Yamaha 4XEC, Supplementary Service Manual

Page 1: ...SUPPLEMENTARY SERVICEMANUAL 4XE3 AE2 2001 YFM250XN ...

Page 2: ...he written permission of Yamaha Motor Co Ltd is expressly prohibited FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM250XN 2001 For complete information on service procedures it is necessary to use this Supplementary Service Manual together with the following manual YFM250XL 99 SERVICE MANUAL 4XE3 AE1 ...

Page 3: ...ications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means A...

Page 4: ...n the section title 4 Lines of asterisks mark the beginning and end of a particularly important procedure The steps of such procedures are marked with bullets 5 Important information such as fluids special tools and torques are framed and marked with a corresponding symbol 6 A circled number refers to an illustrated part 7 A circled lower case letter refers to an illustrated dimension or alignment...

Page 5: ...ue D Wear limit clearance E Engine speed F Ω V A Illustrated symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease Illustrated symbols M to N in the exploded diagrams indicate whe...

Page 6: ...ANCE LUBRICATION 14 CHASSIS 16 FRONT BRAKE FLUID LEVEL INSPECTION 16 FRONT BRAKE PAD INSPECTION 16 BRAKE HOSE INSPECTION 17 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 17 CHASSIS 19 FRONT WHEEL 19 REMOVAL 20 INSPECTION 21 FRONT BRAKE 22 BRAKE PAD REPLACEMENT 23 CALIPER DISASSEMBLY 25 MASTER CYLINDER DISASSEMBLY 26 INSPECTION AND REPAIR 27 CALIPER ASSEMBLY 30 MASTER CYLINDER ASSEMBLY 33 REAR WHEELS REAR BR...

Page 7: ...L 39 ELECTRICAL COMPONENTS 39 IGNITION SYSTEM 40 CIRCUIT DIAGRAM 40 TROUBLESHOOTING 41 ELECTRIC STARTING SYSTEM 46 CIRCUIT DIAGRAM 46 STARTING CIRCUIT OPERATION 47 TROUBLESHOOTING 48 YFM250XN 2001 WIRING DIAGRAM ...

Page 8: ...ORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 9: ...al Fuel reserve amount 1 6 L 0 35 Imp gal 0 42 US gal Tire Type Tubeless Size front AT22 7 10 rear AT22 10 10 Manufacturer front CARLISLE DUNLOP CHENG SHIN rear CARLISLE DUNLOP CHENG SHIN Type front TRAIL WOLF KT701 M905 rear TRAIL WOLF KT705 M906 Brake Front brake type Single disc brake operation Right hand operation Rear brake type Drum brake full sealed operation Left hand and right foot operat...

Page 10: ... 2M 823 Pilot air jet P A J 1 80 Pilot air jet P A J 2 1 3 Pilot outlet P O 0 85 Pilot jet P J 42 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 2 0 turns out Valve seat size V S 2 0 Starter jet G S 1 50 G S 2 0 7 Throttle valve size Th V 130 Float height F H 12 0 14 0mm 0 47 0 55 in Fuel level F L 1 0 2 0 mm 0 04 0 08 in Engine idle speed 1 400 1 500 r min Intake vacuu...

Page 11: ...5 in Optional spring No Front wheel Type Disc wheel Rim size 10 6 0AT Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Front disc brake Type Single Disc outside diameter thickness 161 3 5 mm 6 34 0 14 in Pad thickness 4 5 mm 0 18 in 1 0 mm 0 04 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 32 mm 1 26 in Brake fluid type DOT 4 MAIN...

Page 12: ... Bolt M10 1 25 2 27 2 7 19 Brake pipe and brake hose Nut M10 1 0 2 19 1 9 13 Brake hose and frame Bolt M6 1 0 1 7 0 7 5 1 Caliper bleed screw Bolt M8 1 25 2 6 0 6 4 3 Master cylinder and handlebar Bolt M6 1 0 2 7 0 7 5 1 Brake caliper and caliper bracket Bolt M8 1 25 2 23 2 3 17 Brake pad retaining Bolt M10 1 25 2 18 1 8 13 Steering knuckle and brake disc guard Bolt M6 1 0 2 7 0 7 5 1 Front lower ...

Page 13: ...r short circuit Model manufacturer SH640E 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 14 A Electric starter system Type Constant mesh type Starter motor Model manufacturer SM 14 MITSUBA Output 0 5 kW Armature coil resistance 0 004 0 005 Ω at 20 C 68 F Brush overall length 10 mm 0 4 in 3 5 mm 0 14 in Spring force 730 970 g 7 16 9 52 N Commutator diameter 28 mm 1 10 in 27 ...

Page 14: ... guide ı 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 Ç Fasten the handlebar switch assembly lead and rear brake lever switch lead to the handle bar with the plastic bands Î Fasten the handlebar switch assembly lead to the handlebar with the plastic band Fa...

Page 15: ...h lead 9 Starter motor lead 0 Throttle cable A Rear brake cable B Rear brake breather hose C Carburetor air vent hose D CDI magneto lead Å Route the main switch lead and indicator light lead to the side of the cable guide ı 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 ...

Page 16: ...hole in the rear fender Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp Ó Fasten the taillight lead to the box with the plas tic clamp È Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm Make sure that the hose is not pinched Ô Bend the cable guide after routing the cables Fasten the starter m...

Page 17: ...rake breather hose through the cable guide ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips Ø Route the rear brake breather hose through the cable guide Route the final gear case breather hose through the cable guide Œ 10 mm 0 4 in  40 50 mm 1 6 2 0 in Í 100 mm 4 0 in CABLE ROUTING ...

Page 18: ...6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent ı Route the rear brake cable through the cable guide on the cyl inder Ç Fasten the starter motor lead to the frame with the plastic clamps Î Fasten the battery breather hose to the frame with the plastic clamps 50 60 mm 2 0 2 4 in ...

Page 19: ...reather hose B Taillight lead Å Fasten the wire harness to the frame with the plastic clamps ı Make sure the starter motor lead and wire harness do not contact the ignition coil Ç Fasten the wire harness starter motor lead and ignition coil lead to the frame with the plastic locking tie Î Fasten the wire harness and starter motor lead to the frame with the plastic locking tie Install the starter r...

Page 20: ...tic clamps Ó Install the starter circuit cut off relay onto the tab with its terminal side facing down È Route the throttle cable and rear brake cable through the cable guide Make sure that the throttle cable is routed to the inside of the rear brake cable Ô Make sure that the grommet is installed with the mark facing forward Route the taillight lead through the lead holders on the lid and the bot...

Page 21: ...on Adjust gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Fuel line Check fuel hos...

Page 22: ... potential hazard that could result in serious injury or death Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Battery Check specific gravity Check that the breather hose is working prop erly Correct if necessary ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year ...

Page 23: ...mmediately WARNING Use only the recommended brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor per formance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the f...

Page 24: ... front or rear brake 5 Check Brake hoses Active the brake lever several times Fluid leakage Replace the hose Refer to FRONT BRAKE 6 Install Front fender Front carrier Refer to FENDER AND FUEL TANK AIR BLEEDING HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake...

Page 25: ...e bleed screw and allow the lever to travel towards its limit h Tighten the bleed screw when the lever limit has been reached then release the lever i Repeat steps e to h until all the air bub bles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubb...

Page 26: ...pacer TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa 0 20 kg cm2 2 9 psi 25 kPa 0 25 kg cm2 3 6 psi Minimum 17 kPa 0 17 kg cm2 2 5 psi 22 kPa 0 22 kg cm2 3 2 psi Maximum 23 kPa 0 23 kg cm2 3 3 psi 28 kPa 0 28 kg cm2 4 0 psi FWD A TIRE SIZE AT22 7 10 B TIRE WEAR LIMIT 3 mm 0 12 in C RIM SIZE 12 6 0 AT D RIM RUNOUT LIMIT Radial 2 mm 0 08 in Lateral 2 mm 0 08 in ...

Page 27: ... by placing the suitable stand under the frame 4 Remove Nuts 1 front wheel Front wheel 2 5 Remove Wheel cap Cotter pin 1 Axle nut 2 Plain washer 3 1 3 2 6 Remove Front brake caliper 1 NOTE Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut 1 7 Remove Front wheel hub 1 with brake disc 1 FRONT WHEEL ...

Page 28: ... 21 CHAS FRONT WHEEL 8 Remove Front brake disc 1 1 INSPECTION 1 Inspect Wheel hub 1 Cracks damage Replace ...

Page 29: ...iaphragm 4 Brake master cylinder 5 Brake master cylinder kit 6 Copper washer 7 Union bolt 8 Brake hose 9 Brake pipe 0 Brake disc A Caliper bleed screw B Retaining bolt C Brake caliper D Pad shim E Brake pad F Piston G Piston seal H Brake disc guard FWD A BRAKE FLUID TYPE DOT 4 B BRAKE PAD WEAR LIMIT 1 0 mm 0 04 in C BRAKE DISC WEAR LIMIT 3 0 mm 0 12 in FWD ...

Page 30: ...therwise eye injury may occur Allow brake fluid to contact painted sur faces or plastic parts otherwise damage may occur Disconnect any hydraulic connection oth erwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Re...

Page 31: ...ng Brake pads Installation steps Connect a suitable hose 1 tightly to the cali per bleed screw 2 Then place the other end of this hose into an open container Loosen the caliper bleed screw and push the pistons into the caliper with the finger Tighten the caliper bleed screw 2 Install the pad shim 3 new onto the brake pad new NOTE The arrow mark a on the pad shim must point in the direction of the ...

Page 32: ...a 10 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM CALIPER DISASSEMBLY NOTE Before disassembling the front brake caliper drain the brake hose master cylinder brake caliper and reservoir tank of their brake fluid 1 Remove Front wheel 2 Loosen Union bolt Retaining bolts Retaining bolt caliper bracket 3 Remove Front brake caliper...

Page 33: ...cket disconnect the dust boot from the guide shaft on the bracket 1 2 6 Remove Piston Piston seals 1 Removal steps Blow compressed air into the hose joint opening to force out the caliper piston from the caliper body Remove the piston seals WARNING Never try to pry out the piston MASTER CYLINDER DISASSEMBLY NOTE Before disassembling the front brake master cylinder drain the brake hose master cylin...

Page 34: ... Brake master cylinder reservoir diaphragm Brake master cylinder 2 3 Remove Dust boot 1 Circlip 2 Brake master cylinder kit 3 Drain the excess fluid INSPECTION AND REPAIR WARNING All internal parts should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement schedule Brake pads As required Piston seal Every two ...

Page 35: ...place the piston seal whenever the cali per is disassembled 2 Inspect Brake master cylinder Wear scratches Replace the brake master cylinder assembly Brake master cylinder body Cracks damage Replace Oil delivery passage master cylinder body Blow out with compressed air 3 Inspect Brake master cylinder kit Scratches wear damage Replace as a set 4 Inspect Brake master cylinder reservoir diaphragm Wea...

Page 36: ...ither is found to be worn to the wear limit a Wear limit a 1 0 mm 0 04 in 7 Inspect Brake disc Galling damage Replace 8 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Brake disc thickness a Out of specification Replace 1 Dial gauge Maximum deflection 0 15 mm 0 006 in Minimum thickness 3 0 mm 0 12 in a 1 ...

Page 37: ...ned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the piston seals whenever a cali per is disassembled 1 Install Piston seals 1 Piston 2 WARNING Always use new piston seals Recommended brake fluid DOT 4 New 2 Install Caliper bracket 1 Caliper body 2 NOTE Apply the lithium soap base grease onto the caliper guide shaft and retaining bolt 1 2 ...

Page 38: ...r hose routing is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers T R Union bolt 27 Nm 2 7 m kg 19 ft lb 1 2 4 3 a New New 4 Remove Brake caliper 5 Install Pad spring Brake pads with pad shim Retaining bolts Front brake caliper Refer to BRAKE PAD REPLACEMENT T R Retaining bolt caliper bracket 23 Nm 2 3 m kg 17 ft lb Retaining bolt 18 Nm 1 8 m kg 13 f...

Page 39: ...ill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor per formance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Recommended brake fluid DOT 4 7 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM 8 Inspect Bra...

Page 40: ...e master cylinder is dis assembled Recommended brake fluid DOT 4 1 Install Brake master cylinder kit 1 Circlip 2 Dust boot 3 2 Install Brake master cylinder 1 CAUTION Install the brake master cylinder holder with the UP mark facing upward Align the end of the brake master cylinder holder with the punch mark a in the han dlebar Tighten first the upper bolt then the lower bolt T R Bolt brake master ...

Page 41: ... is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 Install Brake lever T R Union bolt 27 Nm 2 7 m kg 19 ft lb 5 Fill Brake master cylinder reservoir NOTE If DOT 4 is not available 3 can be used CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designated quality brake flu...

Page 42: ...water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 6 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM 7 Inspect Brake fluid level Fluid level is under LOWER level line Replenish Refer to FRONT BRAKE FLUID LEVEL INSPECTION a LOWER level line UP LOWER a ...

Page 43: ... 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE AT22 10 10 B TIRE WEAR LIMIT 2 0 mm 0 08 in C RIM SIZE 8 10AT D RIM RUNOUT LIMIT Radial 2 mm 0 08 in Lateral 2 mm 0 08 in E REAR AXLE RUNOUT LIMIT 1 5 mm 0 06 in FWD REAR WHEELS REAR BRAKE AND REAR AXLE ...

Page 44: ... 37 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing FWD ...

Page 45: ...CK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT End 1 0 mm 0 04 in Side 1 0 mm 0 04 in FWD ...

Page 46: ...erse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fuses 7 Starter relay 8 Rectifier regulator 9 CDI unit 0 Taillight A Battery B Starting circuit cut off relay C Reverse switch D Neutral switch E Headlight F Ignition coil ...

Page 47: ...F RUN G OFF PUSH H R W B K G Y G Y B B B G Y B Y G B Y G K G Y B B G Y Sb G L R W R W Br Br Sb G L G L G L Sb G L G L Sb Br Br L B L B G L B Br Y B L Br Y G L B L B R W R B R W R B 9 W L W R R B R B W G R W L W R W G R B 1 R W G W L W R W G W L W R R W W W W W W 2 B R W W W W W W W R W G R B R B W L O B R W W W BLACK R B GREEN GREEN R B Br M 1 CDI magneto 3 Main switch 4 Battery 5 Fuse 9 CDI unit ...

Page 48: ...ble shooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trouble shooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION Open circuit voltage ...

Page 49: ...arter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty for Europe Oceania OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the ...

Page 50: ...ter lead Spark plug lead Check that the primary coil has the speci fied resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Connect the pocket tester Ω 1 k to the ignition coil 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1 k to the spark plug cap MEETS SPECIFICATION Check that the spark plug cap has the specified resistance Spark plug cap resistance 10...

Page 51: ...istance Pickup coil resistance 189 231 Ω at 20 C 68 F White Green White Red OUT OF SPECIFICATION Replace the pickup coil stator assembly CORRECT 7 Engine stop switch Refer to SWITCH INSPECTION INCORRECT Replace the handlebar switch left CORRECT 8 Main switch Refer to SWITCH INSPECTION INCORRECT Replace the main switch BOTH MEET SPECIFICATION Check that the secondary coil has the specified resistan...

Page 52: ...n coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 100 to the source coil terminal Tester lead Red terminal 1 Tester lead White Blue terminal 2 MEETS SPECIFICATION Check the charging rotor rotation direction detection coil for the specified resistance Charging rotor rotation direction detection coil resistance 270 330 Ω at 20 C 68 F Red White Blu...

Page 53: ...G Y G Y B B B G Y B Y G B Y G K G Y B B G Y Sb G L R W R W Br Br Sb G L G L G L Sb G L G L Sb Br Br L B L B G L B Br Y B L Br Y G L B L B R W R B R W R B 9 W L W R R B R B W G R W L W R W G R B 1 R W G W L W R W G W L W R R W W W W W W 2 B R W W W W W W W R W G R B R B W L O B R W W W BLACK R B GREEN GREEN R B Br M 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit c...

Page 54: ...om operating when the select lever is in gear or in reverse and the rear brake lever is free In this instance the starting circuit cut off relay is off so that current cannot reach the starter motor WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE BRAKE LEVER IS PULLED IN 1 Battery 2 Starter motor 3 Starter relay 4 Start switch 5 Starting circuit cut off relay 6 Engine stop switch 7 Rear brake lever s...

Page 55: ...tion the entire starting system NOTE Remove the following part s before trouble shooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION Open circuit...

Page 56: ...rks so be sure that no flammable gas or fluid is in the vicinity 4 Starting circuit cut off relay Remove the starting circuit cut off relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starting circuit cut off relay terminals Battery terminal Red Black terminal 1 Battery terminal Green Yellow terminal 2 Tester lead Red Black terminal 1 Tester lead Blue White term...

Page 57: ...terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Black terminal 4 Check the starter relay for continuity NO CONTINUITY Replace the starter relay CORRECT 6 Main switch Refer to SWITCH INSPECTION INCORRECT Replace the main switch CORRECT 8 Neutral switch Refer to SWITCH INSPECTION INCORRECT Replace the neutral switch CORRECT 7 Engine stop switch Refer to SWITC...

Page 58: ...ION INCORRECT Replace the rear brake lever switch CORRECT 10 Start switch Refer to SWITCH INSPECTION INCORRECT Replace the handlebar switch left EB803028 11 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ...

Page 59: ...EEN GREEN R M YFM250XN 2001 WIRING DIAGRAM 1 CDI magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Reverse indicator light D Neutral switch E Reverse switch F Rear brake lever switch G Engine stop switch H Starter switch I Lights switch J Headlight K Handl...