Yamaha YFM250BT 2004, Supplementary Service Manual

Page 1: ...LIT 11616 18 41 4XE F8197 13 YFM250BT SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ...C SERVICE MANUAL LIT 11616 12 01 4XE F8197 10 YFM250XN SUPPLEMENTARY SERVICE MANUAL LIT 11616 14 17 4XE F8197 11 YFM250XP SUPPLEMENTARY SERVICE MANUAL LIT 11616 15 03 4XE F8197 12 YFM250BT SUPPLEMENTARY SERVICE MANUAL 2004 by Yamaha Motor Corporation U S A First edition July 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S...

Page 3: ...tions 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 EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol...

Page 4: ...parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read...

Page 5: ...d F Electrical data Ω V A Symbols G to M 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 lithium soap based grease L Apply molybdenum disulfide grease M Apply silicon grease Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and w...

Page 6: ...AND FRONT FENDER 16 REAR CARRIER AND REAR FENDER 18 FUEL TANK 20 FOOTREST BOARDS 21 ENGINE 22 ADJUSTING THE STARTER CABLE 22 CHASSIS 23 ADJUSTING THE REAR BRAKE 23 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 25 ADJUSTING THE HEADLIGHT BEAM 26 REPLACING A HEADLIGHT BULB 26 ENGINE 28 ENGINE REMOVAL 28 SELECT LEVER ASSEMBLY 28 CARBURETION 29 CARBURETOR 29 CHASSIS 32 REAR BRAKE 32 STEERING ...

Page 7: ...ELECTRICAL 37 ELECTRICAL COMPONENTS 37 YFM250BT WIRING DIAGRAM ...

Page 8: ...ning radius 2 900 mm 114 in Basic weight With oil and full fuel tank 216 kg 476 lb Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Tire Type Tubeless Size front AT22 7 10 rear AT22 10 10 Manufacturer front MAXXIS rear MAXXIS Type front M905 rear M906 Electrical Ignition system DC C D I Generator system A C magneto Battery type CB14A A2 Battery capacity 12 V 14 AH Bulb wattage quantity Headlig...

Page 9: ...arter jet G S 2 0 9 Throttle valve size Th V 100 Float height F H 12 0 14 0 mm 0 47 0 55 in Fuel level F L 4 0 5 0 mm 0 16 0 20 in Engine idle speed 1 400 1 500 r min Intake vacuum 30 7 kPa 230 mmHg 9 06 inHg Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb Starter motor holding bracket Screw M6 2 7 0 7 5 1 Bearing retainer 1 bearing housing Nut M50 1 80 8 0 ...

Page 10: ... Front carrier and frame Bolt M8 1 25 4 34 3 4 24 Front carrier and front fender Bolt M6 1 0 2 7 0 7 5 1 Front carrier and front bumper Bolt M8 1 25 2 34 3 4 24 Front bumper and frame Bolt M8 1 25 4 34 3 4 24 Front bumper front fender and front grill Bolt M6 1 0 2 7 0 7 5 1 Front fender and front grill Bolt M6 1 0 2 7 0 7 5 1 Rear carrier and frame Bolt M8 1 25 4 34 3 4 24 Rear carrier and rear fe...

Page 11: ...l manufacturer F8T38683 MITSUBISHI Electric starter system Type Constant mesh type Starter motor Model manufacturer 5XG MORIC TAIWAN Output 0 4 kW Armature coil resistance 0 0144 0 0176 Ω at 20 C 68 F Brush overall length 10 mm 0 4 in 3 5 mm 0 14 in Spring force 563 844 g 5 52 8 28 N Commutator diameter 22 mm 0 87 in 21 mm 0 83 in Mica undercut 1 5 mm 0 059 in Starter relay Model manufacturer MS5F...

Page 12: ...able 3 Rear brake cable 4 Lower bracket cable guide 5 Front brake hose 6 Front brake light switch lead 7 Throttle cable 8 Reverse indicator light 9 Neutral indicator light 0 Fuel tank breather hose A Handlebar switch assembly lead B Rectifier regulator CABLE ROUTING ...

Page 13: ...e 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 Ì Fasten the handlebar switch assembly lead rear brake light switch lead and starter cable to the handlebar with the plastic bands Í Fasten the handlebar switch assembly lead to the handlebar with the plastic band Î Fasten the rear brake light switch lead ...

Page 14: ...4 Main switch lead 5 Indicator light 6 Main switch 7 Fuel tank breather hose 8 Carburetor overflow hose 9 Reverse switch lead 0 Neutral switch lead A Negative battery lead B A C magneto lead C Starter cable D Rear brake cable E Select lever control cable F Throttle cable G Starter motor lead ...

Page 15: ...gear case breather hose into the air duct after routing them through the fuel tank grommet Ì 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 Í Route the reverse switch lead and neutral switch lead to the right of the rear arm boot Î Fasten the starter motor lead to the frame with the p...

Page 16: ...inal gear case breather hose 7 Negative battery lead 8 Ground lead 9 Carburetor air vent hose 0 Rear brake breather hose A Rear brake light switch lead B Rear brake cable C A C magneto lead È Make sure that the starter motor lead has no slack É 0 mm 0 in Ê Fasten the starter motor lead and wire harness to the frame with the plastic band ...

Page 17: ... Î 40 50 mm 1 6 2 0 in Ï Fasten the starter motor lead and wire harness to the frame with the plastic clamp Ð Route the rear brake cable and rear brake breather hose through the cable guide Ñ 100 mm 4 0 in Ò Route the rear brake breather hose through the cable guide Ó Route the final gear case breather hose through the cable guide Ô Fasten the rear brake cable and rear brake breather hose to the s...

Page 18: ... 6 Ignition coil leads 7 Starter motor lead 8 Rear brake light switch 9 Rear brake breather hose È Fasten the battery breather hose to the frame with the plastic band É Fasten the starter motor lead to the frame with the plastic clamps Ê 50 60 mm 2 0 2 4 in Ë Fasten the battery breather hose to the frame with the plastic clamps ...

Page 19: ...lead 9 Carburetor air vent hose 0 Final gear case breather hose A Rear brake breather hose È Fasten the wire harness starter motor lead and select lever control cable to the frame with the plastic band É 5 mm 0 2 in Ê Fasten the positive battery lead to the rear fender with the plastic clamps Ë Make sure that the grommet is installed with the mark facing forward ...

Page 20: ...frame with the plastic clamps É Make sure the starter motor lead and wire har ness do not contact the ignition coil Ê 50 mm 2 0 in Ë Route the throttle cable select lever control 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 Ì Fasten the wire harness starter motor lead and ignition coil lead to the frame with th...

Page 21: ... comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check starter choke Adjust engine idling speed...

Page 22: ...Check balance damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear sus pension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Steering shaft Lubricate every 6 months with lithium soap based grease all purpose grease Fittings and fasten ers Check all ...

Page 23: ...7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the seat front carrier front bumper and front fender Remove the parts in the order listed 1 Seat 1 NOTE Pull up the seat lock lever then pull up on the rear of the seat 2 Front carrier 1 3 Engine skid plate 1 4 Front bumper 1 5 Headlight coupler 2 Disconnect 6 Front grill 1 7 Main switch coupler 1 Disconnect 8...

Page 24: ... 11 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 3 4 m kg 24 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 11 Front fender 1 For installation reverse the removal pro cedure ...

Page 25: ...g 24 ft Ib Order Job Part Q ty Remarks Removing the rear carrier and rear fender Remove the parts in the order listed Seat and fuel tank cover Refer to SEAT FRONT CARRIER FRONT BUMPER AND FRONT FENDER 1 Rear carrier 1 2 Battery cover 1 3 Battery holding bracket 1 4 Battery lead 2 Disconnect CAUTION First disconnect the negative lead then disconnect the positive lead 5 Battery 1 6 Battery breather ...

Page 26: ...4 Nm 3 4 m kg 24 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib Order Job Part Q ty Remarks 8 CDI unit 1 9 Tail brake light connector 3 Disconnect 10 Starter relay coupler 1 Disconnect 11 Starter motor lead 1 Disconnect 12 Starter relay 1 13 Starting circuit cut off relay coupler 1 Disconnect 14 Starting circuit cut off relay 1 15 Rear fender 1 For installation reverse the removal pro cedure ...

Page 27: ...k Remove the parts in the order listed Seat and fuel tank cover Refer to SEAT FRONT CARRIER FRONT BUMPER AND FRONT FENDER 1 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole of the handlebar cover For installation reverse the removal pro cedure ...

Page 28: ...6 5 m kg 47 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the footrest boards Remove the parts in the order listed 1 Footrest 2 2 Left footrest board 1 3 Right footrest board 1 4 Left footrest bracket 1 5 Right footrest bracket 1 For installation reverse the removal pro cedure ...

Page 29: ...i fication adjust it as described below È Fully closed position É Fully open position c Pull back the boot 4 d Loosen the locknut 5 e Turn the adjusting nut 6 in or out until the correct free play is obtained f Tighten the locknut 5 g Push in the boot 4 h Connect the starter cable to the carburetor WARNING After adjusting the cable turn the handle bar to right and left and make sure that the engin...

Page 30: ...e pedal height a brake pedal free play b rear brake lever free play c Out of specification Adjust Brake pedal height 43 53 mm 1 69 2 09 in Brake pedal free play 20 30 mm 0 79 1 18 in Rear brake lever free play 5 7 mm 0 20 0 28 in 3 Adjust brake pedal height brake pedal free play rear brake lever free play a Loosen the locknuts 1 b Turn the adjusting bolt 2 until the brake pedal height is within th...

Page 31: ...ree play to see whether or not it is within the specified lim its If not perform the above steps again Gap 0 1 mm 0 0 04 in i Turn the brake lever cable adjusting nut 4 until the rear brake lever free play is within the specified limits j Tighten the locknut 3 k Adjust the select lever control cable Refer to ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD WARNING After this adjustment is pe...

Page 32: ...elect lever shift rod Control cable a Make sure the select lever is in FORWARD b Adjust the control cable so there is zero free play in the cable When the adjustment is correct slack in the return spring 1 will be taken up NOTE In some cases it will be necessary to further adjust the cable with the locknuts 2 arrange ment that holds the cable to its mount c When the brake begins to work a 20 30 mm...

Page 33: ...knuts 2 c Turn the select lever adjusting nut 3 in or out until lever 4 center line a aligns with match mark b on the crankcase cover d Tighten the locknuts 2 NOTE After adjusting the drive select lever be sure the reverse indicator light comes on when the drive select lever is in reverse position T R Locknut select lever adjuster 15 Nm 1 5 m kg 11 ft lb 1 2 3 4 ADJUSTING THE HEADLIGHT BEAM 1 Adju...

Page 34: ...bulb while it is on since it will be hot Do not touch the bulb until it cools down 3 Install bulb Secure the new bulb with the headlight unit CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or ...