Page 1
2. EXHAUST MUFFLER/FRAME COVERS
2-0
YUP 250
2
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EXHAUST MUFFLER/FRAME COVERS
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SCHEMATIC DRAWING ---------------------------------------------- 2-1
SERVICE INFORMATION -------------------------------------------- 2-2
TROUBLESHOOTING ------------------------------------------------- 2-2
FRAME COVERS REMOVAL----------------------------------------- 2-3
EXHAUST MUFFLER REMOVAL ----------------------------------- 2-10
2
Page 2
2. EXHAUST MUFFLER/FRAME COVERS
2-1
YUP 250
SCHEMATIC DRAWING
Page 3
2. EXHAUST MUFFLER/FRAME COVERS
2-2
YUP 250
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use care not to pull them by force because the cover joint claws
may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler lock bolt 32_ 38N-m
Exhaust muffler joint lock nut 18_ 22N-m
TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Page 4
2. EXHAUST MUFFLER/FRAME COVERS
2-3
YUP 250
FRAME COVERS REMOVAL
RIGHT AND LEFT BACK MIRROR
REMOVAL
Loosen the nut on the back mirror.
Remove the back mirror.
HANDLEBAR FRONT COVER
REMOVAL
Remove the four screws attaching handlebar
rear cover to separate from handlebar rear
cover.
Remove one bolt on the handlebar front
cover.
Disconnect all of the wire connectors,
couplers.
Remove handlebar front cover.
HANDLEBAR REAR COVER REMOVAL
Remove handlebar front cover. (!2-3)
Remove front cover. (
!2-4
)
Remove the two screws attaching handlebar.
Disconnect right/left handlebar switch
couplers.
Nuts
Bolt
Screws
Wire Connectors
Right/Left Handlebar
Switch Coupler
Speedometer Cable
Screws
Page 5
2. EXHAUST MUFFLER/FRAME COVERS
2-4
YUP 250
Disconnect all of the wire connectors and
couplers.
Remove the bolt on the handlebar rear cover.
Remove the handlebar rear cover.
FRONT COVER REMOVAL
Remove the two screws attaching the leg
shield.
Pull the front cover frontward, then remove
front cover.
FRONT BODY COVER REMOVAL
Remove the front cover. (!2-4)
Remove the two screws attaching the front
under cover.
Screw
Screw
Blot
Handlebar Rear Cover
Screw
Front Cover
Screw
Wire Connectors and
Page 6
2. EXHAUST MUFFLER/FRAME COVERS
2-5
YUP 250
Remove the two nuts on the front body cover
and six screws attaching the leg shield.
Disconnect the front body cover from leg
shield and front under cover.
Disconnect all of the wire couplers.
Remove the front body cover.
FRONT FENDER REMOVAL
Remove the four screws, then remove front
fender.
RIGHT/LEFT SIDE COVER REMOVAL
Remove the screw combine right (left) side
cover with front under cover.
Remove the screw combine right (left) side
cover with the floor board.
Remove the right (left) side cover.
Wire Couplers
Screws
Screws
Screws
Nuts
Page 7
2. EXHAUST MUFFLER/FRAME COVERS
2-6
YUP 250
FRONT UNDER COVER REMOVAL
Remove front cover, (!2-4) front body cover
(!2-4) and right/left side cover. (!2-5)
Remove two screws combine front under
cover with leg shield.
Remove two screws combine front under
cover with the floor board.
Remove the front under cover.
CENTER UNDER COVER REMOVAL
Remove the right and left side cover (
!2-5
),
front cover (
!2-4
), front body cover (
!2-4
)
and front under cover. (
!2-6
)
Remove the four bolts on the center under
cover.
Remove the center under cover.
REAR CARRIER REMOVAL
Remove tow rubber caps.
Remove six bolts and remove the rear carrier.
MET-IN BOX REMOVAL
Open the seat with key.
Remove the screw and battery cover.
Remove the twos bolts for disconnect battery
(+) and (-) cable.
Screws
Screws
Bolts
Wire Couplers
Bolts
Bolts
Screws
Bolts
Rubber Caps
Battery Cover
Battery
Page 8
2. EXHAUST MUFFLER/FRAME COVERS
2-7
YUP 250
Remove two bolts and two nuts on the met-in
box.
Remove fuse box cap.
Push the clip and depress fuse box.
Disconnect luggage box wire couplers.
Remove met-in box.
CENTER COVER REMOVAL
Remove met-in box. (
!2-6
)
Remove eight screws center cover.
Remove center cover.
Nuts
Fuse Box
Screws
Luggage Box Wire Couplers
Bolts
Fuse Box Cap
Clip
Page 9
2. EXHAUST MUFFLER/FRAME COVERS
2-8
YUP 250
REAR FENDER A REMOVAL
Remove two screws and two nuts on the rear
fender A.
Disconnect the licence light coupler.
Remove rear fender A.
REAR BODY COVER REMOVAL
Remove rear carrier (
!2-6
), met-in box (
!2-
6
), center cover (
!2-7
) and rear fender A.
(
!2-8
)
Remove two screws on the rear body cover.
Disconnect the open seat control cable from
rear body cover.
Nut
Licence Light Coupler
Screw
Screws
Open Seat Control Cable
Screw
Nut
Page 10
2. EXHAUST MUFFLER/FRAME COVERS
2-9
YUP 250
Disconnect air cleaner tube from air cleaner.
Disconnect tail/stop light coupler, then
remove rear body cover.
REAR FENDER B REMOVAL
Remove rear carrier (
!2-6
), met-in box (
!2-
6
), center cover (
!2-7
), rear fender A. (
!2-
8
) and rear body cover. (
!2-8
)
Remove the screw, then remove rear fender B.
FOOT BOARD REMOVAL
Remove front cover (
!2-4
), front body cover
(
!2-4
), right/left side cover (
!2-5
), front
under cover (
!2-6
), met-in box (
!2-6
) and
center cover (
!2-7
).
Remove four bolts on the foot board.
Tail/Stop Light Coupler
Screw
Bolts
Air Cleaner Tube
Rear Fender Cover B
Page 11
2. EXHAUST MUFFLER/FRAME COVERS
2-10
YUP 250
Remove two screws on the foot board, then
remove foot board.
LEG SHIELD REMOVAL
Remove front cover (
!2-4
), front body cover
(
!2-4
), front under cover (
!2-6
), right/left
side cover (
!2-5
), center cover (
!2-7
) and
foot board. (
!2-6
)
Remove the key and fuel tank cap molding.
Remove three screws on the fuel tank cap
holder, then remove leg shield.
EXHAUST MUFFLER REMOVAL
Remove the two exhaust muffler joint lock
nuts.
Remove the three exhaust muffler lock bolts ,
then remove the exhaust muffler.
Remove the exhaust muffler joint packing
collar.
Screw
Screws
Screw
Key Molding
Fuel Tank Cap Molding
Nuts
Bolts
Fuel Tank Cap Holder
Page 12
2. EXHAUST MUFFLER/FRAME COVERS
2-11
YUP 250
When installing, first install the exhaust
muffler packing collar onto the engine and
then install the exhaust muffler.
Torques:
Exhaust muffler lock bolt: 32_ 38Nm
Exhaust muffler joint lock nut: 18_ 22Nm
Packing Collar
Be sure to install a new exhaust muffler
packing collar.
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