KYMCO YUP 250 User manual

YUP 250

By KWANG YANG Motor Co., Ltd.

First Edition, Mar 2003

use without the written permission of KWANG YANG

Motor Co., Ltd.

is expressly prohibited.

4122-LBB5-S00

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YUP 250

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO YUP 250.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 5 through 13 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 14 is the

removal/ installation of chassis. Section

16 states the testing and measuring

methods of electrical equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS

FINAL REDUCTION

A.C. GENERATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL SYSTEM/CARBURETOR/FUEL

PUMP FUEL TANK

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT /

T HERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

CHASSIS EQUIPMENT

ENGINE

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1. GENERAL INFORMATION

1-0

YUP 250

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER--------------------------------------------- 1-1

SPECIFICATION---------------------------------------------------------- 1-2

SERVICE PRECAUTIONS----------------------------------------------- 1-3

TORQUE VALUES ------------------------------------------------------- 1-7

SPECIAL TOOLS --------------------------------------------------------- 1-8

LUBRICATION POINTS------------------------------------------------- 1-9

CABLE &HARNESS ROUTING-----------------------------------------1-11

WIRING DIAGRAM-------------------------------------------------------------------1-17

TROUBLESHOOTING --------------------------------------------------1-18

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1. GENERAL INFORMATION

1-1

YUP 250

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

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1. GENERAL INFORMATION

1-2

YUP 250

SPECIFICATIONS

Name & Model No.

SH50AA

Motorcycle Name & Type

YUP 250

Overall length

2060mm

Overall width

740mm

Overall height

1165mm

Wheel base

1435mm

Engine type

Water cooled 4-stroke,

OHC engine

Displacement

249.1/251cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

158

1 Person

Front wheel

55kg

Rear wheel

127

Gross weight(kg)

Total

213

Front wheel

120/70-12 58P

Rear wheel

140/70-12 65P

Ground clearance

135mm

Perform

Braking distance (m)

4m/30km/hr

ance

Min. turning radius

2350mm

Starting system

Starting motor

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

72.7 x 60/60.4

Compression ratio

10.3:1

Compression pressure

(kg/cm_-rpm)

16.5±2

Max. output (kw/rpm)

13.34/7000

Max. torque (kg.m/rpm)

2.0/5500

BDC

42°

Port

Intake

TDC

-8°

timin

BDC

33°

Exhaust

TDC

1°

Valve

Intake

0.1

clearance (cold)

Exhaust

0.1

Idle speed (rpm)

1450±50rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

10.5 liters

Type

CVK

Piston dia.

Venturi dia.

30 equivalent

Throttle type

Butterfly type

Type

Full transistor igniter

Ignition timing

repeatedly

Contact breaker

Non-contact point

type

Spark plug

NGK

DPR7EA-9

Spark plug gap

0.7mm

Battery

Capacity

12V10AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic

centrifugal

Type

Two-stage reduction

Reduction

1st

0.83~2.2

ratio

2nd

6.98

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

1.75

(kgf/cm_)

Rear

2.25

Turning

Left

45°

angle

Right

45°

Brake system

Front

Disk brake

type

Rear

Disk brake

Suspension

Front

Telescope

type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

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1. GENERAL INFORMATION

1-3

YUP 250

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

nWhen tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

nUse genuine parts and lubricants.

nWhen servicing the motorcycle, be sure to

use special tools for removal and

installation.

nAfter disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

nApply or add designated greases and

lubricants to the specified lubrication

points.

nAfter reassembly, check all parts for

proper tightening and operation.

nWhen two persons work together, pay

attention to the mutual working safety.

nDisconnect the battery negative (-) terminal

before operation.

nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

nAfter operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

nWhen connecting the battery, the positive

(+) terminal must be connected first.

nAfter connection, apply grease to the

battery terminals.

nTerminal caps shall be installed securely.

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1. GENERAL INFORMATION

1-4

YUP 250

nIf the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

nAfter operation, terminal caps shall be

installed securely.

nWhen taking out the connector, the lock on

the connector shall be released before

operation.

nHold the connector body when connecting

or disconnecting it.

nDo not pull the connector wire.

nCheck if any connector terminal is bending,

protruding or loose.

nThe connector shall be inserted

completely.

nIf the double connector has a lock, lock

it at the correct position.

nCheck if there is any loose wire.

nBefore connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

nCheck the double connector cover for

proper coverage and installation.

nInsert the terminal completely.

nCheck the terminal cover for proper

coverage.

nDo not make the terminal cover opening

face up.

nSecure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

Confirm

Capacity

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1. GENERAL INFORMATION

1-5

YUP 250

nAfter clamping, check each wire to make

sure it is secure.

nDo not squeeze wires against the weld or

its clamp.

nAfter clamping, check each harness to make

sure that it is not interfering with any

moving or sliding parts.

nWhen fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

nRoute wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

nRoute wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

nRoute harnesses so they are neither

pulled tight nor have excessive slack.

nProtect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

nWhen rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

nDo not break the sheath of wire.

nIf a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

nWhen installing other parts, do not press or

squeeze the wires.

Do not pull

too tightð

No Contact

Do not press

or squeeze the

wire

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1. GENERAL INFORMATION

1-6

YUP 250

nAfter routing, check that the wire harnesses

are not twisted or kinked.

nWire harnesses routed along with handlebar

should not be pulled tight, have excessive

slack or interfere with adjacent or

surrounding parts in all steering positions.

nWhen a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

nBe careful not to drop any parts.

nWhen rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

nSymbols:

The following symbols represent the

servicing methods and cautions included in

this service manual.

:Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

:Apply grease for lubrication.

:Transmission Gear Oil (90#)

:Use special tool.

: Caution

:Warning

Special

Engine Oil

Grease

Gear Oil

＊

Do you

understand the

instrument？

Remove

Rustð

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1. GENERAL INFORMATION

1-7

YUP 250

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (N-m)

Item

Torque (N-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

4.5_6

8_12

18_25

30_40

50_60

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut

8mm flange bolt, nut

10mm flange bolt, nut

3.5_5

8.8

10_14

24_30

35_45

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (N-m)

Remarks

Cylinder head bolt A

Cylinder head bolt B

Oil filter screen cap

Cylinder head cap nut

Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt

Clutch outer nut

Clutch drive plate nut

Flywheel nut

Oil pump bolt

Cylinder head cover bolt

Spark plug

Cam chain tensioner bolt

Water pump impeller

Drive face nut

Transmission case cover bolt

Gear oil check bolt

8.9

12.7

24.5

8.8

14.7

53.9

58.8

3.9

11.8

17.2

11.8

Double end bolt

Apply oil to

threads

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