1996 Yamaha YP 250 Majesty Service & Repair Manual

EB000000 YP250 SERVICE MANUAL 1996 by Yamaha Motor Co., Ltd. 1st Edition, January 1996 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Re- pairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi- cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. 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 ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person inspecting or repairing the scooter. A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. NOTE: A NOTE provides key information to make procedures easier or clearer.

1 2 4 3 5 6 7 6 8 YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To heps identify parts and clarify procedure steps, there are exploded diagrams at start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs. 2. Numbers 5 are given in the order of 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 way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

1 3 5 7 9 11 13 15 18 2 4 8 10 12 14 16 6 21 24 25 17 19 20 22 23 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 Possible to maintain with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit, clearance 16 Engine speed 17 Ω, V, A Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lu- brication points. 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight lithium-soap base grease 23 Apply molybdenum disulfide grease Illustrated symbols 24 to 25 in the exploded diagrams indicate the where to apply locking agent 24 and when to install new parts 25 . 24 Apply locking agent (LOCTITE  ) 25 Use new one

GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INDEX

CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER (for E) 1-1 . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL INDICATOR LIGHT 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTO CHOKE SYSTEM 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION CIRCUIT CUT-OFF SYSTEM 1-3 . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-4 . . . . . . . . . . . . . . . REPLACEMENT PARTS 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS, AND O-RINGS 1-4 . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-5 . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING OF CONNECTIONS 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW TO USE THE CONVERSION TABLE 1-7 . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1996 Yamaha YP 250 Majesty Service & Repair Manual

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