YAMAHA YP250R PARTS CATALOGUE 03

YP250

(5SJ9)

EUROPE

YP250R

(5SJB)

AUSTRALIA

1B5SJ−300EA

YP250/YP250R

PARTS CATALOGUE

E2002 by Yamaha Motor Co., Ltd.

1st Edition, Oct. 2002

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

FOREWORD

This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

YP250(5SJ9),YP250R(5SJB)

1. Modifications or additions which have been made after issue of the Parts Catalogue will be announced in the Yamaha Parts News. It is advisable that you make necessary corrections to the Parts Catalogue according to the Yamaha Parts News.

2. Abbreviations The Following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number.

“UN” Use as many as needed.

“AP” Alternate Parts

“LM” Local Made (Parts need to be ordered locally)

“F#” Frame No. (Applicable machine No.)

3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in front of the part name as shown below.

EXAMPLE

CARBURETOR ASSY

.JET, PILOT

.NOZZLE, MAIN

4. Number of component for assembly The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.

EXAMPLE

PART NO. DESCRIPTION Q’TY REMARKS

2F5−83310−60 FRONT FLASHER LIGHT ASSY 2

115−83311−60 .BULB (6V−18W) 1

1M1−83309−60 .REFLECTOR 1

5. Applicable colors of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4−24110−00−X5 FUEL TANK COMP. 1 MXR

3J1−24240−10 .GRAPHIC, FUEL TANK 1 FOR MXR

6. Applicable Serial No.

Engine Serial No. Frame Serial No.

7. Note that the illustrations for reference in finding parts numbers, not to be used for assembling. When assembling, please use the applicable service manual.

8. The asterisk (*) before a reference number indicates modification items after the first edition.

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross−refer the “model code − production code No.” in the catalogue to the “model code − production code No. “indicated on the Model Label affixed onto the product concemed.

(2) “Model Label”Indication

xxxx – xxx

(3) Model Label Affixing Location

a: Model Type Code

b: Production Code No.

c: Colouring Type

4TW1–010

(4) Model Code − Production Code Number of Model Listed in This Parts Catalog

Model

Code

5SJ9

5SJB 010 AUSTRALIA

Production

Code No.

020 BELGIUM

030

060 ENGLAND

070 GREECE

080 ITALY

090 HOLLAND

100 NORWAY

110 PORTUGAL

120 SWEDEN

Country

(destination)

SWITZERLAND

Model

Code

Production

Code No.

(destination)

Country

(5) Coloring Information

Model

Code

5SJ9

5SJB

5SJ9 D 0821 DARK GRAY METALLIC A DNMA

Colouring type

code

A 000L MARBLE SILVER MAS

B 0779 DULL RED METALLIC D DRMD

C 0866

Colour

code

Colour Name

DARK GRAYISH BLUE

METALLIC E

Abbrevi-

ation

DNBME

ENGINE

CYLINDER B2.........................................

CRANKSHAFT. PISTON B3..............................

VALVE B4.............................................

CAMSHAFT. CHAIN B5.................................

WATER PUMP B6......................................

RADIATOR. HOSE B7...................................

OIL PUMP B9..........................................

INTAKE B10............................................

CARBURETOR B11.....................................

EXHAUST B13..........................................

CRANKCASE B15.......................................

CRANKCASE COVER 1 C3..............................

STARTER C5..........................................

CLUTCH C6...........................................

TRANSMISSION C8....................................

CHASSIS

FRAME C9............................................

FENDER C10...........................................

SIDE COVER C11.......................................

REAR ARM. SUSPENSION C13...........................

STEERING C14.........................................

FUEL TANK D2........................................

SEAT D4..............................................

FRONT WHEEL D6.....................................

FRONT BRAKE CALIPER D7............................

REAR WHEEL D8......................................

REAR BRAKE CALIPER D9.............................

STEERING HANDLE. CABLE D10.........................

CONTENTS

FRONT MASTER CYLINDER D11.........................

STAND. FOOTREST D12.................................

LEG SHIELD D14........................................

GENERATOR E3.......................................

STARTING MOTOR E4..................................

FLASHER LIGHT E5....................................

METER E6............................................

HEADLIGHT E7........................................

TAILLIGHT E8.........................................

HANDLE SWITCH. LEVER E9...........................

ELECTRICAL 1 E10.....................................

ELECTRICAL 2 E12.....................................

INDEX

NUMERICAL INDEX M1.................................

FIG. 1 CYLINDER

REF. NO.

10 95027−06020 BOLT, FLANGE 2 2

11 3GC−11186−00 COVER, CYLINDER HEAD SIDE 2 1 1

12 3GC−11187−00 COVER, CYLINDER HEAD SIDE 3 1 1

13 93210−57634 O−RING 2 2

14 95027−06020 BOLT, FLANGE 5 5

15 90176−08026 NUT, CROWN 4 4

PART NO. DESCRIPTION REMARKS

1 5GM−11101−00 CYLINDER HEAD ASSY 1 1

2 4G0−11133−10 .GUIDE, INTAKE VALVE 2 2

3 93440−10085 .CIRCLIP 2 2

4 90153−06029 .SCREW, HEXAGON 1 1

5 90430−06014 .GASKET 1 1

6 95617−08620 BOLT, STUD 2 2

7 95617−06615 BOLT, STUD 2 2

8 4HC−11160−00 BREATHER ASSY 1 1

9 93210−92448 O−RING 1 1

5SJ9

5SJB

16 90201−08609 WASHER, PLATE 4 4

17 4HC−11181−01 GASKET, CYLINDER HEAD 1 1 1

18 99530−14016 PIN, DOWEL 2 2

19 95027−06120 BOLT, FLANGE 2 2

20 94701−00333 PLUG, SPARK (NGK DR8EA) 1 1

21 4HC−11311−00 CYLINDER 1 1 1

22 4HC−11351−00 GASKET, CYLINDER 1 1

23 99530−10114 PIN, DOWEL 2 2

24 4HC−11166−00 PIPE, BREATHER 1 1 1

25 90467−13064 CLIP 2 2

FIG. 2 CRANKSHAFT. PISTON

REF. NO.

PART NO. DESCRIPTION REMARKS

1 5GM−11400−00 CRANKSHAFT ASSY 1 1

2 90170−16425 NUT 1 1

3 90201−160F6 WASHER, PLATE 1 1

4 90280−05013 KEY, WOODRUFF 1 1

5 4HC−11631−01 PISTON (STD) 1 1

4HC−11636−01 PISTON (0.50MM O/S) 1 1 AP

4HC−11638−01 PISTON (1.00MM O/S) 1 1 AP

6 4HC−11603−00 PISTON RING SET (STD) 1 1

4HC−11605−00 PISTON RING SET (0.50MM O/S) 1 1 AP

4HC−11607−00 PISTON RING SET (1.00MM O/S) 1 1 AP

7 4JH−11633−00 PIN, PISTON 1 1

8 90468−12069 CLIP 2 2

5SJ9

5SJB

FIG. 3 VALVE

REF. NO.

10 3Y1−12156−00 SHAFT, ROCKER 2 1 1

11 5H0−12146−00 SHAFT, ROCKER 1 1

12 93210−09165 O−RING 1 1

13 2NX−12159−00 SCREW, VALVE ADJUSTING 2 2

14 90170−06128 NUT 2 2

PART NO. DESCRIPTION REMARKS

1 5GM−12111−00 VALVE, INTAKE 1 1

2 5H0−12121−01 VALVE, EXHAUST 1 1

3 4G0−12116−01 SEAT, VALVE SPRING 2 2

4 4HC−12113−00 SPRING, VALVE INNER 2 2

5 4HC−12114−00 SPRING, VALVE OUTER 2 2

6 5H0−12119−00 SEAL, VALVE STEM 2 2

7 4G0−12117−00 RETAINER, VALVE SPRING 2 2

8 4G0−12118−00 COTTER, VALVE 4 4

9 36X−12151−00 ARM, VALVE ROCKER 2 2

5SJ9

5SJB

FIG. 4 CAMSHAFT. CHAIN

REF. NO.

10 90201−10591 WASHER, PLATE 1 1

11 4KB−11145−00 PLATE, BREATHER 2 1 1

12 94581−63104 CHAIN 1 1

13 4HC−12231−00 GUIDE, STOPPER 1 1 1

14 4HC−12241−00 GUIDE, STOPPER 2 1 1

15 2UJ−12210−01 TENSIONER ASSY, CAM CHAIN 1 1

PART NO. DESCRIPTION REMARKS

1 4HC−12170−00 CAMSHAFT ASSY 1 1 1

2 93306−00518 .BEARING 1 1

3 93306−20204 .BEARING (B6202Z) 1 1 KOYO

4 4GA−1111F−00 PLATE 1 1

5 97007−06012 BOLT 2 2

6 90215−06184 WASHER, LOCK 1 1

7 4HC−12176−00 SPROCKET, CAM CHAIN 1 1

8 93604−10011 PIN, DOWEL 1 1

9 90101−10303 BOLT 1 1

5SJ9

5SJB

16 4RF−12213−00 GASKET, TENSIONER CASE 1 1

17 91317−06014 BOLT 2 2

18 4HC−12157−00 BOLT 1 1

19 93210−15171 O−RING 1 1

FIG. 5 WATER PUMP

REF. NO.

10 99009−10400 .CIRCLIP 1 1

11 90430−06014 .GASKET 1 1

12 95027−06035 .BOLT, FLANGE 1 1

13 93210−33133 O−RING 1 1

14 5GM−12426−00 SHAFT 1 1

15 93603−22028 PIN, DOWEL 1 1

PART NO. DESCRIPTION REMARKS

1 5GM−12420−01 WATER PUMP ASSY 1 1

2 5GM−12450−01 .IMPELLER SHAFT ASSY 1 1

3 4HC−12422−01 .COVER, HOUSING 1 1

4 4HC−12428−10 .GASKET, HOUSING COVER 2 1 1

5 91317−06035 .BOLT 2 2

6 93306−00006 .BEARING (B6000) 1 1

7 4HC−12421−00 .HOUSING, WATER PUMP 1 1

8 93101−10090 .OIL SEAL 1 1

911H−12438−10 .SEAL, MECHANICAL 1 1

5SJ9

5SJB

16 90201−08512 WASHER, PLATE 2 2

17 4HC−12459−00 GEAR, IMPELLER SHAFT 1 1

18 99001−07600 CIRCLIP 1 1

19 4HC−12446−00 JOINT 1 1

20 93210−16275 O−RING 2 2

21 91317−06016 BOLT 2 2

22 4HC−2637G−00 HOLDER, WIRE 1 1

23 95027−06030 BOLT, FLANGE 1 1

24 90464−23199 CLAMP 1 1

FIG. 6 RADIATOR. HOSE

REF. NO.

10 5GM−12481−00 PIPE 1 1 1

11 5GM−12482−00 PIPE 2 1 1

12 5GM−12483−00 PIPE 3 1 1

13 5GM−12484−00 PIPE 4 1 1

14 5GM−12485−00 PIPE 5 1 1

15 5GM−12476−00 PIPE 6 1 1

PART NO. DESCRIPTION REMARKS

1 4HC−12411−00 THERMOSTAT 1 1

2 4HC−12413−00 COVER, THERMOSTAT 1 1

3 91317−06020 BOLT 2 2

4 5GM−12461−10 RADIATOR ASSY 1 1

5 5GM−12405−00 BLOWER ASSY 1 1

6 95024−06010 BOLT, FLANGE 3 3

7 4JH−12462−00 CAP, RADIATOR 1 1

8 4HC−12591−00 SUPT, FILLER NECK 1 1

9 97007−05012 BOLT 1 1

5SJ9

5SJB

16 90467−26131 CLIP 2 2

17 90450−28014 HOSE CLAMP ASSY 2 2

18 90467−22100 CLIP 2 2

19 90501−14001 SPRING, COMPRESSION 1 1

20 90450−28014 HOSE CLAMP ASSY 4 4

21 4HC−12576−00 HOSE 1 1 1

22 4HC−12577−00 HOSE 2 1 1

23 90467−10038 CLIP 4 4

24 95807−06010 BOLT, FLANGE 3 3

25 5GM−12443−00 STAY 1 1

26 95807−06008 BOLT, FLANGE 1 1

27 90480−14323 GROMMET 1 1

FIG. 6 RADIATOR. HOSE

REF. NO.

28 90480−16301 GROMMET 2 2

29 90387−0714B COLLAR 2 2

30 90119−06118 BOLT, WITH WASHER 2 2

31 5GM−82560−00 THERMO SWITCH ASSY 1 1

32 5GH−82560−00 THERMO SWITCH ASSY 1 1

PART NO. DESCRIPTION REMARKS

5SJ9

5SJB

FIG. 7 OIL PUMP

REF. NO.

10 90501−18576 SPRING, COMPRESSION 1 1

11 4HC−15351−00 PLUG, DRAIN 1 1

12 93210−35520 O−RING 1 1

PART NO. DESCRIPTION REMARKS

1 4HC−13300−00 OIL PUMP ASSY 1 1

2 93603−12221 .PIN, DOWEL 2 2

3 4HC−13325−00 .GEAR, PUMP DRIVEN 1 1

4 93603−22028 .PIN, DOWEL 1 1

5 90201−08512 .WASHER, PLATE 1 1

6 99001−06600 .CIRCLIP 1 1

7 4HC−13475−00 GASKET 1 1

8 92017−06025 BOLT, BUTTON HEAD 2 2

9 51Y−13411−00 STRAINER, OIL 1 1

5SJ9

5SJB

FIG. 8 INTAKE

REF. NO.

10 4HC−14451−00 ELEMENT, AIR CLEANER 1 1

11 4HC−14472−00 PLATE, ELEMENT 1 1

12 4HC−14452−00 SEAL 1 1

13 97707−50125 SCREW, TAPPING 7 7

14 90446−11303 HOSE 1 1

15 90338−08174 PLUG 1 1

PART NO. DESCRIPTION REMARKS

1 4HC−13586−11 JOINT, CARBURETOR 1 1 1

2 93210−35537 O−RING 3 3

3 90109−067E6 BOLT 2 2

4 4HC−13595−00 JOINT 1 1

5 95707−06500 NUT, FLANGE 2 2

6 4HC−14411−00 CASE, AIR CLEANER 1 1 1

7 5GM−14412−01 CAP, CLEANER CASE 1 1 1

8 5GM−14437−00 DUCT 1 1

9 4HC−14453−01 JOINT, AIR CLEANER 1 1 1

5SJ9

5SJB

B10

16 90467−10008 CLIP 2 2

17 90480−13598 GROMMET 2 2

18 5GM−1441A−00 COVER, CLEANER CASE 1 1 1

19 90387−064W3 COLLAR 2 2

20 90109−067E6 BOLT 2 2

21 90450−60001 HOSE CLAMP ASSY 1 1

22 5GM−14294−00 HOSE 1 1

23 90467−11032 CLIP 2 2

24 90464−13001 CLAMP 1 1

FIG. 9 CARBURETOR

REF. NO.

10 4KL−14386−00 .PIN, FLOAT 1 1

11 98501−04012 .SCREW, PAN HEAD 4 4

12 4HC−1490H−08 .DIAPHRAGM SET 5 1 1

13 4HC−14958−00 .COVER, DIAPHRAGM 1 1

14 4HC−14147−00 .O−RING 2 2

15 4KL−14272−01 .VALVE, CHECK SEAT 1 1

PART NO. DESCRIPTION REMARKS

1 5GM−14301−11 CARBURETOR ASSY 1 1 1

2 5GM−14105−00 .PILOT SCREW SET 1 1

3 97801−05010 .THROTTLE SCREW 4 4

4 4HC−14103−00 .THROTTLE SCREW SET 1 1

5 4HC−1490A−00 .DIAPHRAGM SET 1 1 1

6 214−24535−00 .SCREW, LEVER FITTING 9 9

7 4HC−14390−00 .NEEDLE VALVE ASSY 1 1

8 98901−04006 .SCREW, BIND 1 1

9 25N−14385−00 .FLOAT 1 1

5SJ9

5SJB

B11

16 4KL−14115−00 .PLUG, DRAIN 1 1

17 4KL−14384−00 .GASKET, FLOAT CHAMBER 1 1

18 4KL−14404−00 .BOOT 1 1

19 4HC−14429−00 .SCREW 1 1

20 4HC−14592−00 .SCREW 1 1

21 5H0−14397−00 .O−RING 1 1

22 4KL−14536−00 .GASKET 1 1

23 4KL−14397−00 .O−RING 1 1

24 5GM−1410A−10 .STARTER SET 1 1

25 4JP−14243−01 .PLATE 1 1

26 5GM−1490J−00 .NEEDLE SET 1 1

27 4HC−14340−01 .VALVE ASSY 1 1

FIG. 9 CARBURETOR

REF. NO.

28 4HC−14286−00 .SPRING 1 1

29 4UC−14341−00 .NOZZLE, MAIN 1 1

30 4UC−14341−10 .NOZZLE, MAIN 1 1

31 50M−14343−64 .JET, MAIN (#128) 1 1

32 38V−14342−22 .JET, PILOT (# 44) 1 1

33 50M−14355−00 .PLUG 1 1

34 4HC−14197−00 .PIPE 1 1

35 4HC−14196−00 .PIPE 1 1

36 5GM−14197−00 .PIPE 1 1

37 5GM−14565−00 .SCREW 1 1

38 5GM−14243−00 .CLAMP 1 1

39 5GM−85885−00 .THROTTLE SENSOR ASSY 1 1

40 97801−05014 .SCREW, PAN HEAD 1 1

PART NO. DESCRIPTION REMARKS

5SJ9

5SJB

B12

FIG. 10 EXHAUST

REF. NO.

10 5RB−14748−00 PROTECTOR, MUFFLER 4 1 1

11 90111−06020 BOLT 3 3

12 5RB−14766−00 WASHER, PROTECTOR 6 6

13 5GM−1482K−00 PLATE 1 1

14 5GM−14611−10 PIPE, EXHAUST 1 1 1

15 4HC−14628−00 PROTECTOR, EXHAUST PIPE 1 1

PART NO. DESCRIPTION REMARKS

1 5RB−14711−00 MUFFLER 1 1 1

2 5SJ−14718−00 PROTECTOR, MUFFLER 1 1 1

3 90111−06015 BOLT 2 2

4 90480−10332 GROMMET 2 2

5 4BH−14714−00 GASKET, MUFFLER 1 1

6 5SJ−14799−00 CAP 1 1

7 5GM−14728−00 PROTECTOR, MUFFLER 2 2 2

8 5GM−14738−00 PROTECTER, MUFFLER 3 1 1

9 5RB−14758−00 PROTECTER, SILENCER 1 1

5SJ9

5SJB

B13

16 92017−06012 BOLT, BUTTON HEAD 2 2

17 92907−06200 WASHER 2 2

18 4BD−14766−00 WASHER, PROTECTOR 4 4

19 3MT−14613−00 GASKET, EXHAUST PIPE 1 1

20 95607−08200 NUT, SELF−LOCKING 2 2

21 95817−10050 BOLT, FLANGE 3 3

22 5GM−14815−00 GASKET 1 1

23 5GM−14871−01 PIPE 1 1 1

24 5GM−14881−00 HOSE, BEND 1 1 1

25 90467−16181 CLIP 1 1

26 90467−13062 CLIP 1 1

27 95807−06020 BOLT, FLANGE 2 2

FIG. 10 EXHAUST

REF. NO.

28 5GM−14803−00 AIR INDUCTION SYSTEM ASSY 1 1

29 5GM−14882−00 HOSE, BEND 2 1 1

30 5GM−14883−00 HOSE, BEND 3 1 1

31 90467−16195 CLIP 3 3

32 5GM−13542−00 HOSE, VACUUM SENSING 1 1 1

33 90467−09006 CLIP 1 1

34 90467−07138 CLIP 1 1

35 5GM−14806−00 AIR FILTER 1 1

36 90201−06380 WASHER, PLATE 2 2

37 95807−06014 BOLT, FLANGE 2 2

38 95607−06200 NUT, SELF U−FLANGE 2 2

39 90464−11004 CLAMP 1 1

PART NO. DESCRIPTION REMARKS

5SJ9

5SJB

B14

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