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Yamaha WR250FM 2021, Owner'S Service Manual


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SPECIAL TOOLS

1-14

EAM20121

SPECIAL TOOLS

The following special tools are required for accurate and complete adjustment and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and tool number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.

TIP

•

For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.

•

For others, use tool number starting with “90890-”.

Tool name/Tool No.

Illustration

Reference

pages

Digital circuit tester (CD732)

90890-03243

Model 88 Multimeter with tachometer

YU-A1927

1-13, 5-46, 8-58, 

8-59, 8-59, 8-59, 

8-62, 8-64, 8-65, 

8-66, 8-66, 8-66, 

8-67, 8-67, 8-68, 

8-69, 8-69, 8-70, 

8-70, 8-71, 8-71

Thickness gauge

90890-03268

Feeler gauge set

YU-26900-9

3-7, 4-11, 5-51

Valve lapper (ø14)

90890-04101

Valve lapper (ø14)

YM-A8998

3-8, 5-27

Yamaha diagnostic tool USB (US)

90890-03269

3-12, 7-8, 8-31

Yamaha diagnostic tool (A/I)

90890-03264

3-12, 7-8, 8-31

FI diagnostic tool sub–lead

90890-03212

FI diagnostic tool sub–lead

YU-03212

3-12, 7-8, 8-31

90890-04101

YM-A8998

Summary of Contents for WR250FM 2021

Page 1: ...Read this manual carefully before operating this vehicle 2021 OWNER S SERVICE MANUAL WR250F WR250FM LIT 11626 34 56 BAK 2819U 11...

Page 2: ...cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wea...

Page 3: ...ANUAL 2021 by Yamaha Motor Corporation U S A First edition July 2020 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 4: ...manual is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill conce...

Page 5: ...EAM20093 YAMAHA MOTOR CORPORATION U S A WR MOTORCYCLE LIMITED WARRANTY...

Page 6: ...teps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassemb...

Page 7: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Page 8: ......

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS...

Page 10: ......

Page 11: ...CONNECTING OPTIONAL PART 1 7 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARI...

Page 12: ...IN 1 31 FUEL 1 31 HANDLING NOTE 1 31 STARTING A COLD ENGINE 1 31 STARTING A WARM ENGINE 1 32 BREAK IN PROCEDURES 1 32 SHIFTING 1 32 MAINTENANCE AFTER BREAK IN 1 34 MAJOR MAINTENANCE 1 34 AIR FILTER MA...

Page 13: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 14: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 15: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Page 16: ...BELS Please read the following important labels carefully before operating this vehicle 2 4 1 3 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read...

Page 17: ...13 15 17 16 18 19 20 21 22 5 6 8 7 9 10 12 11 4 2 3 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Multi function display 5 Front brake lever 6 Throttle grip 7 Start switch...

Page 18: ...dentify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is...

Page 19: ...other foreign materials from entering the inside when the fuel hose is discon nected EAM30008 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and so...

Page 20: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Page 21: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Page 22: ...y dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct ba...

Page 23: ...ti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes...

Page 24: ...th sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All...

Page 25: ...f there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732...

Page 26: ...ing with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A192...

Page 27: ...3 27 4 57 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501...

Page 28: ...e spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 27 5 31 Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 29 Valve guide installer 5 9...

Page 29: ...eamer 4 5 mm YM 04118 5 29 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 34 Rotor puller 90890 04151 Rotor puller YM 04151 5 39 Sheave holder 90890 01903 Primary clutch holder YS 0188...

Page 30: ...haft installer pot 90890 01274 Installing pot YU 90058 5 72 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 72 Adapter M12 90890 01278 Adapter 3 YU 90063 5 72 Spacer crankshaft installer 90890 0...

Page 31: ...33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM...

Page 32: ...SPECIAL TOOLS 1 20 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 70 Tool name Tool No Illustration Reference pages...

Page 33: ...The electrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initial...

Page 34: ...is supplied by the starter knob 1 Pushing the knob toward a turns ON the start er resulting in a larger angle of throttle valve TIP When operating the throttle grip in the closing di rection the star...

Page 35: ...To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicle Install the fuel tank cap cover after placing the bands 3 all the w...

Page 36: ...ws the tire diametrical difference in percentage as the trip meter travel distance is corrected EAM30326 DESCRIPTION Operation buttons Screen display TIP The operation buttons can be pushed in the fol...

Page 37: ...s with tire wear tire pressure and course condition If the outer diameter of a tire varies with tire wear or tire pressure it can be corrected in the follow ing manner TIP The initial value is preset...

Page 38: ...RACE MODE forces the digits for tripmeter A TRIP A in BASIC MODE to be reset Changeover from BASIC MODE to RACE MODE 1 Push the SLCT1 button and SLCT2 button for 2 seconds or more at the same time to...

Page 39: ...pushing the SLCT1 button and SLCT2 button at the same time TIP If the machine is run while timer measurement is not made no change will occur to the digit in trip meter A TRIP A 4 To resume the measu...

Page 40: ...ushing the RST button for 2 seconds or more TIP If reset the travel distance display and average speed display will go on flashing for four seconds Resetting average speed AVS tripmeter A TRIP A and t...

Page 41: ...me and enter tire diameter correction mode TIP Changeover to tire correction mode will cause the timer display to change and show the dia metric digit of the tire 2 Change the digits of the travel dis...

Page 42: ...ULTI FUNCTION DISPLAY 1 30 EAM30330 FUNCTION DIAGRAM TIP The following diagram illustrates the multi function display regarding the direction and operation condi tion involved in each of its functions...

Page 43: ...in a closed ar ea The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throt...

Page 44: ...left idling for 7 minutes If the engine stops push the start switch to restart the engine 2 Make a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about...

Page 45: ...ot to shift the transmission into the neutral position 6 Open the throttle part way and gradually re lease the clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When s...

Page 46: ...and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the brac...

Page 47: ...frame Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tighten...

Page 48: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Page 49: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Page 50: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 51: ...k plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate...

Page 52: ...MOTORCYCLE CARE AND STORAGE 1 40...

Page 53: ...TIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSI...

Page 54: ...lbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 115 kg 254 lb Riding capacity 1 person Shift up points 1st 2nd 20 km h 12 mph 2nd 3rd 30 km h 19 mph 3rd 4th 40 km h 25 mph 4t...

Page 55: ...filter removal 0 75 L 0 79 US qt 0 66 Imp qt Quantity disassembled 0 95 L 1 00 US qt 0 84 Imp qt Oil filter Oil filter type Cartridge Cooling system Coolant quantity Radiator including all routes 0 9...

Page 56: ...iameter 76 955 76 970 mm 3 0297 3 0303 in Measuring point from piston skirt bottom 4 0 mm 0 16 in Piston pin bore inside diameter limit 16 043 mm 0 6316 in Piston pin outside diameter limit 15 971 mm...

Page 57: ...lter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pump type Electrical Maximum consumption amperage 2 4 A Fuel injector...

Page 58: ...measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit a...

Page 59: ...adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 11 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link su...

Page 60: ...amping Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 8 Adjustment value from the start position Hard 0 Drive chain Size 520 Ch...

Page 61: ...R Headlight Bulb type Halogen bulb Bulb wattage Headlight HS1 35 0 W 35 0 W Brake tail light LED Meter lighting EL Electroluminescent Indicator light Fuel level warning light 1 7 W Engine trouble warn...

Page 62: ...ELECTRICAL SPECIFICATIONS 2 9 Radiator fan motor fuse 5 0 A Spare fuse 15 0 A...

Page 63: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 64: ...N m 3 8 kgf m 28 lb ft Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10...

Page 65: ...sing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left sid...

Page 66: ...oth sides of the lock washers Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stat...

Page 67: ...rk protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Speed sensor bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Plate bolt M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft...

Page 68: ...0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting nut front side M10 1 55 N m 5 5 kgf m...

Page 69: ...ap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover...

Page 70: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view...

Page 71: ...ack end of the engine mounting bracket boss I Route the gear position switch lead along the crankcase without slack J Pass the gear position switch lead to the inside of the lower engine bracket the s...

Page 72: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view...

Page 73: ...the radiator G When installing the engine ground lead termi nal it can face either way Make sure that the terminal does not contact the cylinder head bolt and that it faces to the rear beyond the cyli...

Page 74: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view...

Page 75: ...e fastened at the gray tape Face the end of the plastic locking tie to the right side of the vehi cle The excess should be cut D Connect the headlight lead to the headlight E After fastening the speed...

Page 76: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view...

Page 77: ...ing the bolts is accepted E Right side of the vehicle F 10 G Install the plug cap so that it faces to the right side of the vehicle H Install the collar with its flange facing to the head of the bolt...

Page 78: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view...

Page 79: ...gative battery lead with their battery sides downward C No slack in this section D No slack to the rear side of the vehicle E Absorb the slack in this section F Connect the positive battery lead and s...

Page 80: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view...

Page 81: ...e hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that...

Page 82: ...CABLE ROUTING DIAGRAM 2 29 Front brake front view and right side view...

Page 83: ...speed sensor lead B Clamp securely the speed sensor lead to the hook of the protector C Install the front brake hose with its paint aligning with the upper end of the clamp The circumference direction...

Page 84: ...CABLE ROUTING DIAGRAM 2 31 Taillight top view and right side view...

Page 85: ...CABLE ROUTING DIAGRAM 2 32 1 Taillight lead 2 Clamp 3 Taillight A Pass the taillight lead to the groove of the rear fender B There should be no slack of the taillight lead...

Page 86: ...CABLE ROUTING DIAGRAM 2 33...

Page 87: ...G THE FUEL LINE 3 18 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 18 CHECKING THE EXHAUST SYSTEM 3 19 CHECKING THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3...

Page 88: ...G THE CHASSIS FASTENERS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICAT...

Page 89: ...l Odometer readings 600 mi 1000 km or 1 month 1800 mi 3000 km or 3 months 3000 mi 5000 km or 6 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check conditio...

Page 90: ...Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every ride 12 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease ever...

Page 91: ...runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data a...

Page 92: ...vel and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses 22 Outside nuts and bolts Retighten 23 Air filter Clean and lubricate Replace 24 Oil filter Replace 25 Engine...

Page 93: ...Swingarm Inspect lube and retighten 37 Relay arm connect ing rod Inspect lube and retighten 38 Sidestand Lubricate 39 Steering head Inspect free play and retighten Clean and lubricate Replace bearing...

Page 94: ...23 3 24 3 24 3 24 3 24 3 25 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 70 4 70 4 71 4 71 4 71 Wheels Check for excessive wear and...

Page 95: ...Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 14 3 Remove Timing mark acces...

Page 96: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field w...

Page 97: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 14 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

Page 98: ...80 185 190 195 200 205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195...

Page 99: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Page 100: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Page 101: ...Remove Holder Spark plug cap Spark plug Refer to CAMSHAFT on page 5 14 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylind...

Page 102: ...l to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1 Start the engine warm this up for several minutes and then stop the engine and wait about 5 min...

Page 103: ...a Slightly loosen the oil pressure check bolt 1 WARNING EWA19120 When the engine is started with the check bolt removed oil will spout therefore al ways loosen it before the checkup b Start the engine...

Page 104: ...clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return...

Page 105: ...hat the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oil TIP The element should be permeated with oil so that it is wet b...

Page 106: ...tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Crack damage Replace EAM30222 CHECKING THE FUEL LINE 1 Remove Seat Side cover left right Air scoop left right Ref...

Page 107: ...bolts 2 c Remove the tail pipe 3 tail pipe gasket 4 and spark arrester 5 TIP Pull the spark arrester out of the muffler d Remove the spark arrester gasket 6 e Clean the spark arrester TIP Tap the spar...

Page 108: ...wly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise...

Page 109: ...hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and s...

Page 110: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is...

Page 111: ...will consid erably reduce braking performance NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRA...

Page 112: ...en refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid m...

Page 113: ...aster cylinder cap Reservoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough br...

Page 114: ...ff the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive...

Page 115: ...g head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 37 Upper bracket Refer to STEE...

Page 116: ...ork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times...

Page 117: ...just Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the...

Page 118: ...ion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct...

Page 119: ...necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Tur...

Page 120: ...f clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWI...

Page 121: ...ll sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in...

Page 122: ...LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and...

Page 123: ...eft crankcase cover is within the firing range b on the generator rotor Incorrect firing range Check generator ro tor and crankshaft position sensor 5 Install Timing mark accessing screw EAM30339 REPL...

Page 124: ...he head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly c...

Page 125: ...ISC 4 20 REPLACING THE FRONT BRAKE PADS 4 20 REMOVING THE FRONT BRAKE CALIPER 4 22 DISASSEMBLING THE FRONT BRAKE CALIPER 4 22 CHECKING THE FRONT BRAKE CALIPER 4 22 ASSEMBLING THE FRONT BRAKE CALIPER 4...

Page 126: ...NG THE STEERING HEAD 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE RE...

Page 127: ...arks 1 Seat 1 2 Side cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 Radiator fan moto...

Page 128: ...er case cover 1 Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 2 Air scoop left 1 3 Air scoop right 1 4 Side cover right 1 5 Rear fender 1 5 4 1 3 2 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m...

Page 129: ...ect 3 Headlight unit 1 4 Speed sensor coupler 1 Disconnect 5 Multi function meter coupler 1 Disconnect 6 Indicator light coupler 1 Disconnect 7 Multi function meter 1 8 Meter bracket 1 4 2 6 7 8 5 1 3...

Page 130: ...n serting the grooves c into the ribs d of the air filter case and inserting the projection e into the slot f in the air filter case install the air scoop and secure it with the bolts EAM30459 REMOVIN...

Page 131: ...GENERAL CHASSIS 4 5 a Projection b Slot c Rib side cover d Rib rear fender a a a 1 1 c c b b d d...

Page 132: ...ge 4 45 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Speed sensor bracket 1 5 Speed sensor 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 10 Brake disc...

Page 133: ...attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the speed sensor Do not drop or shock the speed sensor or t...

Page 134: ...P After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of specification Repair replace 6 Check Collar Damage wear Replace 7 Check Bearing Fro...

Page 135: ...s marks or numbers facing outward NOTICE ECA24420 Install the bearing by pressing its outer race parallel TIP Use a socket 5 that matches the diameter of the bearing outer race and that of the oil sea...

Page 136: ...eel sensor lead for twists 3 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 4 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front whe...

Page 137: ...If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front...

Page 138: ...round 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 9 LS LS 6 4 6 1 6...

Page 139: ...2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measu...

Page 140: ...umbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install...

Page 141: ...the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel axle at this point 5 Adjust Drive ch...

Page 142: ...SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake cal...

Page 143: ...assembling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 3 4 S S S 6 N m...

Page 144: ...on bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylind...

Page 145: ...ONT BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S New N...

Page 146: ...inutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a...

Page 147: ...euse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Page 148: ...the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston d...

Page 149: ...a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluid...

Page 150: ...nder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace...

Page 151: ...per bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24470 During installation...

Page 152: ...Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any s...

Page 153: ...3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake...

Page 154: ...sassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 1 2 3 4 S BF 6 N m 0...

Page 155: ...age 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cyl...

Page 156: ...REAR BRAKE 4 30 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S New New...

Page 157: ...ush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc...

Page 158: ...l the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 a...

Page 159: ...the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston d...

Page 160: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brak...

Page 161: ...eplace 4 Check Brake hose Cracks damage wear Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubric...

Page 162: ...using leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perf...

Page 163: ...7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar ho...

Page 164: ...M30054 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower hand...

Page 165: ...lebar position 3 Tighten Lower handlebar holder nut 4 Install Clutch lever holder 1 Clutch lever 2 Clutch switch 3 TIP The clutch lever holder 1 should be installed according to the dimensions shown 5...

Page 166: ...es straight upward 7 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 8 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE...

Page 167: ...ottle grip 3 moves smoothly If it does not retighten the screws for adjustment 13 Install Rubber cover 1 Cover throttle cable housing 2 14 Install Start switch 1 Front brake master cylinder assembly 2...

Page 168: ...HANDLEBAR 4 42 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 12 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 2 5 1 4 3 4...

Page 169: ...Front brake caliper Refer to FRONT BRAKE on page 4 16 Headlight Refer to GENERAL CHASSIS on page 4 1 1 Protector 2 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch...

Page 170: ...1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 LS 15 2 8 10 12 13 5 4 1 7...

Page 171: ...t fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner t...

Page 172: ...erously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage R...

Page 173: ...r tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE...

Page 174: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper...

Page 175: ...e damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tig...

Page 176: ...ct the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube T...

Page 177: ...Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring seat with...

Page 178: ...the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure...

Page 179: ...ighten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bo...

Page 180: ...fork protector 6 Install Protector 1 Bolt protector 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Cap bolt ring wre...

Page 181: ...FRONT FORK 4 55 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1 1...

Page 182: ...page 4 1 Handlebar Refer to HANDLEBAR on page 4 37 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 43 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1...

Page 183: ...ace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c...

Page 184: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 5 Check the steering...

Page 185: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 186: ...o GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear shock absorber assembly 1 4 Locknu...

Page 187: ...er assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft 10 N m 1 0 kgf m 7 4 lb f...

Page 188: ...Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M...

Page 189: ...er be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a...

Page 190: ...ring outer race because it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bushing Stopper ring into the rear shock absorber assembly up pe...

Page 191: ...sorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting...

Page 192: ...heel off the ground Brake hose holder Refer to REAR BRAKE on page 4 27 Rear brake caliper Refer to REAR BRAKE on page 4 27 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bus...

Page 193: ...ngarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot s...

Page 194: ...SWINGARM 4 68 4 Install Rear wheel Refer to REAR WHEEL on page 4 12 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in...

Page 195: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1...

Page 196: ...ength b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Ch...

Page 197: ...OCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 13 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP...

Page 198: ...rockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engin...

Page 199: ...HEAD 5 23 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 23 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES...

Page 200: ...HE CLUTCH 5 52 SHIFT SHAFT 5 56 REMOVING THE SEGMENT 5 57 CHECKING THE SHIFT SHAFT 5 57 CHECKING THE STOPPER LEVER 5 57 INSTALLING THE SHIFT SHAFT 5 57 OIL PUMP 5 60 REMOVING THE BALANCER 5 62 CHECKIN...

Page 201: ...M20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Relief valve 7 Oil pump 8 Oil strai...

Page 202: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 203: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Oil filter element 2 Oil pump...

Page 204: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Intake camshaft 2 Exhaust camshaft...

Page 205: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Camshaft 2 Oil pressure check bolt 3 Oil pump 4 Oil filter element...

Page 206: ...BER ASSEMBLY on page 4 60 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer cap 1 9 Spark...

Page 207: ...et band using the boots band installation tool 90890 01526 YM 01526 4 6 New New New LT 11 New 10 N m 1 0 kgf m 7 4 lb ft 20 N m 2 0 kgf m 15 lb ft 30 N m 3 0 kgf m 22 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9...

Page 208: ...efer to FUEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Refer to THROTTL...

Page 209: ...on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 48 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 56 Refer to CHAIN DRIVE on page 4 69 1 En...

Page 210: ...2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 75 N m 7 5 kgf m 55 lb ft 34 N m 3 4 kgf m 25 lb ft 53 N m...

Page 211: ...e engine and remove this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lowe...

Page 212: ...hem to 10 N m 1 0 kgf m 7 4 lb ft 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respe...

Page 213: ...and rear joints are inserted in position Make sure that the exhaust pipe clamp 1 does not ride on the projection a on the ex haust pipe 2 or silencer 3 Be sure to insert the projection b into the slot...

Page 214: ...left right Refer to GENERAL CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1...

Page 215: ...crew 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 LS 5 8 3 4 1 2 7 6 5 4 4 6 M M E E E 6 N m 0 6 kgf m 4 4 lb ft...

Page 216: ...ith the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a c...

Page 217: ...p bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the wid...

Page 218: ...our fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come ou...

Page 219: ...rankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips the camshaft caps and the bolts camshaft cap TIP Before installing the clips cover the cylin...

Page 220: ...mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cylinder head co...

Page 221: ...EL TANK on page 7 1 Exhaust pipe Silencer Refer to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Ca...

Page 222: ...er head Order Job Parts to remove Q ty Remarks 6 Timing chain guide intake side 1 7 Oil passage plug 1 M 1st 3rd 4th 2nd 30 N m 3 0 kgf m 22 lb ft 15 N m 1 5 kgf m 11 lb ft 60 60 10 N m 1 0 kgf m 7 4...

Page 223: ...ECKING THE VALVE SEATS on page 5 29 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straighted...

Page 224: ...en the bolts to the specified torque in two or three steps in the proper tightening sequence as shown e Remove the one bolt according to the tightening order of the bolts f Again apply molybdenum disu...

Page 225: ...r ther according to the tightening order TIP Tighten the bolts in two steps 60 to reach the specified angle in the proper tightening se quence Total tightening angle 60 60 120 l Tighten the nuts to th...

Page 226: ...s Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem s...

Page 227: ...THE VALVE SEATS on page 5 29 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 R...

Page 228: ...ve guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide c...

Page 229: ...the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head Intake...

Page 230: ...ng compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve fa...

Page 231: ...e is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve s...

Page 232: ...ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smooth...

Page 233: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set...

Page 234: ...ift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and repla...

Page 235: ...a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is e...

Page 236: ...s face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the...

Page 237: ...e compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b Upper oil r...

Page 238: ...L CHASSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stato...

Page 239: ...stall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil asse...

Page 240: ...keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankca...

Page 241: ...ngine oil Refer to CHANGING THE ENGINE OIL on page 3 14 Clutch Refer to CLUTCH on page 5 48 1 Clutch housing 1 2 Starter clutch gear 1 3 Starter clutch assembly 1 4 Side plate 1 5 Absorber 8 6 Primary...

Page 242: ...Check Starter clutch operation a Install the starter clutch gear 1 onto the primary driven gear 2 and hold the pri mary driven gear b When turning the starter clutch gear clock wise A the starter clu...

Page 243: ...tarter clutch side 4 Install Starter clutch TIP Install the starter clutch so that the side of the starter clutch assembly with the arrow mark is toward the primary driven gear While holding the side...

Page 244: ...RIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 6 1 Starter motor lead 1 2 Starter motor 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb...

Page 245: ...r assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Washer 1 Starter motor front cover 5 Starter motor yoke 1 6 Gasket 2 7 Armature assembly 1 8 Washer 1 9 Circlip 1 10 Starter motor rear cover 1...

Page 246: ...easure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Chec...

Page 247: ...4 Install Circlip 1 Plain washer 2 Gasket 3 Washer starter motor front cover 4 Starter motor front cover 5 TIP For installation align the projections on the washer with the slots in the front cover A...

Page 248: ...h cover 1 3 Gasket 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 2 Identification color black 13 Clutch plate 7...

Page 249: ...Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 T R 18 17 16 E E E E LT E E E E 95 N m 9 5 kgf m 70 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m...

Page 250: ...NE OIL on page 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 48 1 Oil filter element cover 1 2 Oi...

Page 251: ...of specification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of sp...

Page 252: ...cation Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the...

Page 253: ...Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away from the vehi c...

Page 254: ...tification color orange 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TI...

Page 255: ...ts in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7...

Page 256: ...l 1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper...

Page 257: ...T 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOP...

Page 258: ...lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install Ro...

Page 259: ...SHIFT SHAFT 5 59 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b...

Page 260: ...ary driven gear Refer to CLUTCH on page 5 48 Right crankcase cover Refer to CLUTCH on page 5 48 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive...

Page 261: ...r 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer weight 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer drive gear 1 10 Conical washer 1 11 B...

Page 262: ...ce 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pump o...

Page 263: ...relief valve before installing the pri mary drive gear and collar 2 Install Collar 1 Balancer weight gear 2 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning...

Page 264: ...num plate a between the teeth of the balancer drive gear 9 and balancer weight gear 10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat por...

Page 265: ...OIL PUMP 5 65 A Primary drive gear side B Crankcase cover side 5 7 mm 0 02 0 28 in 5 c d 6 8 b 8 6 7 E...

Page 266: ...fer to GENERATOR on page 5 38 1 Timing chain guide stopper plate 1 2 Timing chain guide exhaust side 1 3 Timing chain 1 4 Bolt 7 L 45 mm 1 77 in 5 Bolt 3 L 60 mm 2 36 in 6 Bolt 3 L 75 mm 2 95 in 7 Rig...

Page 267: ...s Transmission Refer to TRANSMISSION on page 5 73 Shift cam Shift fork Refer to TRANSMISSION on page 5 73 1 Circlip 2 2 Oil seal 3 3 Bearing 13 1 2 3 3 3 3 3 3 3 E E E E LT 3 3 3 3 LT E LT E 3 E 1 2 2...

Page 268: ...nly on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt...

Page 269: ...oft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 4 5...

Page 270: ...AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 Transmission Refer to TRANSMISSION on p...

Page 271: ...1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3...

Page 272: ...pply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bo...

Page 273: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 66 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Sprin...

Page 274: ...1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to stra...

Page 275: ...oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 22T 2 3rd wheel gear 26T 3 4th wheel gear 24...

Page 276: ...ase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply e...

Page 277: ...k guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmissio...

Page 278: ...TRANSMISSION 5 78...

Page 279: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING...

Page 280: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left...

Page 281: ...k Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator fan 1 4 Radiator right 1 5 Radiator hose 2 1 6 Radiator...

Page 282: ...11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 10 12 13 11 New LS New New 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7...

Page 283: ...e 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for...

Page 284: ...s of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection...

Page 285: ...l Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 48 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Circlip 1 6 Washer 2 7 Impeller...

Page 286: ...e EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right cran...

Page 287: ...Gasket 2 5 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New 1 1...

Page 288: ...WATER PUMP 6 9...

Page 289: ...UEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THR...

Page 290: ...left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N...

Page 291: ...or cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the...

Page 292: ...nstall Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel...

Page 293: ...coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Throttle pos...

Page 294: ...y 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 2 2 2 11 11 11 11 13 15 14 12 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0...

Page 295: ...the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3...

Page 296: ...f the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not...

Page 297: ...sor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 70 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 31...

Page 298: ...THROTTLE BODY 7 9...

Page 299: ...8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 25 FUEL INJECTION SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 ECU SELF DIAGNOSTIC FUNCTION 8 29 TROUBLESHOOTING METHOD 8 30 YAMAHA DIAGNOSTIC TOOL 8 31 CONNECTING THE...

Page 300: ...67 CHECKING THE RECTIFIER REGULATOR 8 67 CHECKING THE SPEED SENSOR 8 68 CHECKING THE FUEL SENDER 8 68 CHECKING THE RESISTOR 8 68 CHECKING THE RADIATOR FAN MOTOR 8 69 CHECKING THE COOLANT TEMPERATURE S...

Page 301: ......

Page 302: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...

Page 303: ...egulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 22 ECU Engine Control Unit 23 Ignition coil 24 Spark plug 35 En...

Page 304: ...page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 13 NG Correct or replace the spark plug OK 5 Check the ign...

Page 305: ...coil assembly Refer to CHECKING THE STA TOR COIL on page 8 67 NG Replace the stator coil assembly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or repla...

Page 306: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Page 307: ...ry 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 22 ECU Engine Control Unit 35 Engine stop switch 36 Gear position switch 37 Diode 1 38 Starting circuit cut off r...

Page 308: ...ch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has...

Page 309: ...SSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Diode 3 5 Starting circuit cut off relay 6 Start switch 7 Diode 1 8 Clutch switch 9 Gear po...

Page 310: ...THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 67 OK Starter motor is OK Perform the electric start...

Page 311: ...rt switch Refer to CHECKING THE SWITCHES on page 8 57 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the...

Page 312: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Page 313: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse A Battery sub lead B Wire harness...

Page 314: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULA...

Page 315: ...CHARGING SYSTEM 8 14...

Page 316: ...SIGNALING SYSTEM 8 15 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM...

Page 317: ...Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 15 Warning light 17 Fuel level warning light 19 Resistor 22 ECU Engine Control Unit 26 Fuel sender 43 Multi function display 44 Speed...

Page 318: ...RGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check...

Page 319: ...el warning light bulb socket or both OK 2 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 68 NG Replace the fuel pump assembly OK 3 Check the resistor Refer to CHECKING THE RESIS TOR...

Page 320: ...LIGHTING SYSTEM 8 19 EAM20153 LIGHTING SYSTEM EAM30346 CIRCUIT DIAGRAM...

Page 321: ...20 4 Joint connector 5 Headlight relay 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 22 ECU Engine Control Unit 42 Taillight 43 Multi function display 45 Headlight A Battery sub l...

Page 322: ...FUSES on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the m...

Page 323: ...LIGHTING SYSTEM 8 22...

Page 324: ...COOLING SYSTEM 8 23 EAM20155 COOLING SYSTEM EAM30350 CIRCUIT DIAGRAM...

Page 325: ...r 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 22 ECU Engine Control Unit 28 Radiator fan motor fuse 29 Radiator fan motor 30 Radiator fan motor relay 32 Coolant temperature sens...

Page 326: ...ain relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 69 NG Replace the radiator fan moto...

Page 327: ...COOLING SYSTEM 8 26...

Page 328: ...FUEL INJECTION SYSTEM 8 27 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM...

Page 329: ...e warning light 20 Diode 2 21 Yamaha diagnostic tool coupler 22 ECU Engine Control Unit 23 Ignition coil 24 Spark plug 25 Fuel injector 27 Fuel pump 31 Intake air temperature sensor 32 Coolant tempera...

Page 330: ...rning light Engine trouble warning light indication and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switc...

Page 331: ...system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 33 4 After pushing the engine stop switch push the start switch to check w...

Page 332: ...2 Connect the FI diagnostic tool sub lead 3 Connect the FI diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub lead special tool to the battery Otherwise beca...

Page 333: ...4 5 6 1 Vehicle 2 Coupler for connecting optional part 3 FI diagnostic tool sub lead 4 Sub harness included with the Yamaha diag nostic tool 5 Vehicle communication cable included with the Yamaha diag...

Page 334: ...Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool d...

Page 335: ...of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor...

Page 336: ...ng the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sensor Ch...

Page 337: ...ensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Co...

Page 338: ...Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely...

Page 339: ...ned 86 92 displays Incorrect display range Replace the throttle position sensor Push the start switch main relay ON and then check the condition of the fault code using the malfunction mode of the Yam...

Page 340: ...nostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the faul...

Page 341: ...condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Push the start switch main r...

Page 342: ...cted Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of...

Page 343: ...ble to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or mo...

Page 344: ...ion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Imprope...

Page 345: ...on of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for app...

Page 346: ...jector Refer to CHECKING THE INJECTOR on page 8 71 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnosti...

Page 347: ...relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push th...

Page 348: ...d the engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Re...

Page 349: ...n Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Push the start switch main relay ON and then check the condition of...

Page 350: ...nd locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition...

Page 351: ...e No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Push the start switch main relay O...

Page 352: ...he fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is l...

Page 353: ...FUEL INJECTION SYSTEM 8 52...

Page 354: ...FUEL PUMP SYSTEM 8 53 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 355: ...STEM 8 54 2 AC magneto 3 Rectifier regulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 22 ECU Engine Control Unit 27 Fuel pump 35 Engine stop switch A Battery sub lead B...

Page 356: ...on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Page 357: ...Injector 4 Rectifier regulator 5 Intake air temperature sensor 6 ECU Engine Control Unit 7 Ignition coil 8 Coolant temperature sensor 9 Resistor 10 Starter relay 11 Main fuse 12 Battery 13 Radiator f...

Page 358: ...ELECTRICAL COMPONENTS 8 57 EAM30289 CHECKING THE SWITCHES Y W P Sb 2 1 3 P Sb Y W 4 1 Engine stop switch 2 Gear position switch 3 Engine start switch 4 Clutch switch...

Page 359: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Page 360: ...espective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket EAM30290 CHECKING THE FUSES The following procedure app...

Page 361: ...g caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid bat...

Page 362: ...ntact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reco...

Page 363: ...rging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the bat...

Page 364: ...gative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L G 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery...

Page 365: ...7 1 2 3 4 P L R L R W Br R W No continuity Positive tester probe Sky blue 1 Negative tester probe Green Black 2 Continuity Positive tester probe Green Black 2 Negative tester probe Sky blue 1 No conti...

Page 366: ...occurs EAM30295 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the...

Page 367: ...igital circuit tester to the crankshaft position sensor coupler b Measure the crankshaft position sensor resistance Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88...

Page 368: ...oduce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil assembly coupler from the w...

Page 369: ...tarter motor lead from the starter relay 2 Connect Fuel pump coupler 3 Push the start switch 4 Check Fuel level warning light Out of specification Replace the fuel pump EAM30360 CHECKING THE RESISTOR...

Page 370: ...sor resistance Out of specification Replace a Connect the digital circuit tester to the coolant temperature sensor b Immerse the coolant temperature sensor in a container filled with coolant TIP Make...

Page 371: ...G EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Chec...

Page 372: ...hom eter YU A1927 Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Positiv...

Page 373: ...7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF LIGHTING SYSTEM 9 11 TROUBLESHOOT...

Page 374: ...TEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil S...

Page 375: ...ace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Sympt...

Page 376: ...orque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from around cy...

Page 377: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Page 378: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Page 379: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Page 380: ...tor Faulty radiator fan motor Refer to TROUBLESHOOTING under COOLING SYSTEM on page 8 23 Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly...

Page 381: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Page 382: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Page 383: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 384: ...or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Refer to TROUBLESHOOTING under CHARGING SYSTEM on page 8 11 Symptom P...

Page 385: ...ry lead of the ignition coil 8 43 39 Injector open or short circuit detected 8 45 41 ECU built in lean angle sensor malfunction 8 46 43 Fuel system voltage incorrect voltage supplied to the main relay...

Page 386: ...Displays the fuel system volt age Approximately 12 0 V 21 Neutral switch Operate the shift pedal Gear in neutral ON Gear not in neutral OFF 25 Gear position switch Operate the shift pedal Gear in 1st...

Page 387: ...nd intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates th...

Page 388: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 389: ...1 FRONT FORK SETTING 10 1 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH...

Page 390: ...line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate othe...

Page 391: ...ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As th...

Page 392: ...t length of the spring Change the spring 2 Setting of damping force Change the rebound damping force Change the compression damping force EAM30176 CHOOSING SET LENGTH 1 Place a stand or a block under...

Page 393: ...et it 1 Use of soft spring Adjust to decrease rebound damping force to compensate for less spring load Run with the rebound damping force adjuster one or two clicks turned out and readjust it to suit...

Page 394: ...D mark SOFT 50 B3J 22212 00 Blue Green B3J 22212 10 Black 52 BR9 22212 00 Blue Yellow BR9 22212 50 Black 54 BR9 22212 10 Blue Pink BR9 22212 60 Black 56 BR9 22212 20 Blue White BR9 22212 70 Black 58 B...

Page 395: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Page 396: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Page 397: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 398: ...CHASSIS 10 9...

Page 399: ...ensor 33 Throttle position sensor 34 Intake air pressure sensor 35 Engine stop switch 36 Gear position switch 37 Diode 1 38 Starting circuit cut off relay 39 Clutch switch 40 Start switch 41 Diode 4 4...

Page 400: ......

Page 401: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Page 402: ......

Page 403: ...WR250FM 2021 WIRING DIAGRAM BAK 2819U 11_W D indd 1 2020 07 01 12 01 28...

Page 404: ...WR250FM 2021 WIRING DIAGRAM BAK 2819U 11_W D indd 2 2020 07 01 12 01 28...

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