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2002 Yamaha majesty YP250 5SJ Motorcycle Repair Manual

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The Yamaha Majesty YP250, model year 2002 with chassis code 5SJ, is a premium maxi-scooter celebrated for its comfortable touring ergonomics, spacious underseat storage, and smooth, reliable performance. Designed to...
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Type: Motorcycle
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2002 Yamaha majesty YP250 5SJ Motorcycle Repair Manual
The Yamaha Majesty YP250, model year 2002 with chassis code 5SJ, is a premium maxi-scooter celebrated for its comfortable touring ergonomics, spacious underseat storage, and smooth, reliable performance. Designed to cater to commuters and touring riders seeking a practical step-through motorcycle, the Majesty YP250 represents a commitment to quality and innovation in the 250cc class. Its 4-stroke, liquid-cooled, single-cylinder engine, displacing 249 cc, delivers an estimated 20-22 HP, providing ample power for urban travel and longer journeys. The scooter features a fuel-injected system for efficient operation and a continuously variable transmission (CVT) for seamless acceleration. This comprehensive workshop repair manual provides full service and repair coverage for the Yamaha Majesty YP250. It details essential maintenance procedures, including oil changes, filter replacements, and component adjustments, alongside in-depth engine overhaul instructions and troubleshooting guidance for common issues. The manual covers all major vehicle systems, such as the engine, fuel and combustion, lubrication and cooling, transmission, chassis, suspension, and electrical systems, complete with detailed wiring diagrams. Its extensive scope and technical depth, supported by clear illustrations and diagrams, make it an indispensable resource for owners, mechanics, and technicians aiming to maintain and repair the vehicle effectively.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Majesty YP250
Year:
2002
Chassis Code:
5SJ
Codes
Vin Code Region:
J
👋 Introduction
Market Position
Segment:
Premium Scooter / Maxi-Scooter
Competitive Analysis
Competitors:
Competed against other 250cc class maxi-scooters from brands like Honda (e.g., Forza), Suzuki (e.g., Burgman 250), and Kymco.
Key Features
Design Philosophy:
Yamaha's Majesty series is known for its comfortable touring ergonomics, spacious underseat storage, and smooth, reliable performance.
Target Audience:
Commuters, touring riders, and those seeking a comfortable and practical step-through motorcycle.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service and Repair
Specific Systems Covered:
Engine, Fuel System, Lubrication, Cooling, Transmission, Chassis, Electrical, Braking, Suspension, Bodywork, Frame, Wheels, Tires, Battery, Ignition, Starter, Lights, Meters, Switches, Wiring Diagrams, Troubleshooting
Page Count
Estimated Page Count:
Approximately 300-400 pages (typical for this type of manual)
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed breakdown of engine components, including cylinder head, valves, crankcase, piston, cylinder, crankshaft, transmission, and balancer. Covers removal, installation, and overhaul.
Fuel And Combustion:
Comprehensive coverage of the fuel injection system, including fuel pump, injectors, sensors, ECU, and troubleshooting. Also covers combustion system analysis.
Lubrication And Cooling:
In-depth details on the lubrication system (oil pump, passages, oil filter) and the cooling system (radiator, fan, thermostat, coolant). Includes fluid capacities and specifications.
Transmission And Drivetrain:
Covers gearbox and clutch operation, maintenance, and repair. Includes details on the transmission system and final drive.
Chassis And Suspension:
Detailed instructions for front wheel and steering system, rear wheel system, chassis components, and suspension (front forks, rear shock absorber). Includes geometry specifications.
Braking System:
Coverage of hydraulic brake systems (front and rear), including brake fluid specifications, pad replacement, caliper maintenance, and bleeding procedures.
Electrical System:
Extensive coverage of the electrical system, including battery, charging system (alternator, regulator/rectifier), ignition system, electric starter, lights, meters, switches, and detailed wiring diagrams.
Bodywork And Fixtures:
Information on fenders, exhaust pipe, body panels, frame, and general fixtures. Includes removal and installation procedures for cosmetic and structural components.
Procedures Included
Maintenance:
Covers routine maintenance, periodic checks, and adjustments, including oil changes, filter replacements, spark plug checks, drive belt inspection, and brake adjustments.
Troubleshooting:
Dedicated section for diagnosing and resolving common issues and problems across all vehicle systems, aiding in fault finding.
Engine Overhaul:
Step-by-step instructions for complete engine disassembly, inspection, measurement, and reassembly, including torque specifications for all critical fasteners.
Component Replacement:
Detailed procedures for replacing individual components such as brake pads, spark plugs, air filters, oil filters, bulbs, and drive belts.
Diagnostic Procedures:
Guidance on diagnosing issues with the fuel injection system, electrical components, and mechanical systems, including basic electrical testing.
Technical Depth
Depth:
Comprehensive. Ranges from basic maintenance and adjustments to advanced engine and transmission rebuilding, electrical diagnostics, and troubleshooting.
Diagrams And Illustrations:
Features highly detailed exploded pictures and diagrams for clear visualization of component relationships and assembly sequences.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
All pages are printable for convenient workshop use.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
Searchability
Text Search:
Typically, PDF manuals are text-searchable, allowing for quick retrieval of specific information.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, liquid-cooled, OHC, 2-valve, single cylinder
Displacement:
249 cc (249.4cc)
Bore X Stroke:
72.0 mm x 60.2 mm
Performance
Horsepower Est:
Approx. 20-22 HP @ 7500 RPM (varied by market and tuning)
Torque Est:
Approx. 22-24 Nm @ 6000 RPM (varied by market and tuning)
Fuel System
Fuel Delivery:
Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Cooling System
Cooling Method:
Liquid Cooled
Ignition System
Ignition Type:
TCI (Transistor Controlled Ignition)
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Features
Drive System:
V-belt automatic
Fluid Specifications
Cvt Oil Type:
Yamaha recommends specific CVT oil or equivalent SAE 10W-30/10W-40 API SG or higher for the transmission/final drive.
📐 Dimensions
Exterior
Length Est:
Approx. 2250 mm
Width Est:
Approx. 770 mm
Height Est:
Approx. 1385 mm
Weights
Dry Weight Est:
Approx. 170 kg
Wet Weight Est:
Approx. 185 kg (with fluids)
Fuel Capacity:
Approx. 12 Liters (including reserve)
🛡️ Safety Features
Active Features
Braking System Type:
Hydraulic disc brakes front and rear.
Front Brake:
267 mm disc brake
Rear Brake:
240 mm disc brake
Passive Features
Lighting:
Halogen headlamp, LED tail light, turn signals.
💡 Technology Features
Infotainment
Instrument Panel:
Digital speedometer, analog tachometer, fuel gauge, odometer, trip meter, indicator lights (oil, battery, temperature, turn signals, high beam).
Driver Assistance
Parking Brake:
Manual parking brake lever for added security when parked.
Connectivity
Storage:
Large underseat storage compartment, capable of holding a full-face helmet and more.
Comfort Features
Ergonomics:
Designed for comfortable riding, featuring a spacious and padded seat, floorboard-style footrests, and relaxed riding posture.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or annually. Specific intervals detailed in manual.
Air Filter Service:
Inspect every 5,000 km, replace as needed. Detailed in manual.
Spark Plug Replacement:
Replace around 10,000-20,000 km, depending on plug type. Specifics in manual.
Cvt Belt Inspection:
Inspect for wear and damage every 10,000-15,000 km. Replacement interval varies. Detailed in manual.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (SAE 10W-40) or API SG, SH, SJ, SL MA/MA2 compliant. Check manual for exact grade and capacity.
Coolant Type:
Permanent type anti-freeze coolant (ethylene glycol based), mixed with distilled water 1:1 ratio. Check manual for specific type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Check manual for exact specification and change interval.
Known Issues
Common Wear Items:
CVT belt wear, brake pad wear, suspension wear (especially rear shock), exhaust system corrosion, fuel injector clogging (less common with EFI).
Electrical Common Faults:
Battery health, charging system components (regulator/rectifier), switchgear durability, wiring harness integrity (though generally robust).
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Company is a Japanese manufacturer renowned for its motorcycles, marine products, and musical instruments, with a strong reputation for innovation and quality in motorcycling.
Model Evolution
Majesty Lineage:
The Majesty series has a long history, with the YP250 models representing a significant step in the evolution of Yamaha's maxi-scooter offerings, focusing on comfort, utility, and performance.
Production
Manufacturing Region:
Typically manufactured in Japan or other Yamaha global facilities.
🏆 Awards & Recognition
Recognitions
Market Perception:
Generally well-regarded for its reliability, comfort, and practicality within the maxi-scooter segment of its era. Often praised for its touring capabilities.
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