
306
-
UNSTABLE HANDLING
307
-
YAMAHA MOTOR CO., LTD
310
-
YFM250RX WIRING DIAGRAM
311
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