Yamaha YFM250BT Service Manual

LIT-11616-18-41 4XE-F8197-13YFM250BTSUPPLEMENTARYSERVICE MANUAL

– 3 –SPECMAINTENANCE SPECIFICATIONSCHASSISTightening torquesItem Standard LimitBrake lever and brake pedal:Front brake lever free play (at lever pivot

– 4 –SPECMAINTENANCE SPECIFICATIONSELECTRICALItem Standard LimitC.D.I.:Magneto model/manufacturer F4T259/MITSUBISHI ----Pickup coil resistance/color 1

– 5 –SPECCABLE ROUTING1 Rear brake light switch lead2 Starter cable3 Rear brake cable4 Lower bracket cable guide5 Front brake hose6 Front brake light

– 6 –SPECCABLE ROUTINGÈ Do not route the handlebar switch assemblylead through the lower bracket cable guide.É Fasten the front brake light switch lea

– 7 –SPECCABLE ROUTING1 Headlight lead2 Lower bracket cable guide3 Indicator light lead4 Main switch lead5 Indicator light6 Main switch7 Fuel tank bre

– 8 –SPECCABLE ROUTINGÈ Fasten the headlight lead to the front bumperwith the plastic band.É Route the main switch lead and indicator lightlead to the

– 9 –SPECCABLE ROUTING1 A.C. magneto lead couplers2 Wire harness3 Starter motor lead4 Tail/brake light lead5 Battery breather hose6 Final gear case br

– 10 –SPECCABLE ROUTINGË Fasten the negative battery lead with the plasticclamp.Ì Fasten the tail/brake light lead and negative bat-tery lead with the

– 11 –SPECCABLE ROUTING1 Battery breather hose2 Rear brake cable3 Select lever control cable4 Spark plug cap5 Ignition coil6 Ignition coil leads7 Star

– 12 –SPECCABLE ROUTING1 Positive battery lead2 Battery3 Tail/brake light lead4 Negative battery lead5 CDI unit6 Starter relay7 Wire harness8 Starter

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theYFM250BT. For complete service information proced

– 13 –SPECCABLE ROUTING1 Headlight leads2 Wire harness3 Starter motor lead4 Rear brake cable5 Throttle cable6 Starter cable7 Select lever control cabl

– 14 –CHKADJEB300000PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjus

– 15 –CHKADJPERIODIC MAINTENANCE/LUBRICATION* It is recommended that these items be serviced by a Yamaha dealer.NOTE:• Recommended brake fluid: DOT 4•

– 16 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKSEAT, CARRIERS, FENDERS AND FUEL TANKSEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER1234567891011(

– 17 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANK1234567891011(6)(6)T R..34 Nm (3.4 m • kg, 24 ft • Ib)T R..34 Nm (3.4 m • kg, 24 ft • Ib)T R..34 Nm (

– 18 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKREAR CARRIER AND REAR FENDER(6)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)2344511141312879151(6)T R..7 Nm (0.

– 19 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANK(6)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)2344511141312879151(6)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7

– 20 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKFUEL TANK21T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’t

– 21 –CHKADJFOOTREST BOARDSFOOTREST BOARDS124135(12)(12)T R..34 Nm (3.4 m • kg, 24 ft • Ib)T R..65 Nm (6.5 m • kg, 47 ft • Ib)T R..65 Nm (6.5 m • kg,

– 22 –CHKADJADJUSTING THE STARTER CABLEENGINEADJUSTING THE STARTER CABLE1. Adjust:▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Disconnect the starter

EBS00002NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possibl

– 23 –CHKADJADJUSTING THE REAR BRAKECHASSISADJUSTING THE REAR BRAKEWARNINGAlways adjust both the brake pedal and therear brake lever whenever adjustin

– 24 –CHKADJADJUSTING THE REAR BRAKEd. Loosen the locknut 3 and fully screw in thebrake lever cable adjusting bolt 4.e. Fully loosen the brake lever c

– 25 –CHKADJADJUSTING THE SELECT LEVER CONTROL CABLEAND SHIFT RODADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 FORWARD2 REVERSE3 Control ca

– 26 –CHKADJADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFTROD/ADJUSTING THE HEADLIGHT BEAM/REPLACING A HEADLIGHT BULBe. Check that locknuts 2 are

– 27 –CHKADJREPLACING A HEADLIGHT BULB2. Remove:• bulb holder 1 • bulbNOTE:Turn the bulb holder counterclockwise andremove the defective bulb by unhoo

EBS00004HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “symbols”)1st title 1: Thi

EBS00005SYMBOLSThe following symbols are not relevant toevery machine. Symbols 1 to 9 indicate the subject of eachchapter.1General information 2Specif

CONTENTSSPECIFICATIONS ...1GENERAL SPECIFICATIONS ...

ELECTRICAL ...37ELECTRICAL COMPONENTS ...

– 1 –SPECGENERAL SPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code: 1P01Dimensions:Overall length 1,916 mm (75.4 in)Overall wi

– 2 –SPECMAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINETightening torquesItem Standard LimitCarburetor:I. D. mark 1P01 00 ----Main jet (M