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FRONT FORK

4-47

ate the oil, then measure the fork oil level.

CAUTION:

ECA32D1010

Add the suspension oil to the top level of in-
ner tube and deaerate the oil. If the oil is be-
low this level, each part is not lubricated and
you cannot get the desired spring perfor-

mance.

17.Measure:

●

Front fork oil level “a” (at highest pressure)
Out of specification

→

Adjust.

18.Install:

●

Fork spring “1”

●

Push rod“ 2”

●

Spring guide “3”

●

Nut “4”

●

Cap bolt

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install the nut “3” with a finger until it is

stopped.

b. Set adjusting screw “5” to the position before

disassembling.
Refer to “ADJUSTING THE FRONT FORK
LEGS” on page 1-28.

c. Tighten cap bolt “5” until it reaches nut “6” us-

ing your fingers.

d. Install the cap bolt on the outer tube, and

tighten it temporarily.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS23050

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Install:

●

Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.

NOTE:

Install the front fork so that difference “a” be-
tween the cap bolt top face and upper bracket

Oil level

105 mm (4.13 in)

1

2

3

4

Nut

15 Nm (1.5 m•kg, 11 ft•lb)

T

R

.

.

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Summary of Contents for WR250R

Page 1: ...SERVICE MANUAL WR250RX C 2008 32C 28197 10 WR250XX C LIT 11616 21 66 ...

Page 2: ......

Page 3: ...08 by Yamaha Motor Corporation U S A First edition December 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 21 66 ...

Page 4: ...is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where appli...

Page 5: ... each page 1 Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disassem bly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job ...

Page 6: ...T New BF S T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the...

Page 7: ...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 EAS20110 TABLE OF CONTENTS ...

Page 8: ......

Page 9: ...UTLINE OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 MULTI FUNCTION DISPLAY 1 4 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 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 10: ...20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 ...

Page 11: ...rating conditions of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an ...

Page 12: ...that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is required by the engine can be supplied at all times in acco...

Page 13: ... accurate tripmeter reading a stopwatch which shows the time that has been accumulated since the start of stopwatch measurement a self diagnosis device NOTE Be sure to turn the key to ON before using the SELECT 1 SELECT 2 and RESET but tons When the key is turned to ON all of the dis play segments of the multi function display will appear and then disappear in order to test the electrical circuit ...

Page 14: ...hing and holding either button will increase or decrease the digits continuously until the button is released To set the clock 1 Push the SELECT 1 button for at least two seconds 2 When the hour digits start flashing push ei ther select button to set the hours 3 Push the RESET button and the minute digits will start flashing 4 Push either select button to set the minutes 5 Push the RESET button an...

Page 15: ...nduro course map will help fa miliarize the rider with the course In addition calibrating the meter may also be necessary when using tire wheel chain sprocket sizes etc other than specified Calibrate the distance compensation tripmeter as follows To increase the reading push the SELECT 1 button To decrease the reading push the SE LECT 2 button Pushing and holding either but ton will increase or de...

Page 16: ...system Refer to FUEL INJECTION SYSTEM on page 8 29 CAUTION ECA32D1007 If the display indicates an error code the ve hicle should be checked as soon as possible in order to avoid engine damage 1 Error code display 1 ...

Page 17: ... Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts...

Page 18: ...damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives ...

Page 19: ...al times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at...

Page 20: ...ing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 62 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 51 Crankshaft installer pot 90890 01274 I...

Page 21: ...2 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 2 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 25 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 4 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 45 Tool name Tool No Illustration Reference pages YM 91044 YU 24460 01 ...

Page 22: ...Engine compression tester YU 33223 3 9 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 10 5 32 8 65 8 66 8 67 8 71 8 72 8 73 8 74 8 75 8 76 8 77 8 78 8 79 8 81 Timing light 90890 03141 Inductive clamp timing light YU 03141 3 9 Pressure gauge 90890 03153 YU 03153 7 6 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 7 6 Tool name Tool No Illustration Refere...

Page 23: ...YM 03176 7 6 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 7 Mechanical seal installer 90890 04145 6 7 Universal clutch holder 90890 04086 YM 91042 5 38 5 40 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Valve spring compressor 90890 04019 YM 04019 5 18 5 23 Tool name Tool No Illustration Reference pages ...

Page 24: ...4117 YM 04117 5 20 Valve guide reamer 4 5ø 90890 04118 YM 04118 5 20 Rotor puller 90890 04142 YM 04142 5 53 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 74 Digital tachometer 90890 06760 YU 39951 B 3 6 3 9 Yamaha bond No 1215 Three Bond No 1215 90890 85505 5 60 Tool name Tool No Illustration Reference pages ...

Page 25: ...GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 29 CABLE ROUTING 2 31 Front rear brake hose 2 39 Throttle body 2 41 Canister for California 2 43 ...

Page 26: ... 48 4 in WR250X 1190 mm 46 9 in Seat height WR250R 930 mm 36 6 in WR250X 895 mm 35 2 in Wheelbase WR250R 1420 mm 55 9 in WR250X 1425 mm 56 1 in Ground clearance WR250R 295 mm 11 61 in CAL WR250R 300 mm 11 81 in U49 WR250X 260 mm 10 24 in CAL WR250X 265 mm 10 43 in U49 Minimum turning radius 2300 mm 90 6 in Weight With oil and fuel WR250R 134 0 kg 295 lb U49 WR250R 135 0 kg 298 lb CAL WR250X 136 0 ...

Page 27: ... 59 US qt 1 32 Imp qt Without oil filter element replacement 1 30 L 1 37 US qt 1 14 Imp qt With oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 090 0 160 mm 0 0035 0 0063 in Limit 0 230 mm 0 0091...

Page 28: ...ns Intake A 34 550 34 650 mm 1 3602 1 3642 in Limit 35 450 mm 1 3957 in Intake B 25 953 26 053 mm 1 0218 1 0257 in Limit 25 853 mm 1 0178 in Exhaust A 34 850 34 950 mm 1 3720 1 3760 in Limit 34 750 mm 1 3681 in Exhaust B 25 986 26 086 mm 1 0231 1 0270 in Limit 25 886 mm 1 0191 in Camshaft runout limit 0 015 mm 0 0006 in Timing chain Model number of links 98XRH2010 118M Tensioning system Automatic ...

Page 29: ...4 500 4 512 mm 0 1772 0 1776 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 04...

Page 30: ...ke Clockwise Winding direction exhaust Clockwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Wear limit 77 100 mm 3 0354 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 10 mm 0 0039 in Diameter D 76 975 76 990 mm 3 0305 3 0311 in Height H 12 0 mm 0 47 in Offset 0 50 mm 0 0197 in Offset direction...

Page 31: ... 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 09 in End gap installed 0 10 0 40 mm 0 0039 0 0157 in Crankshaft Width A 61 95 62 00 mm 2 439 2 441 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 650 mm 0 0138 0 0256 in Balancer Balancer drive method Gear C...

Page 32: ...7 14 2 642 2nd 29 16 1 813 3rd 29 22 1 318 4th 26 25 1 040 5th 24 27 0 888 6th 22 28 0 786 Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0 050 mm 0 0020 in Shift fork thickness 4 85 mm 0 1909 in Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Foam air filter oil or engine oil Throttle ...

Page 33: ...ENGINE SPECIFICATIONS 2 8 Oil temperature 60 0 C 140 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 34: ...t 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 0 02 in Front tire Type With tube Size WR250R 80 100 21M C 51P WR250X 110 70R17M C 54H Manufacturer model WR250R BRIDGESTONE TW 301 F WR250X BRIDGESTONE BT090F RADIAL G Rear tire Type With tube Size WR250R 120 80 18M C 62P WR250X 140 70R17M C 66H Manufacturer model WR250R BRIDGESTONE TW 302 F WR250X BRIDGES...

Page 35: ...ke pedal position 11 5 mm 0 45 in Rear disc brake Disc outside diameter thickness 230 0 4 5 mm 9 06 0 18 in Brake disc thickness limit 4 0 mm 0 16 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder i...

Page 36: ...lb in 8 16 kgf mm Spring stroke K1 0 0 95 0 mm 0 00 3 74 in Optional spring available No Enclosed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm2 Spring preload adjusting positions Minimum 216 0 mm 8 50 in Standard 211 5 mm 8 33 in Maximum 206 0 mm 8 11 in Rebound damping adjusting positions Minimum 25 Standard WR250R 12 WR250X 13 Maximum 3 Compression damping adjusting positions Minimum 12 S...

Page 37: ...rcuit Model manufacturer SH678 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity DC 35 0 A Withstand voltage 200 0 V Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate amperage 0 60 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 W 55 0 W Tail brake light LED Front turn signal position ...

Page 38: ... 1 11 Ω Performance 108 116 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Built in self canceling device No Turn signal blinking frequency 75 95 cycles min Starting circuit cut off relay Model manufacturer G8R 30Y V4 OMRON Coil resistance 162 0 198 0 Ω Headlight relay Model manufacturer ACM33211 M04 MATSUSHITA Coil resistance 86 40 105 60 Ω Sidestand relay Mod...

Page 39: ...ELECTRICAL SPECIFICATIONS 2 14 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A ...

Page 40: ...mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Camshaft cap bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Cylinder head straight screw plug M12 1 28 Nm 2 8 m kg 20 ft lb Cylinder head stud bolt exhaust pipe bolt M8 2 15 Nm 1 5 m kg 11 ft lb Spark plug M10 1 13 Nm 1 3 m kg 9 4 ft l...

Page 41: ... 6 Nm 0 6 m kg 4 3 ft lb EXUP pully bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb EXUP servo motor bolt M6 2 6 Nm 0 6 m kg 4 3 ft lb EXUP servo motor cover bolt M5 2 2 Nm 0 2 m kg 1 4 ft lb Bearing cover plate bolt M6 6 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolts M6 12 10 Nm 1 0 m kg 7 2 ft lb Crankcase and holder screw M6 2 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessing screw M14 1 2 Nm 0 2 m kg 1 4 ft lb Cran...

Page 42: ... 0 m kg 7 2 ft lb Speed sensor bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator hose clamp screw 6 2 Nm 0 2 m kg 1 4 ft lb Radiator fan bolt M6 3 8 Nm 0 8 m kg 5 8 ft lb Radiator M6 1 1 10 Nm 1 0 m kg 7 2 ft lb Radiator cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Seat guide screw M6 2 7 Nm 0 7 m kg 5 1 ft lb Throttle position sensor screw M5 2 3 5 Nm 0 3...

Page 43: ...sorber nut lower M10 1 53 Nm 5 3 m kg 38 ft lb Frame and connecting rod nut M14 1 80 Nm 8 0 m kg 58 ft lb Connecting rod and relay arm nut M14 1 80 Nm 8 0 m kg 58 ft lb Relay arm and swing arm nut M14 1 70 Nm 7 0 m kg 51 ft lb Chain case bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Chain cover bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Sidestand nut M10 1 64 Nm 6 4 m kg 46 ft lb Sidestand switch screw M5 2 4 Nm 0 4 m...

Page 44: ...er cylinder bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Rear caliper protector bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear brake caliper support bolt M8 2 17 Nm 1 7 m kg 12 ft lb Rear master cylinder bracket bolt M8 2 10 Nm 1 0 m kg 7 2 ft lb Passenger footrest bolt left M8 1 23 Nm 2 3 m kg 17 ft lb Passenger footrest bolt right M8 1 30 Nm 30 m kg 22 ft lb Drive chain tensioner bolt upper lower M8 2 23 Nm 2 3 m...

Page 45: ... the lower ring nut and retighten it with the 7 Nm 0 7 m kg 5 1 ft lb torque Headlight unit bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose holder screw M5 5 2 Nm 0 2 m kg 1 4 ft lb Front drive chain guide bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Delivery pipe screw M6 2 5 Nm 0 5 m kg 3 6 ft lb Canister cover bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Item Thread size Q ty Tightening torque Remarks ...

Page 46: ...sembly crankshaft pin surface Both sliding surfaces of connecting rod big end Piston pin surface Piston surface Cylinder body inner surface Impeller shaft Oil pump assembly shaft Oil pump assembly drain port Idle gear inner diameter and end idle gear shaft and end Throttle body joint Rotor boss end surface Thrust gear surface Starter clutch assembly Rotor assembly Shaft surface crankcase bearings ...

Page 47: ... semicircular surface Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Stator assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication points Lubrication types E E E E M M E E E E Lubrication points Lubrication types Upper bearings and oil seal lip steering head Lower bearings and oil seal lip steering head Handle lower holder t...

Page 48: ... lever cable Clutch lever bolt Clutch lever Pivot shaft Swing arm bearing collar spacer and oil seal Relay arm bearing collar and oil seal Connecting rod bearing collar and oil seal Connecting rod bolt Rear shock absorber assembly lower bolt Rear wheel axle Sidestand switch Sidestand bracket and sidestand Sidestand spring and link Sidestand bolt collar Drive chain tensioner roller collar upper Lub...

Page 49: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS ...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Camshaft 2 Timing chain tensioner 3 Piston cooler 4 Oil filter 5 Main axle 6 Delivery pipe 7 Drive axle 8 Oil pump 9 Relief valve 10 Oil strainer 11 Oil pan ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil pump assembly 2 Relief valve 3 Main axle 4 Delivery pipe 5 Drive axle 6 Crankshaft 7 Oil filter 8 Oil strainer ...

Page 54: ...COOLING SYSTEM DIAGRAMS 2 29 EAS20420 COOLING SYSTEM DIAGRAMS 8 5 1 2 3 4 6 7 9 ...

Page 55: ...COOLING SYSTEM DIAGRAMS 2 30 1 Radiator cap 2 Radiator 3 Radiator inlet hose 4 Radiator outlet hose 5 Recovery tank hose 6 Cap 7 Side cover stay 8 Water pump housing cover 9 Impeller shaft ...

Page 56: ...CABLE ROUTING 2 31 EAS20430 CABLE ROUTING ...

Page 57: ... sidestand switch lead to the inside of battery band P Fasten the rear frame and sidestand switch lead using a cable tie Q Fasten the rear frame sidestand switch lead using a cable tie They must be fixed to the T stud of the rear frame Any locking position can be used R Position the recovery tank hose end between the engine bracket and down tube S Pass the clutch cable through the inside of FID ho...

Page 58: ...CABLE ROUTING 2 33 ...

Page 59: ...heir connectors in the cover E Fasten the main switch lead front brake switch lead and handlebar switch right lead using a clamp They must be placed between the front edge of the cable guide and below the H within the range of the handlebar turns from straight ahead to the fully left F Slightly pull out the end of rear brake switch lead backward G Fasten the rear brake switch lead to the frame wit...

Page 60: ...CABLE ROUTING 2 35 ...

Page 61: ... motor lead under the breather hose and pull them out C Pass the injector lead between the fuel pipe D Fasten the ECU lead using a clamp E Fasten the right and rear left turn signal light lead license plate light lead and taillight lead to the rear frame with a clamp F Fasten the right and left rear turn signal light lead license plate light lead and taillight lead to the rear frame with a cable t...

Page 62: ...CABLE ROUTING 2 37 ...

Page 63: ...ch switch lead and handlebar switch left lead through the wire guide Route the clutch cable in the top position The others can be in any position H Pass the throttle cable front brake switch lead right handlebar switch lead and main switch lead through the wire guide Place the throttle cable in the top position The others can be in any position I Route the main switch lead upward to the side of he...

Page 64: ...Front rear brake hose 2 39 Front rear brake hose ...

Page 65: ...e hose 2 Hose guide 3 Union bolt 4 Copper washer 5 Front brake caliper assembly 6 Rear brake disc 7 Rear brake caliper assembly 8 Copper washer 9 Union bolt 10 Rear brake hose 11 Rear brake master cylinder 12 Rear brake switch 13 Brake pedal ...

Page 66: ...Throttle body 2 41 Throttle body ...

Page 67: ...e of vehi cle C Face the clip holder to the right front of vehicle D Face the clip holder upward of the vehicle E Face the white paint mark backward of the vehi cle F Face the clip holder to the front side of vehicle G Align the throttle body joint with the hose clamp H Face the white paint mark to the left side of vehi cle I Insert the IST boost hose into position until it is stopped J Install th...

Page 68: ...Canister for California 2 43 Canister for California 5mm 0 20 in 4 5 ...

Page 69: ...lve canister using the clamp Install the clamp to T stud of the down tube securely G Fasten the recovery tank hose and the hose roll over canister Install the clamp to T stud of the down tube Face the lock part forward of the vehi cle H Align the paint mark with the projection of the bot tom of the roll over valve I Face the paint leftward of the vehicle J Face the clip end downward of the vehicle...

Page 70: ...Canister for California 2 45 ...

Page 71: ...E CANISTER FOR CALIFORNIA ONLY 3 17 CHECKING THE COOLANT LEVEL 3 17 CHECKING THE COOLING SYSTEM 3 17 CHANGING THE COOLANT 3 18 CHASSIS 3 20 ADJUSTING THE FRONT DISC BRAKE 3 20 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSE 3 22 CHECKING THE REAR BRAKE HOSE 3 22 ADJUSTING THE R...

Page 72: ...ELECTRICAL SYSTEM 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULB 3 33 ADJUSTING THE HEADLIGHT BEAM 3 33 ...

Page 73: ...EADINGS 600 mi 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 km or 18 months 13000 mi 21000 km or 24 months 16000 mi 26000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 7000 mi 11000 km or 12 months and there after every 6000 mi 10000 km or 12 months R...

Page 74: ...eels Check runout spoke tight ness and for damage Tighten spokes if necessary 7 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check bearing assemblies for looseness 10 Drive chain Check chain slack align ment and condition Adjust and lubricate ch...

Page 75: ...Front fork Check operation and for oil leakage Replace if necessary 19 Shock absorber assembly Check operation and for oil leakage Replace if necessary 20 Rear suspension link pivots Check operation Correct if necessary 21 Engine oil Change warm engine before draining 22 Engine oil filter ele ment Replace 23 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene ...

Page 76: ...sembly Spark plug Refer to CAMSHAFT on page 5 6 5 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 4 Air vent hose Air induction Cylinder head cover Refer to CAMSHAFT on page 5 6 6 Remove Timing mark accessing screw 1 Crankshaft end cover 2 7 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b Align TDC mark a of the generator rotor with mark b of ...

Page 77: ...n order to reach the closest equivalent to the original Remember that the replacement valve pad number is a rough value Repeat the above procedure until you have the standard valve clearance d Install the new valve pad 3 and the valve lift er 4 NOTE When installing the valve pad direct the pad having a number on it toward the lifter Lubricate the valve pad with molybdenum disulfide grease Lubricat...

Page 78: ...ession 1 Start the engine and let it warm up until it reaches the specified temperature 2 Use a temperature probe tester 1 and con tact it to the drain bolt thread 3 Install Digital tachometer Red black ignition coil leads 4 Measure Engine idling speed Out of specification Adjust 5 Adjust Engine idling speed a Adjust the engine idling speed by turning the adjust screw 1 in direction a or b 6 Adjus...

Page 79: ...nnot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut WARNING EWA12920 After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to e...

Page 80: ...cification Regap 7 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Connect Ignition coil assembly Ignition coil assembly lead NOTE Apply silicone hydrate to the sealing point of the ignition coil and install the ignition coil assembly by positioning its connector to the right 9 Install Fuel tank Refer to GENERAL CHASSIS on page 4 1 Air scoop left ...

Page 81: ...nce 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 4 Disconnect Ignition coil assembly coupler 5 Remove Ignition coil assembly Spark p...

Page 82: ...ad coupler 11 Install Fuel tank Refer to FUEL TANK on page 7 1 Air scoop left right Side cover left right Seat Refer to GENERAL CHASSIS on page 4 1 EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level T...

Page 83: ...s until the oil has settled EAS20810 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter element is also to be replaced perform the following procedure a Re...

Page 84: ...oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP AND BALANC ER GEAR on page 5 45 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil check bolt to specification EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust 2 Adjust Clutch cable free play H...

Page 85: ...Open the air filter case cover by removing its screws 4 Remove the air filter element assembly 1 by removing the clip 2 5 Remove Air filter element Remove the air filter element from the air filter element frame 6 Clean Air filter element with solvent WARNING EWA13020 Never use low flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explosion ...

Page 86: ...L CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Throttle body joint 1 Cracks damage Replace Insulator manifold 2 Cracks damage Replace 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Air scoop left right Side cover left right Seat Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel vacuum and breather hos...

Page 87: ...Refer to GENERAL CHASSIS on page 4 1 EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Remove Muffler protector 2 Check Exhaust pipe Muffler Cracks damage Replace Gasket Exhaust gas leaks Replace 3 Check Tightening torque 4 Install Muffler protector EAS21100 ADJUSTING THE EXUP CABLES 1 Remove Side cover left right Refer to GENERAL CHASS...

Page 88: ...e 2 to the position when the cable has the same tension as for pulley cable 1 e Tighten both locknuts 1 with specification f Install the EXUP valve pully cover 6 Install Side cover left right Refer to GENERAL CHASSIS on page 4 1 EAS28970 CLEANING THE SPARK ARRESTER 1 Clean Spark arrester WARNING EWA14680 Select a well ventilated area free of com bustible materials Always let the exhaust system coo...

Page 89: ...nt to the proper level CAUTION ECA13470 Adding water instead of coolant lowers the antifreeze 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 not available soft water may be used 4 Start the engine warm it up for several min utes and then turn it off 5 Che...

Page 90: ...sure Therefore do not remove the radiator cap when the en gine is 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 slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has s...

Page 91: ...er is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install Radiator cap 12 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Coolant reservoir cap 14 Start the engine warm it up for several min utes and then stop it 15 Check Coolant lev...

Page 92: ...e braking performance CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21200 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position a distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the sp...

Page 93: ...ded brake fluid to the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water d...

Page 94: ...damage wear Replace 2 Check Brake hose clamp Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 23 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch ...

Page 95: ...er level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 and place an oil pan under the vinyl hose end on one side d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake pedal a...

Page 96: ...in an intermediate position between the chain tensioner and the chain support bolt 4 Adjust Drive chain slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn the drive chain puller 3 in direction a or b until the specified drive chain slack is obtained NOTE To maintain the proper wheel alignment adjust both sides evenly Push the rear wheel forward to make sure there is no clearance b...

Page 97: ...djust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 34 Upper bracket Refer to STEERING HEAD on page 4 49 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Tighten the lower ring nut 4 with a steering nut wrench 5 c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not...

Page 98: ... times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 39 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA32D1006 Always adjust the left and right front forks evenly If this is not done the vehicle will have poor stability Securely support the vehicle so that there is no danger of it ...

Page 99: ...front fork Bleed the air from the front fork by removing bleed screw 1 CAUTION ECA32D1001 Always bleed the left and right front fork evenly If this is not done the vehicle will have poor stability 3 Install Bleed screw EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload CAUTION ECA13590 Never...

Page 100: ...minimum adjustment positions 1 Adjust Compression damping Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring length c Standard 211 5 mm 8 33 in Minimum hard 206 mm 8 11 in Maximum soft 216 mm 8 50 in 1 a b 2 c Locknut 42 Nm 4 2 m kg 30 ft lb Direction a Rebound damping ...

Page 101: ...lace the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Direction a Compression damping is increased sus pension is harder Direction b Compression damping is decreased sus pension is softer Compression damping Maximum hard 1 click s out Standard 10 click s out WR250R 7 click s out WR250X Minimum soft 12 click s out With the adjusting screw fully turned in 1 a b Loading conditi...

Page 102: ...teristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 In stall the tire with the mark p...

Page 103: ...sure to tighten the spokes before and after break in EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough m...

Page 104: ...ng parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease Recommented lubricant Lithium soap based grease ...

Page 105: ...Headlight bulb holder 1 Headlight bulb 2 4 Install Headlight bulb Fasten the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the 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 clean it with a cloth ...

Page 106: ...ELECTRICAL SYSTEM 3 34 a b a b ...

Page 107: ...ELECTRICAL SYSTEM 3 35 ...

Page 108: ...ELECTRICAL SYSTEM 3 36 ...

Page 109: ...IPER 4 18 ASSEMBLING THE FRONT BRAKE CALIPER 4 19 INSTALLING THE FRONT BRAKE CALIPER 4 19 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 20 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 20 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 21 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 21 REAR BRAKE 4 23 INTRODUCTION 4 28 CHECKING THE REAR BRAKE DISC 4 28 REPLACING THE REAR BRAKE PADS 4 28 REMOVING THE REAR B...

Page 110: ...REAR SHOCK ABSORBER 4 54 DISPOSING OF A REAR SHOCK ABSORBER 4 54 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 CHECKING THE CONNECTING ARM AND RELAY ARM 4 54 INSTALLING THE RELAY ARM 4 55 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 55 SWINGARM 4 56 REMOVING THE SWINGARM 4 57 CHECKING THE SWINGARM 4 57 INSTALLING THE SWINGARM 4 57 CHAIN DRIVE 4 59 R...

Page 111: ...eft side cover 1 3 Right side cover 1 4 Left air panel 1 5 Left air scoop 1 6 Right air panel 1 7 Right air scoop 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 112: ... bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Cap 1 For Europe 5 Front wheel assembly 1 6 Collar 1 7 Collar 1 8 Front brake disc 1 9 Wheel ring 1 Only WR250R For installation reverse the removal proce dure LT WR250X WR250R 2 4 3 4 1 5 6 8 6 6 9 T R 23 Nm 2 3 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 63 Nm 6 3 m kg 46 ft Ib T R 23 Nm 2 3 m kg 17 ft ...

Page 113: ...FRONT WHEEL 4 3 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 2 3 1 ...

Page 114: ...r Replace Refer to CHECKING THE TIRES on page 1 31 and CHECKING THE WHEELS on page 1 33 3 Check Spokes Bends damage Replace Loose Tighten Tap the spokes with a screwdriver NOTE A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten Spokes Refer to CHECKING AND TIGHTENING THE SPOKES on page 1 33 NOTE After tightening the spokes measure the front wheel runout 5 Measure ...

Page 115: ...y CAUTION ECA14130 Do not contact the wheel bearing inner race or balls Contact should be made only with the outer race NOTE Use a socket 1 that matches the diameter of the wheel bearing outer race and oil seal EAS22000 INSTALLING THE FRONT WHEEL DISC The following procedure applies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips 2 Tighten Wheel axle nut 1 Wheel axle pinch bolt CAU...

Page 116: ...FRONT WHEEL 4 6 1 ...

Page 117: ...ting bolt is tightened fully 3 Rear wheel axle 1 4 Chain puller left right 1 1 5 Drive chain 1 6 Rear wheel assembly 1 7 Collar left Dust cover 1 1 8 Collar right Dust cover 1 1 9 Rear brake disc 1 10 Rear wheel sprocket 1 For installation reverse the removal proce dure 1 2 3 4 4 5 6 6 6 6 7 8 9 10 LT T R 125 Nm 12 5 m kg 90 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 16 Nm 1 6 m kg 12 ft Ib T R 35 Nm ...

Page 118: ...REAR WHEEL 4 8 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left right 1 1 2 Bearing left right 1 1 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 1 2 3 ...

Page 119: ...FRONT WHEEL on page 4 5 EAS22100 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 4 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 1 31 and CHECKING THE WHEELS on page 1 33 3 Check Spokes Refer to CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to...

Page 120: ...FRONT WHEEL on page 4 5 EAS22160 INSTALLING THE REAR WHEEL DISC 1 Install Brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 28 2 Lubricate Wheel axle Oil seal lips 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 1 26 4 Tighten Wheel axle nut Rear wheel sprocket self locking nut 35 Nm 3 5 m kg 25 ft lb Recommended lubricant Lithium soap based grease T R New Driv...

Page 121: ...in plug 1 WR250X only 2 Front brake caliper support bolt 1 3 Front brake caliper assembly 1 4 Brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure 1 2 2 3 4 5 S S WR250X T R 23 Nm 2 3 m kg 17 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 2 5 Nm 0 25 m kg 1 8 ft Ib ...

Page 122: ...er washer 2 6 Front brake hose 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm holder 1 9 Brake master cylinder reservoir diaphragm 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder 1 For installation reverse the removal proce dure S 1 2 3 4 5 6 7 8 9 10 11 S S T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 123: ...FRONT BRAKE 4 13 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 For assembly reverse the disassembly pro cedure 1 ...

Page 124: ...5 Pin plug 1 Only WR250X 6 Front brake caliper support bolt 1 7 Brake pad 2 8 Brake pad spring 2 9 Front brake caliper assembly 1 10 Front brake caliper bracket 1 For installation reverse the removal proce dure S 5 6 6 9 7 8 10 1 4 S 2 3 T R 2 5 Nm 0 25 m kg 1 8 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg...

Page 125: ...ake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 2 3 4 S S BF BF T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 126: ...SC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 2 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that...

Page 127: ...nstall new brake pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Install Brake pad pins Brake pad clips Brake pad co...

Page 128: ... brake fluid carefully EAS22320 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons 1 Brake caliper dust seals 2 Brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake cali...

Page 129: ...caliper bracket Front brake caliper temporarily Copper washers Brake hose Union bolt WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 30 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Install Front brake caliper Brake pad sp...

Page 130: ...on page 1 22 Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 1 25 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Brake switch coupler 1 from the brake master cylinder 2 Remove Union bolt Copper washers Brak...

Page 131: ...ower bolt 2 Install Copper washers 1 Brake hose 2 Union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 30 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessa...

Page 132: ...ock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 1 25 5 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 1 23 6 Check Brake lever fr...

Page 133: ...WHEEL on page 4 7 1 Protector 1 2 Pin plug 1 3 Brake pad support bolt 1 4 Rear brake pad 2 5 Pad shim 2 6 Insulator 2 7 Rear brake pad spring 1 8 Rear brake caliper assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 5 6 6 7 8 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 2 5 Nm 0 25 m kg 1 8 ft Ib ...

Page 134: ...on bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Plain washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 7 5 8 6 9 10 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 135: ...EAR BRAKE 4 25 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder kit 1 For assembly reverse the disassembly pro cedure S 1 T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 136: ...R BRAKE on page 4 23 1 Union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Pin plug 1 5 Brake caliper support bolt 1 6 Rear brake pad assemblyl 2 7 Rear brake caliper bracket 1 8 Brake pad spring 2 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 8 9 S T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 2 5 Nm 0 25 m kg 1 8 ft Ib ...

Page 137: ...brake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 2 3 4 S BF T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 138: ...ing Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 16 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 16 5 Adjust Brake disc deflection Refer to CHECKING...

Page 139: ...CHECKING THE BRAKE FLUID LEVEL on page 1 23 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 1 25 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt Copper washers Brake hose NOTE Put the end of the brake hose into ...

Page 140: ...e caliper brackets Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals...

Page 141: ...vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 1 25 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 1 23 7 Check Brake...

Page 142: ...inder cup Master cylinder piston 2 Install Spring 1 Master cylinder piston 2 Adjusting rod 3 Circlip 4 Dust boot 5 EAS22750 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hoses Union bolt WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CA BLE ROUTING on page 2 30 CAUTION ECA32D1002 When installing the brake hose onto the ...

Page 143: ...fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 1 25 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on p...

Page 144: ...6 Throttle cable housing 1 7 Throttle cable 2 8 Throttle grip 1 9 Clutch cable 1 10 Clutch switch 1 11 Clutch lever holder 1 12 Clutch lever 1 13 Left handlebar switch 1 14 Handlebar grip 1 15 Special washer 1 16 Handlebar upper holder 2 17 Handlebar 1 18 Handlebar lower holder 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 16 T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m k...

Page 145: ...ce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 16 T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 146: ...ighten a bent handle bar as this may dangerously weaken it EAS22921 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar 1 Upper handlebar holders 2 NOTE Align the punch marks a on the handlebar with the upper surface of the lower handlebar holders The upper handlebar holders ...

Page 147: ...nstall Throttle grip 1 Throttle cable housing 2 Throttle cables 3 NOTE Align projection a of slot cable housing with hole b of the handlebar Slightly coat the end of slot cable and inside of throttle grip with lithium soap based grease Then mount the throttle grip onto the handle bar 7 Install Right handlebar switch 1 NOTE Align projection a of the right handlebar switch with hole b of the handleb...

Page 148: ... to ADJUSTING THE CLUTCH CA BLE FREE PLAY on page 1 14 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 1 8 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Throttle cable free play 3 0 5 0 mm 0 12 0 20 in a 2 1 ...

Page 149: ...ose holder 2 3 Front brake caliper 1 4 Upper bracket pinch bolt 2 Loosen 5 Front fork cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 150: ...t 1 7 Spring guide 1 8 Dust seal 1 9 Stopper ring 1 10 Base valve 1 11 Copper washer 1 12 O ring 2 13 Damper rod 1 14 Outer tube 1 15 Oil seal 1 16 Oil sealWasher 1 17 Slide metal 1 18 Piston metal 1 19 Inner tube 1 20 Rubber cap 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 LT 20 T R 30 Nm 3 0 m kg 22 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 151: ... the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 LT 20 T R 30 Nm 3 0 m kg 22 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 152: ...sening the upper and lower brack et pinch bolts support the front fork leg 3 Remove Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from outer tube by loosening the nut 2 2 Remove Nut Spring guide Push rod Front fork spring Spring guide 3 Drain Fork oil NOTE Drain the fork oil by stroking the inner tube se...

Page 153: ...G EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air 4 Check Base valve Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air 5 Check Push rod Bends damage wear R...

Page 154: ...N ECA14210 Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Install O ring 1 Copper washer Base valve 2 4 Tighten Base valve 1 NOTE While holding the damper rod assembly 3 with the damper rod holder 2 tighten the base valve 5 Install Dust seal 1 Sto...

Page 155: ...polyethyl ene bag b and mount the oil seal 6 Install Piston metal 1 on the inner tube 7 Install Outer tube 1 on the inner tube 2 8 Install Slide metal 1 Oil washer 2 on the outer tube using fork seal driver 3 9 Install Oil seal 1 Using fork seal driver 2 hammer the seal until you see the stopper ring slot of outer tube 1 2 3 4 5 6 a New New New Fork seal driver 90890 01442 Adjstable fork seal driv...

Page 156: ...disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 14 When the front fork is filled with oil slowly move dumper rod 1 up and down at least 10 times for lubrication of fork NOTE Move dumper rod slowly not to leak the fork oil 15 Slowly move the inner tube up and down for lubrication again 1 stroke Approx 250 mm NOTE Do not move more than 250 m...

Page 157: ... 3 with a finger until it is stopped b Set adjusting screw 5 to the position before disassembling Refer to ADJUSTING THE FRONT FORK LEGS on page 1 28 c Tighten cap bolt 5 until it reaches nut 6 us ing your fingers d Install the cap bolt on the outer tube and tighten it temporarily EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front...

Page 158: ... 3 WARNING EWA32D1003 Check to see that the brake hose is installed correctly Refer to CABLE ROUTING on page 2 30 5 Adjust Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 1 28 Lower bracket pinch bolt 20 Nm 2 0 m kg 14 ft lb Cap bolt 30 Nm 30 m kg 22 ft lb Upper bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb a T R T R T R 1 2 3 ...

Page 159: ...ge 4 39 1 Brake hose guide 1 2 Headlight assembly 1 3 Headlight coupler 1 Disconnect 4 Meter assembly coupler 3 Disconnect 5 Front turn signal light connector left right 2 2 Disconnect 6 Meter assembly 1 7 Turn signal light left right 1 1 8 Front fender 1 9 Brake hose guide 1 For installation reverse the removal proce dure 1 2 3 4 5 5 6 4 7 7 8 9 4 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9...

Page 160: ...ut 1 4 Upper bracket 1 5 Special washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Bearing cover 1 11 Upper bearing 1 12 Lower bearing 1 13 Bearing races 2 For installation reverse the removal proce dure 2 3 4 5 6 7 8 9 10 11 12 13 13 1 2 T R 120 Nm 12 0 m kg 87 ft Ib 38 Nm 3 8 m kg 27 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Loosen fully T R 1st 2nd T R 20 Nm 2 0 m kg 14 ...

Page 161: ... Bearing races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new bearing races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set 4 Check Upper bracket Lowe...

Page 162: ...all Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 39 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Steering stem nut 120 Nm 12 0 m kg 87 ft lb 3 2 1 4 T R ...

Page 163: ...VE on page 4 59 1 Rear shock absorber assembly 1 2 Connection rod 1 3 Relay arm 1 4 Collar short 1 5 Collar long 1 6 Oil seal 4 7 Bearing 2 8 Collar 1 9 Oil seal 2 10 Bearing 2 11 Collar 1 12 Bearing 1 13 Oil seal 2 For installation reverse the removal proce dure 2 3 1 4 5 6 6 6 7 7 8 9 9 10 10 11 12 13 13 LS LS LS LS LS LS LS LS T R 53 Nm 5 3 m kg 38 ft Ib T R 80 Nm 8 0 m kg 58 ft Ib T R 80 Nm 8 ...

Page 164: ...s end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Connecting arm bolt 1 Re...

Page 165: ...ting rod Nut Relay arm and connecting rod Nut Relay arm and swingarm Nut Rear shock absorber assembly lower and Relay arm Recommended lubricant Lithium soap based grease Installed depth connecting rod bearing a 5 0 5 5 mm 0 20 0 22 in Installed depth rear cushion low er bearing b 4 0 mm 0 16 in Installed depth relay arm bear ing c 6 mm 0 24 in Installed depth connecting rod oil seal relaly arm oil...

Page 166: ...1 4 Chain cover 1 5 Chain support 1 6 Pivot shaft nut 1 7 Pivot shaft 1 8 Swingarm 1 9 Dust cover 2 10 Front drive chain guide 1 11 Collar 2 12 Oil seal 2 13 Bearing 4 For installation reverse the removal proce dure 2 2 3 4 5 6 7 8 9 9 10 11 11 12 12 13 13 13 13 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 2 Nm 0 2 m kg 1 4 ft Ib T R 85 Nm 8 5 m kg 62 ft Ib T R 70 Nm 7 0 m kg 51 f...

Page 167: ...p and down If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm 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 Pivot shaft Dust covers Collar Washers Bearings 4...

Page 168: ...R WHEEL on page 4 7 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 1 26 Installed depth a 15 mm 0 59 in Installed depth b 8 5 9 0 mm 0 33 0 35 in Installed depth c 0 0 5 mm 0 0 02 in Pivot shaft nut 85 Nm 8 5 m kg 62 ft lb Drive chain slack WR250R 38 0 48 0 mm 1 50 1 89 in WR250X 40 0 50 0 mm 1 57 1 97 in a b c b c a c b a c b a 1 1 2 T R ...

Page 169: ...on page 4 56 1 Drive sprocket cover 1 2 Drive sprocket nut 1 3 Drive sprocket 1 4 Drive chain 1 5 Drive chain tensioner top 1 6 Drive chain tensioner bottom 1 For installation reverse the removal proce dure 1 2 3 4 5 6 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 95 Nm 9 5 m kg 69 ft Ib ...

Page 170: ...E CHAIN 1 Measure 15 link section a of the drive chain Out of specification Replace the drive chain a Measure the length a between the inner sides of the pins and the length b between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length c of the 15 link section of the drive chain using the following formula Drive chain 15 link sect...

Page 171: ...mage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear Replace the drive chain 5 Lubricate Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 9 EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET o...

Page 172: ...E CHAIN SLACK on page 1 26 CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack WR250R 38 0 48 0 mm 1 50 1 89 in WR250X 40 0 50 0 mm 1 57 1 97 in 1 ...

Page 173: ... THE VALVE SEATS 5 20 CHECKING THE VALVE SPRINGS 5 22 CHECKING THE VALVE LIFTERS 5 23 INSTALLING THE VALVES 5 23 CYLINDER AND PISTON 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDER AND PISTON 5 26 CHECKING THE PISTON RINGS 5 27 CHECKING THE PISTON PIN 5 27 INSTALLING THE PISTON AND CYLINDER 5 28 STARTER MOTOR 5 30 CHECKING THE STARTER MOTOR 5 32 ASSEMBLING THE STARTER MOTOR 5 33 CLUTCH 5 34 RE...

Page 174: ...UTCH 5 54 INSTALLING THE GENERATOR 5 54 CRANKCASE 5 56 DISASSEMBLING THE CRANKCASE 5 59 CHECKING THE TIMING CHAIN TIMING CHAIN GUIDE OIL STRAINER NOZZLE DELIVERY PIPE 5 59 CHECKING THE CRANKCASE 5 59 ASSEMBLING THE CRANKCASE 5 59 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 61 REMOVING THE CRANKSHAFT ASSEMBLY 5 62 CHECKING THE CRANKSHAFT ASSEMBLY 5 62 INSTALLING THE CRANKSHAFT ASSEMBLY 5 62 TRANSMISSI...

Page 175: ... CHASSIS on page 4 1 1 Muffler protector 1 2 EXUP pulley cover 1 3 Side cover right stay 1 4 EXUP cable 2 5 Muffler 1 6 Exhaust pipe 1 7 Exhaust pipe gasket 1 8 Muffler gasket 1 For installation reverse the removal proce dure 2 3 4 5 6 7 8 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m ...

Page 176: ...ket nut 1 5 Drive sprocket 1 6 Speed sensor coupler 1 Disconnect 7 Coolant temperature sensor coupler 1 Disconnect 8 Generator coupler 2 Disconnect 9 Crankshaft position sensor coupler 1 Disconnect 10 Horn lead coupler 1 Disconnect 11 Fuse box 1 12 Side cover stay 1 13 Ground lead 1 14 Neutral switch lead 1 Disconnect 15 Ignition coil lead coupler 1 Disconnect 95 Nm 9 5 m kg 69 ft Ib 1 2 3 4 5 6 7...

Page 177: ... removal proce dure Removing the shift pedal leads and hoses Order Job Parts to remove Q ty Remarks 95 Nm 9 5 m kg 69 ft Ib 1 2 3 4 5 6 7 8 9 10 11 12 15 13 14 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 178: ...mounting bolt front upper 1 2 Engine mounting bolt front 1 3 Engine mounting bolt front lower 1 4 Down tube bolts front upper 2 5 Down tube bolts rear lower 2 6 Down tube 1 7 Pivot shaft 1 8 Engine assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 T R 85 Nm 8 5 m kg 62 ft Ib T R 67 Nm 6 7 m kg 48 ft Ib T R 56 Nm 5 6 m kg 41 ft Ib T R 113 Nm 11 3 m kg 82 ft Ib ...

Page 179: ...de Engine mounting nut EAS32D1009 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal NOTE Install the shift pedal so that pedal top face a is 5 mm 0 20 in lower than the footrest top face Pivot shaft nut 85 Nm 8 5 m kg 62 ft lb Downtube nut rear lower side 113 Nm 11 3 m kg 82 ft lb Downtube nut front upper side 113 Nm 11 3 m kg 82 ft lb Engine mounting nut front lower side 56 Nm 5 6 m kg 41 ft lb En...

Page 180: ...OLANT on page 3 18 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Throttle cable 2 2 Throttle body 1 3 Clutch cable 1 Disconnect 4 Ignition coil coupler 1 Disconnect 5 Cylinder head cover breather hose 1 6 Ignition coil assembly 1 7 Spark plug 1 8 Cylinder head cover 1 9 Cylinder head cover gasket 1 For installation reverse the removal proce dure 1 2 9 4 5 6 7 3 8 T R 13 Nm 1 3 m...

Page 181: ...end cover 1 3 Timing chain tensioner assembly 1 4 Camshaft cap 1 5 Dowel pin 2 6 Camshaft IN 1 7 Camshaft EX 1 8 Camshaft sprocket IN 1 9 Camshaft sprocket EX 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 M M T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib E E ...

Page 182: ...linder head cover 4 Loosen Camshaft sprocket bolt 5 Remove Timing chain tensioner assembly Gasket 6 Remove Camshaft cap bolts Camshaft cap CAUTION ECA32D1006 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in satages and in order from 1 to 8 7 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To prevent the timing chain from falling into the crankcase...

Page 183: ...ap Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft lobe dimension limit Intake A 34 550 34 650 mm 1 3602 1 3642 in Limit 35 450 mm 1 3957 in Intake B 25 953 26 053 mm 1 0218 1 0257 in Limit 25 853 mm 1 0178 in Exhaust A 34 850 34 950 mm 1 3720 1 3760 in Limit 34 750 mm 1 3681...

Page 184: ...Check Timing chain tensioner Cracks damage Replace a Using a finger push and insert timing chain tensioner rod 1 into the timing chain tensioner housing NOTE Push the timing chain tensioner rod in direction a and turn the timing chain tensioner body 2 in direction b until it stops b Keep pressing the timing chain tensioner rod mount clip 3 into groove 4 and lock the timing chain tensioner rod c Pu...

Page 185: ... the crankshaft counterclockwise b When piston is at TDC on the compression stroke align the mark a on the generator ro tor with the mark b on the crankcase cover c Install the timing chain onto both camshaft sprockets and then install the exhaust cam shaft onto the cylinder head first NOTE Locate mark c of exhaust system camshaft chain sprocket 1 and mark d of intake system camshaft chain sprocke...

Page 186: ... 5 Install Timing chain tensioner a Using a finger push and insert timing chain tensioner rod 1 into the timing chain tensioner housing NOTE Push the timing chain tensioner rod in direction a and turn the timing chain tensioner body 2 in direction b until it stops b Keep pressing the timing chain tensioner rod mount clip 3 into groove 4 and lock the timing chain tensioner rod c In the status of st...

Page 187: ... is in the compression pro cess align TDC mark a of the rotor with mark b of crankshaft case cover NOTE You can check the TDC in compression process when the camshaft robes face outward Punch mark on the camshaft Check the matching of stamp line c of the camshaft punch mark timing chain sprocket and the cylinder head end Out of alignment Reinstall Refer to the installation steps above 8 Measure Va...

Page 188: ...Hose thermostat cover Refer to THERMOSTAT on page 6 4 Coolant temperature sensor coupler Thermostat Air induction pipe Refer to AIR INDUCTION SYSTEM on page 7 9 1 Cylinder head assembly 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure 1 2 3 3 E E M M T R 40 Nm 4 0 m kg 29 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E ...

Page 189: ...r jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sandi...

Page 190: ...er head bolts M10 155 2 Cylinder head bolts M6 60 3 NOTE Lubricate the cylinder head bolts with engine oil Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages Cylinder head bolt M10 40 Nm 4 0 m kg 29 ft lb Cylinder head bolt M6 10 Nm 1 0 m kg 7 2 ft lb M M New 4 4 4 1 2 2 T R d a c b e f 1 3 1 2 ...

Page 191: ...remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 14 1 Valve lifter 4 2 Valve pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Exhaust valve 2 7 Intake valve 2 8 Valve stem seal 4 9 Valve spring seat 4 For installation reverse the removal proce dure 1 1 2 2 3 3 4 4 5 5 6 7 8 8 9 9 M M M ...

Page 192: ...eakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 20 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 4 Re...

Page 193: ...de remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valve guide cle...

Page 194: ...KING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head Valve guide remover ø4 5 90890 04116 YM 04116 Valve guide installer ø4 5 90890 04117 YM 04117 Valve guide reamer ...

Page 195: ...eplace the valves without lapping the valve seats and valve faces When replacing the valves or valves guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c ...

Page 196: ...pring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring free length Free length intake 36 03 mm 1 42 in Limit 34 23 mm 1 35 in Free length exhaust 36 03 mm 1 42 in Limit 34 23 mm 1 35 in a Compressed valve spring force b Installed length Installed compression spring force ...

Page 197: ...eal 2 with the recommended lubricant 3 Install Valve 1 Spring seat 2 Valve stem seal 3 Valve spring 4 Valve spring retainer 5 onto the cylinder head NOTE Make sure each valve is installed in its original place Refer to the following embossed marks Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring wit...

Page 198: ...3800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad 1 Valve lifter 2 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Molybdenum disulfide oil 1 2 M 1 2 ...

Page 199: ...ove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 14 1 Cylinder 1 2 Dowel pin 2 3 Water pipe 1 4 O ring 1 5 Cylinder gasket 1 6 Piston pin clip 2 7 Piston pin 1 8 Piston 1 9 Piston ring set 1 For installation reverse the removal proce dure 1 2 2 3 4 5 6 6 7 8 9 E E E T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 200: ... AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore D with the cylinder bore gauge NOTE Measure cylinder bore D by taking side to side and front to back measurements of the cylinder Then find the average of the measurements b If out of...

Page 201: ...end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings EAS24440 CHECKING THE PISTON PIN 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin Piston to cylinder clearance Cylinder bore D Piston skirt diameter P Piston ...

Page 202: ... Dowel pins 2 O ring 3 3 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil the piston pin Make sure the mark a on the piston points to wards the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16...

Page 203: ...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 Recommended lubricant Engine oil a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm Cylinder bolt 10 Nm 1 0 m kg 7 2 ft lb 1 2 3 New a T R ...

Page 204: ... Remarks Seat Air scoop left ritht Refer to GENERAL CHASSIS on page 4 1 EXUP cable Exhaust pipe Muffler Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For assembly reverse the disassembly pro cedure 1 2 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 205: ... motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Lock washer 1 3 Armature assembly 1 4 Starter motor yoke 1 5 Starter motor rear cover 1 6 Brush holder set 1 For assembly reverse the disassembly pro cedure 1 2 3 4 5 6 ...

Page 206: ... commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica u...

Page 207: ...n the brush seat with the slot in the starter motor rear cover 2 2 Install Thrust support 1 NOTE Align the tab of thrust support with the slot of sta tor motor front cover 2 3 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks on the starter motor yoke with the match marks on the starter motor front cover a and starter motor rear cover b ...

Page 208: ...Water pump housing cover 1 3 Gasket 1 4 Oil cleaner element cover 1 5 Oil cleaner element 1 6 Cover 1 7 Clutch cover 1 Remove the clutch cover only if you do not remove the primary drive gear 8 Clutch cover gasket 1 9 Dowel pin 2 10 Crankcase cover right 1 11 Crankcase cover right gascket 1 12 Water pipe 1 13 O ring 1 14 Dowel pin 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 209: ...the removal proce dure Removing the clutch cover Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 210: ...e gear nut 1 8 Lock washer 1 9 Clutch boss nut 1 10 Lock washer 1 11 Clutch boss 1 12 Thrust washer 1 13 Clutch housing 1 14 Ball 1 15 Clutch push rod 1 16 Primary drive gear 1 For installation reverse the removal proce dure 2 3 4 5 5 1 5 6 7 8 9 10 11 12 13 14 15 16 E E T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 80 Nm 8 0 m kg 58 ft Ib T R 75 Nm 7 5 m kg 54 ft Ib E ...

Page 211: ...e sprocket cover Refer to ENGINE REMOVAL on page 5 1 Clutch Refer to CLUTCH on page 5 34 1 Clutch cable 1 2 Clutch cable holder 1 3 Push lever shaft 1 4 Push lever spring 1 5 Oil seal 1 6 Bearing 1 For installation reverse the removal proce dure 1 2 3 4 5 6 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 212: ...ary drive gear nut EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies ...

Page 213: ...H BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch operation 2 Check Primary driven gear Damage wear Replace the primary drive and clutch housing as a set Excessive noise during operation Replace the primary drive and clutch housing as a set EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 C...

Page 214: ... NOTE Align the lock washer projection with the clutch boss slit during assembling Install the primary drive gear by facing its flat face toward the crankcase 2 Tighten Clutch boss nut 1 NOTE While holding the clutch boss 3 with the univer sal clutch holder 2 tighten the clutch boss nut 3 Bend the lock washer tab along a flat side of the nut 4 Tighten Primary drive gear nut 1 NOTE Insert aluminum ...

Page 215: ... becomes hard in the position where the marks match 12 Adjust Push lever position a Loosen locknut 2 of push rod 1 b Return or tighten push rod 1 until the mark of push lever matches the mark of clutch ca ble holder c Hold the push rod not to move it and tighten the push rod locknut 13 Install Water pipe 1 O ring 2 Dowel pin 3 Crankcase cover right gascket 4 Crankcase cover right 5 NOTE Tighten bo...

Page 216: ...p housing cover Refer to WATER PUMP on page 6 6 16 Fill Crankcase with the specified amount of the engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 17 Fill Cooling system with the specified amount of the the coolant Refer to CHANGING THE COOLANT on page 3 18 18 Install Brake spring 5 3 4 1 2 3 New New ...

Page 217: ...er to ENGINE REMOVAL on page 5 1 Clutch housing Refer to CLUTCH on page 5 34 1 Shift shaft 1 2 Plate washer 1 3 Stopper lever spring 1 4 Circlip 1 5 Plate washer 1 6 Stopper lever 1 7 Spacer 1 8 Shift shaft spring 1 9 Stopper screw 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 E E E 9 LT T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 218: ... LEVER 1 Check Stopper lever Bends damage Replace Roller turns roughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft 1 Shift shaft spring 2 Stopper lever 3 Stopper lever spring NOTE Hook the ends 4 of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly 1 2 3 4 ...

Page 219: ...to SHIFT SHAFT on page 5 43 1 Balancer weight gear nut 1 2 Lock washer 1 3 Balancer weight gear 1 4 Straight key 1 5 Absorber plate 1 6 Balancer drive gear 1 7 Straight key 1 8 Circlip 1 9 Plain washer 2 10 Idle gear 1 11 Gasket 1 12 Oil pump assembly 1 13 Dowel pin 2 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 11 12 13 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 50 Nm 5 0 m kg 36 ft...

Page 220: ...ts to remove Q ty Remarks 1 Pump cover 1 2 Outer rotor 1 3 Inner rotor 1 4 Dowel pin 1 5 Plain washer 1 6 Driven gear 1 7 Circlip 1 8 Relief valve assembly 1 9 Oil pump housing 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 E T R 2 Nm 0 2 m kg 1 4 ft Ib ...

Page 221: ... rotor to oil pump housing clearance b Oil pump housing to inner rotor and out er rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 1 2 1 Inner rotor to outer rotor tip clearance...

Page 222: ...slot b of the buffer boss Install the dowel pin on the spring as shown 3 Install Drive gear 1 Balancer weight gear 2 Lock washer 3 Balancer weight gear nut 4 NOTE Align mark a of the drive gear with mark b of the balancer shaft weight gear during assem bling 4 Tighten Primary drive gear nut Refer to CLUTCH on page 5 34 5 Tighten Balancer weight gear nut 1 NOTE Insert aluminum plate a between drive...

Page 223: ...OIL PUMP AND BALANCER GEAR 5 49 6 Install Be sure to bend the lock washer tab along to the nut side face 1 2 3 a ...

Page 224: ...ge 4 1 1 Crankshaft position sensor coupler Stator assembly coupler 1 1 2 Timing mark accessing screw 1 3 Crankshaft end cover 1 4 Crankcase cover left 1 5 Crankcase cover gascket left 1 6 Dowel pin 1 7 Stator assembly 1 8 Damper assembly 1 9 Starter idle gear shaft 1 10 Starter idle gear 1 11 Generator rotor 1 12 Woodruff key 1 13 Starter clutch gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LT LT...

Page 225: ... 1 16 Starter clutch assembly 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LT LT E E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib ...

Page 226: ...ssembling the damper assembly Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Limiter disc 1 3 Starter reduction gear 1 4 Limiter disc 1 5 Outer torque limiter 1 6 Circlip 1 For installation reverse the removal proce dure 1 2 3 4 5 6 M ...

Page 227: ...Starter clutch gear Damage pitting wear Replace the starter clutch gear 4 Check Damper assembly Damage pitting wear Replace the damper assembly Check the gear of the starter motor armature 5 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the ...

Page 228: ... the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly sealed in the key way of the crankshaft 2 Tighten Generator rotor nut 1 NOTE While holding the generator rotor 3 with the sheave holder 2 tighten the generator rotor bolt Do not allow the sheave holder to touch the projection on the generator rotor 3 Install Starter idler gears 4 ...

Page 229: ...GENERATOR AND STARTER CLUTCH 5 55 1 2 ...

Page 230: ...AR on page 5 45 Shift shaft Refer to SHIFT SHAFT on page 5 43 Oil pump Balancer gear Refer to OIL PUMP AND BALANCER GEAR on page 5 45 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 50 1 Timing chain guide intake side 1 2 Stopper guide plate 1 3 Timing chain guide exhaust side 1 4 Timing chain 1 5 Speed sensor 1 6 Neutral switch 1 7 Delivery pipe 1 1 2 3 4 5 6 7 8 9 9 10 11 12 LT L...

Page 231: ...on reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 9 10 11 12 LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LT ...

Page 232: ... BALANCER SHAFT on page 5 61 Transmission assembly Refer to TRANSMISSION on page 5 64 1 Bearing cover plate 1 2 Bearing cover plate 2 3 Stopper plate 2 4 Oil seal 2 5 Bearing 7 6 Needle bearing 2 For installation reverse the removal proce dure 1 2 3 4 5 5 5 5 6 6 LT LT LT E E E E E E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 233: ...IVERY PIPE 1 Check Timing chain Stiffness Replace the camshaft sprocket timing chain and crankshaft sprocket as a set 2 Check Timing chain guide Damage wear Replace 3 Check Oil strainer Obstruction Blow out with compressed air Cracks damage Replace 4 Check Nozzle Delivery pipe Obstruction Blow out with compressed air Bends cracks damage Replace EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the...

Page 234: ... left crankcase NOTE Turn the shift drum segment as shown so that the shift drum segment teeth do not contact the crankcase during its assembling Tighten the bolts in a crisscross pattern in two 2 stages with 1 4 turn each Yamaha bond No 1215 Three Bond No 1215 90890 85505 Crankcase bolt 10 Nm 1 0 m kg 7 2 ft lb 4 3 1 2 T R 1 M6 90 mm 2 M6 65 mm 3 M6 45 mm 2 1 3 2 3 2 3 2 ...

Page 235: ... ASSEMBLY 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 56 1 Balancer shaft 1 2 Crankshaft assembly 1 For installation reverse the removal proce dure 1 2 ...

Page 236: ...nd bearing crankshaft pin or connecting rod 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket 1 Damage Replace the crankshaft 5 Check Crankshaft journal oil passage Obstruction Blow out with compressed air EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly NOTE Install the crankshaft assembly with the crank shaft installer po...

Page 237: ...TE 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 bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer pot 1 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 2 90890 01275 Bolt YU 90060 Adapter M12 3 90890 01278 Adapter 3 YU 90063 Spacer cra...

Page 238: ... Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Shift fork guide bar 1 2 Shift drum 1 3 Shift fork R 1 4 Shift fork C 1 5 Shift fork L 1 6 Main axle assembly 1 7 Drive axle assembly 1 8 O ring 1 9 Collar 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 E E E ...

Page 239: ... 4 Circlip 1 5 Washer 1 6 5th pinion gear 1 7 Main axle 1 8 Circlip 1 9 Plain washer 1 10 1st wheel gear 1 11 Washer 1 12 Collar 1 13 5th wheel gear 1 14 Circlip 1 15 Washer 1 16 4th wheel gear 1 17 3rd wheel gear 1 18 6th wheel gear 1 19 Circlip 1 20 Washer 1 21 2nd wheel gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 M M M M M M ...

Page 240: ...ION 5 66 22 Drive axle 1 For installation reverse the removal proce dure Disassembling the transmission Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 M M M M M M ...

Page 241: ... 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing Damage pitting Replace the shift drum as sembly EAS26290 CHE...

Page 242: ...gear Incorrect Reassemble the transmission axle assemblies NOTE When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check Transmission gear movement Rough movement Replace the defective part s EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Shift fork guide bar 1 Shift fork R 2 Shift fork C 3 Shift fork L 4 NOTE The embossed marks on the shift for...

Page 243: ...TRANSMISSION 5 69 EAS26340 INSTALLING THE TRANSMISSION 1 Install Transmission 2 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly ...

Page 244: ...TRANSMISSION 5 70 ...

Page 245: ...SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 2 INSTALLING THE RADIATOR 6 2 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT ASSEMBLY 6 5 WATER PUMP 6 6 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 ...

Page 246: ...motor coupler 1 Disconnect 2 Radiator inlet hose 1 Disconnect 3 Coolant reservoir hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 FID Hose radiator side 1 6 Radiator cover 1 7 Breather hose 1 Disconnect 8 Recovery tank 1 9 Radiator 1 10 Radiator fan 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 10 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 ...

Page 247: ...no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 2 Check Cooling system Leakage Collect or replace a Attach the radiator cap tester 1 to the radia tor Radiator cap opening pre...

Page 248: ... 100 kPa 14 22 psi 1 0 kg cm2 pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 1 ...

Page 249: ...ASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Drains the coolant Refer to CHANGING THE COOLANT on page 3 18 1 Radiator inlet hose 1 Disconnect 2 FID hose thermostat side 1 Disconnect 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure 1 2 3 4 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 2 Nm 0 2 m kg 1 4 ft Ib ...

Page 250: ...ause serious overheating or overcooling 2 Check Thermostat housing cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat 1 Thermostat cover 2 NOTE Install the thermostat by facing breather hole up ward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 3 Check Cooling system Leaks Repair or r...

Page 251: ...engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Water pump housing cover Refer to CLUTCH on page 5 34 Crank case cover light Refer to CLUTCH on page 5 34 1 Circlips 1 2 Impeller shaft gear 1 3 Dowelpin 1 4 Plate 1 5 Impeller shaft 1 6 Mechanical seal 1 7 Bearing 1 For installation reverse the removal proce dure LT 1 2 3 4 5 6 7 LT E T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 252: ...er 3 2 Lubricate Mechanical seal lip Impeller shaft 3 Install Impeller shaft 1 Plate 2 NOTE Tighten the plate bolt with appling the LOCTITE 4 Lubricate Engine oil to the bearing 5 Install Plate washer Dowel pin Impeller shaft gear 1 Plate washer 2 Circlip 3 6 Install Crankcase cover right gascket Crankcase cover right Refer to CLUTCH on page 5 34 7 Install Water pump housing cover gascket Water pu...

Page 253: ...WATER PUMP 6 8 Crankcase Refer to CHANGING THE ENGINE OIL on page 3 11 9 Fill Cooling system Refer to CHANGING THE COOLANT on page 3 18 ...

Page 254: ...WATER PUMP 6 9 ...

Page 255: ... INSTALLING THE FUEL TANK 7 2 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 6 CHECKING THE THROTTLE BODIES 7 6 CHECKING THE PRESSURE REGULATOR 7 6 CHECKING THE PRESSURE REGULATOR OPERATION 7 6 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 12 CANISTER FOR CALIFORNIA 7 13 ...

Page 256: ... coupler 1 Disconnect 3 Hose fuel tank roll over valve 1 Disconnect for California 4 Fuel tank bracket front rear 1 1 5 Fuel pump bracket 1 6 Fuel pump assembly 1 7 O ring 1 For installation reverse the removal proce dure 1 2 4 4 5 6 7 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ...

Page 257: ...TION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26700 INSTALLING THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Align the projection a on the fuel pump with the slot...

Page 258: ...FUEL TANK 7 3 1 ...

Page 259: ...NK on page 7 1 Throttle cable Refer to CAMSHAFT on page 5 6 Clutch cable Coolant Drain Refer to CHANGING THE COOLANT on page 3 18 Ignition coil lead Refer to CAMSHAFT on page 5 6 1 Injector coupler 1 Disconnect 2 Vacuum hose 1 3 ITS boost hose 1 4 FID hose Thermostat side radiator side 2 5 Hose canister throttle body 1 for California 6 Throttle bodies assembly 1 For installation reverse the remova...

Page 260: ... throttle body Order Job Parts to remove Q ty Remarks 1 Delivery pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 For installation reverse the removal proce dure 1 2 3 4 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 3 5 Nm 0 4 m kg 2 5 ft Ib ...

Page 261: ...place EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1 Check Pressure regulator operation a Remove the fuel tank Refer to FUEL TANK on page 7 1 b Connect the pressure gauge 1 and adapter 2 to the fuel injection pipe c Install the fuel tank Refer to FUEL TANK on page 7 1 d Start the engine e Measure the fuel pressure f Use the vacuum pressure pump gauge set to adjust the fuel pressure in relati...

Page 262: ...e a Connect the throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the throttle position sensor c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws Positive tester probe B...

Page 263: ...THROTTLE BODIES 7 8 ...

Page 264: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 2 1 3 4 ...

Page 265: ...AIR INDUCTION SYSTEM 7 10 1 Air filter case 2 Air induction system hose 3 Air cut off valve 4 Air induction system pipe ...

Page 266: ...ide cover left right Air scoop left right Fuel tank Refer to FUEL TANK on page 7 1 1 Air induction coupler 1 Disconnect 2 Air induction system pipe 1 3 Gasket 1 4 Pipe3 1 5 Air induction system hose 1 6 Air cut off valve assembly 1 For installation reverse the removal proce dure 1 2 3 4 5 6 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 267: ... burned exhaust gases is approximately 600 to 700 C Air cut off valve The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cr...

Page 268: ...rts to remove Q ty Remarks 1 Canister cover 1 2 Canister 1 3 Hose fuel tank roll over valve 1 4 Roll over valve 1 5 Hose roll over valve canister 1 6 Hose canister throttle body 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib 1 T R 10 Nm 1 0 m kg 7 2 ft Ib 2 5 6 3 4 ...

Page 269: ... 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 32 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 34 TROUBLESHOOTING DETAILS 8 41 FUEL PUMP SYSTEM 8 55 CIRCUIT DIAGRAM 8 55 TROUBLE SHOOTING 8 57 ELECTRICAL COMPONENTS 8 59 CHECKING THE SWITCHES 8 63 CHECK...

Page 270: ...RN 8 77 CHECKING THE SPEED SENSOR 8 77 CHECKING THE FUEL SENDER FUEL PUMP 8 78 CHECKING THE COOLANT TEMPERATURE SENSOR 8 78 CHECKING THE RADIATOR FAN MOTOR 8 79 CHECKING THE THROTTLE POSITION SENSOR 8 79 CHECKING THE EXUP SERVO MOTOR 8 80 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 80 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 80 CHECKING THE INTAKE SOLENOID 8 81 ...

Page 271: ......

Page 272: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM ...

Page 273: ...eto 3 Main switch 4 Battery 5 Main fuse 8 Right handlebar switch 9 Engine stop switch 11 Relay unit 12 Sidestand switch 13 Neutral switch 14 Clutch switch 16 ECU 17 Ignition coil 18 Spark plug 27 Lean angle sensor 56 Ignition fuse ...

Page 274: ...n page 3 8 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING THE IGNITION SPARK GAP on page 8 74 OK The ignition system is normal NG 5 Check the ignition coil Refer to CHECKING THE IGNITION COIL on page 8 74 NG Replace the ignition coil OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 75 NG Replace the stat...

Page 275: ...lay unit Refer to CHECKING THE RELAYS on page 8 71 NG Replace the relay unit OK 13 Check the diode Refer to CHECKING THE DIODE on page 8 73 NG Replace the relay unit OK 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 75 NG Replace the lean angle sensor OK 15 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair...

Page 276: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 277: ...n switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Right handlebar switch 9 Engine stop switch 10 Start switch 11 Relay unit 12 Sidestand switch 13 Neutral switch 14 Clutch switch 55 Signaling system fuse 56 Ignition fuse ...

Page 278: ...s pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starti...

Page 279: ... UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Signal fuse 8 Diode 9 Diode 10 Clutch switch 11 Sidestand switch 12 Neutral switch 13 Start switch 14 Starter relay 15 Starter motor ...

Page 280: ...pair or replace the starter motor OK 4 Check the relay unit Refer to CHECKING THE RELAYS on page 8 71 NG Replace the relay unit OK 5 Check the diode Refer to CHECKING THE DIODE on page 8 73 NG Replace the relay unit OK 6 Check the starter relay Refer to CHECKING THE RELAYS on page 8 71 NG Replace the starter relay OK 7 Check the main switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace th...

Page 281: ...ace the clutch switch OK 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the right handlebar switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the starting system s wiring OK The starting system circuit is OK ...

Page 282: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 283: ...CHARGING SYSTEM 8 12 1 AC magneto 2 Rectifier regulator 4 Battery 5 Main fuse ...

Page 284: ...G AND CHARG ING THE BATTERY on page 8 68 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 76 NG Replace the stator assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 76 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT D...

Page 285: ...CHARGING SYSTEM 8 14 ...

Page 286: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 287: ...ain fuse 16 ECU 34 High beam indicator 39 Front right turn signal position light 40 Front left turn signal position light 42 Headlight relay 43 Dimmer switch 44 Headlight 50 Tail brake light 51 License light 54 Headlight fuse 55 Signaling system fuse ...

Page 288: ...to CHECKING THE FUSES on page 8 67 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 8 68 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the left handlebar...

Page 289: ...LIGHTING SYSTEM 8 18 ...

Page 290: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 291: ...t 33 Fuel level warning light 35 Turn signal indicator light 36 Turn signal relay 37 Turn signal switch 38 Rear right turn signal light 39 Front right turn signal position light 40 Front left turn signal position light 41 Rear left turn signal light 45 Horn 46 Horn switch 47 Left handlebar switch 48 Rear brake switch 49 Front brake switch 50 Tail brake light 54 Headlight fuse 55 Signaling system f...

Page 292: ...HE FUSES on page 8 67 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 8 68 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair...

Page 293: ...ight 1 Check the turn signal light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 66 NG Replace the turn signal light bulb socket or both OK 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the left handlebar switch OK 3 Check the turn signal relay Refer to CHECKING THE RELAYS on page 8 71 NG The turn signal relay is faulty and must be r...

Page 294: ... 8 19 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER FUEL PUMP on page 8 78 NG Replace the fuel pump assembly OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly 1 Check the c...

Page 295: ...SIGNALING SYSTEM 8 24 ...

Page 296: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 297: ...COOLING SYSTEM 8 26 3 Main switch 4 Battery 5 Main fuse 16 ECU 23 Coolant temperature sensor 52 Radiator fan motor relay 53 Radiator fan motor 56 Ignition fuse 57 Radiator fan fuse ...

Page 298: ...ce the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the main switch OK 4 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 71 NG Replace the radiator fan motor relay OK 5 Check the radiator fan motor Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 79 NG The radiator fan motor is faulty and must be replaced OK 6 Check the coola...

Page 299: ...COOLING SYSTEM 8 28 ...

Page 300: ...FUEL INJECTION SYSTEM 8 29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 301: ...ump 16 ECU 17 Ignition coil 18 Spark plug 19 ITS solenoid 20 Fuel injector 21 AI solenoid 22 Intake air temperature sensor 23 Coolant temperature sensor 24 Speed sensor 25 Throttle position sensor 26 Intake air pressure sensor 27 Lean angle sensor 28 EXUP servo motor 32 Engine trouble warning light 42 Headlight relay 52 Radiator fan motor relay 54 Headlight fuse 55 Signaling system fuse 56 Ignitio...

Page 302: ...ns stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and when...

Page 303: ... sor pipe system Intake air pressure sensor pipe sys tem malfunction clogged or detached hose Able Able 15 Throttle position sensor open or short circuit Throttle position sensor open or short circuit detected Able Able 16 Throttle position sensor stuck The throttle position sensor is stuck Able Able 17 EXUP servo motor cir cuit open or short circuit EXUP servo motor circuit open or short circuit ...

Page 304: ... automatically stops the engine Able Able Start unable warning Engine trouble warning light flashes when the start switch is turned ON Relay is not turned ON even if the crank signal is input while the start switch is turned ON When the start switch is turned ON while an error is detected with the fault code of No 12 19 30 41 or 50 Unable Unable Faultcode No Item Symptom Able unable to start Able ...

Page 305: ...e main switch to OFF and set the en gine stop switch to ON 2 Disconnect the wire harness coupler from the fuel pump 3 Simultaneously press and hold the SELECT1 1 and RESET 2 buttons turn the main switch to ON and continue to press the buttons for 8 seconds or more NOTE All displays on the meter disappear except the clock and tripmeter displays dIAG appears on the clock LCD 4 Press the SELECT1 butt...

Page 306: ...data representing the operating condi tions of the sensor appears on the trip LCD Actuator operation Set the engine stop switch to ON to operate the actuator NOTE If the engine stop switch is set to ON set it to OFF and then set it to ON again 9 Turn the main switch to OFF to cancel the diagnostic mode ...

Page 307: ...tor ECU is defective 53 18 EXUP servo motor is stuck Open circuit in wire harness EXUP servo motor lockup valve or motor 53 19 Open circuit is detected in the input line from the sidestand switch to the ECU Open or short circuit in wire harness Malfunction in ECU 20 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sen...

Page 308: ...pear on the meter Malfunction in ECU The program and data are not properly written on or read from the internal memory 70 Left idle control After 20 minutes left idling the ECU auto matically stops the engine Er 1 No signals are received from the ECU Open or short circuit in communication line Malfunction in meter unit Malfunction in ECU Er 2 No signals are received from the ECU within the specifi...

Page 309: ...lse 0 999 Check that the number changes integrating when the rear wheels are rotated 08 Lean angle sensor Remove the lean angle sen sor and incline it more than 65 degrees Upright 0 4 1 4 V Overturned 3 7 4 4 V 09 Fuel system voltage battery voltage Approximately 12 0 V Compare with the actually measured battery voltage If the battery voltage is lower perform recharging 20 Sidestand switch Set ON ...

Page 310: ... of trouble code No malfunction code 0 Malfunction code exists Trouble code 24 70 Control number 00 255 Diagnos tic monitori ng code No Item Meter display Checking method Diagnos tic monitori ng code No Item Actuation Checking method 30 Ignition coil Actuates the ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ignition ch...

Page 311: ...ive times 51 Radiator fan motor relay Actuates the radiator fan motor relay for five times every sec ond ON two seconds OFF three seconds Illuminates the engine trouble warning light Check the operating sound of the relay five times 52 Headlight relay Actuates the headlight relay for five times every five second ON two seconds OFF three seconds Illuminates the engine trouble warning light five tim...

Page 312: ...m No normal signals are received from the crankshaft position sensor Diagnostic monitoring code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of crankshaft position sensor Check the installed area for loose ness or pinching Cranking the engine 2 Connected state of connector Crankshaft position sensor coupler Main wire harness ECU co...

Page 313: ...03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 80 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged hose Diagnostic monitoring code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Intake air pressure sensor hose clogged Check the intake air pressure sen ...

Page 314: ...pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler Black Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open circuit output voltage check C...

Page 315: ...E POSITION SEN SOR on page 8 79 Fault code No 17 Symptom EXUP servo motor circuit open or short circuit Diagnostic monitoring code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector EXUP servo motor coupler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking cond...

Page 316: ...UP valve pully and cable Replace if defective Fault code No 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU Diagnostic monitoring code No 20 Sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector Main wire harness ECU coupler Execute the diagnostic monitoring mode Code No 20 C...

Page 317: ...olant temperature sensor coupler Main wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between coolant temperature sen sor couple...

Page 318: ...Brown White Brown White 4 Defective intake air temperature sensor Execute the diagnostic monitoring mode Code No 05 Replace if defective Refer to CHECKING THE IN TAKE AIR TEMPERATURE SEN SOR on page 8 80 Fault code No 30 Symptom Latch up detected No normal signal is received from the lean angle sensor Diagnostic monitoring code No 08 Lean angle sensor Order Item components and probable cause Check...

Page 319: ...ostic monitoring mode Code No 30 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNI TION COIL on page 8 74 Fault code No 41 Symptom Lean angle sensor open or short circuit detected Diagnostic monitoring code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector L...

Page 320: ... vehicle speed signals by oper ating the motor cycle at a low speed of 20 30 km h A 2 Connected state of connector Speed sensor coupler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely A 3 Open or short circuit in speed sensor lead Repair or replace if there is an ...

Page 321: ...witch coupler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely B 3 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler Black Yellow Black Yellow Between neutral switch and rela...

Page 322: ...or short circuit Between relay unit and ECU cou pler Red Blue Red Blue Between relay unit and fuse EFI Brown Yellow Brown Yellow Between fuse EFI and battery Brown Yellow Brown Yellow 3 Faulty battery voltage Execute the diagnostic monitoring mode Code No 09 Charge or replace if defective Fault code No 44 Symptom Error is detected while reading or writing on EEPROM CO adjustment valve Diagnostic m...

Page 323: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 68 3 Malfunction of the rectifier regulator Replace if defective Refer to CHARGING SYSTEM on page 8 11 4 Open or short circuit in the wire harness Repair or replace if there is an open or short circuit Between battery and main switch Red Red Between main switch and fuse ignition Brown Brown Between fuse ignition and ECU Red White Red Whit...

Page 324: ...e Yellow Blue 3 Malfunction in meter unit Replace the meter unit 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic monitoring code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector Main wire harness ECU coupler Check the coupler for any ...

Page 325: ...ellow Blue Yellow Blue 3 Malfunction in meter unit Replace the meter unit 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic monitoring code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connected state of connector Main wire harness ECU coupler Check the coupler for any pins ...

Page 326: ...FUEL PUMP SYSTEM 8 55 EAS27580 FUEL PUMP SYSTEM EAS27590 CIRCUIT DIAGRAM ...

Page 327: ...FUEL PUMP SYSTEM 8 56 3 Main switch 4 Battery 5 Main fuse 8 Right handlebar switch 9 Engine stop switch 11 Relay unit 15 Fuel pump 16 ECU 56 Ignition fuse 58 EFI fuse ...

Page 328: ...e battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the main switch OK 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 63 NG Replace the right handlebar switch OK 5 Check the relay unit fuel pump relay Refer to CHECKING THE SWITCHES on page 8 63 NG Replace relay unit fuel pump relay OK 6 Check fuel pressure Refer to CHECKING THE PRES ...

Page 329: ...FUEL PUMP SYSTEM 8 58 ...

Page 330: ...ELECTRICAL COMPONENTS 8 59 EAS27971 ELECTRICAL COMPONENTS EAS32D1011 2 3 4 7 5 8 10 12 1 11 6 9 13 ...

Page 331: ... 8 60 1 Main switch 2 Battery 3 Main fuse 4 Starter relay 5 ECU 6 Lean angle sensor 7 Intake solenoid 8 Throttle position sensor 9 Sidestand switch 10 Neutral switch 11 Rear brake switch 12 Fan motor 13 Rectifier regulator ...

Page 332: ...ELECTRICAL COMPONENTS 8 61 2 3 4 9 5 10 14 13 1 6 7 11 12 15 8 ...

Page 333: ...rter motor 4 Radiator fan motor relay 5 Turn signal relay 6 Relay assembly 7 Headlight relay 8 Intake air temperature sensor 9 Coolant temperature sensor 10 Speed sensor 11 EXUP servo motor 12 Injector 13 Ignition coil 14 Fuel pump 15 Air cut off valve ...

Page 334: ...ELECTRICAL COMPONENTS 8 63 EAS27980 CHECKING THE SWITCHES 7 9 8 11 10 4 2 3 5 6 1 ...

Page 335: ... COMPONENTS 8 64 1 Horn switch 2 Dimmer switch 3 Turn signal switch 4 Clutch switch 5 Neutral switch 6 Sidestand switch 7 Main switch 8 Engine stop switch 9 Start switch 10 Front brake switch 11 Rear brake switch ...

Page 336: ...ng for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustra tion similar to the one on below The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between ...

Page 337: ...3320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of th...

Page 338: ... The following procedure applies to all of the fus es CAUTION ECA13680 To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Side cover left Air scoop left Refer to GENERAL CHASSIS on page 4 1 2 Check Main fuse 1 Fuse box 2 a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket test...

Page 339: ... medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION ECA13660 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF batte...

Page 340: ...sure to re move it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery c...

Page 341: ...han 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage af ter leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage ...

Page 342: ...1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 2 1 3 4 Result C...

Page 343: ...efective part s a Connect the pocket tester DC 20 V to the turn signal relay terminal b Turn the main switch to ON c Measure turn signal relay applied voltage 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 Turn signal relay input voltage DC 12V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Tester ...

Page 344: ...ty Tester positive lead Sky blue 1 Tester negative lead Light green 2 No continuity Tester positive lead Light green 2 Tester negative lead Sky blue 1 Continuity Tester positive lead Blue Green 3 Tester negative lead Blue Yel low 4 No continuity Tester positive lead Blue Yel low 4 Tester negative lead Blue Green 3 Continuity Tester positive lead Sky blue 1 Tester negative lead Blue Yel low 4 No co...

Page 345: ...p a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil lead coupler from wire harness b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resis...

Page 346: ...ECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect the lean angle sensor coupler to the wireharness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Secondary coil resistance 8 50 11 50 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe...

Page 347: ...Set the digital tachometer to the ignition coil of cylinder 1 b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown Tester positive probe Blue 1 Negative tester probe Yellow Green 2 Stator coil resistance 0 168 0 252 Ω W W Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Neg...

Page 348: ... the adjusting screw in direction a or b until the specified horn sound is obtained EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Horn resistance 1 01 1 11 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Horn...

Page 349: ...OOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 4 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to t...

Page 350: ...G THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Check Throttle position sensor a Connect the pocket tester DC 20 V to the throttle position sensor as shown b While slowly...

Page 351: ...ry EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler wire har ness side as shown b Set the main switch to ON c Measure the intake air pressure sensor out put voltage EAS28420 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air tempe...

Page 352: ...n Replace a Disconnect the intake solenoid coupler from the wire harness b Connect the pocket tester Ω 10 to the in take solenoid terminal as shown c Measure the intake solenoid resistance Intake air temperature sensor re sistance 2 21 2 69 kΩ 20 C Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Brown White 1 Negative tester probe Black Blue 2...

Page 353: ...ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 ...

Page 354: ...m 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5 Ignition system ECU failure Faulty cranksha...

Page 355: ...rum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen ...

Page 356: ...ity Incorrect oil level EAS28690 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broke...

Page 357: ...aulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb Horn does not sound Improperly adjusted horn Dama...

Page 358: ...TROUBLESHOOTING 9 5 ...

Page 359: ...tion light 40 Front left turn signal position light 41 Rear left turn signal light 42 Headlight relay 43 Dimmer switch 44 Headlight 45 Horn 46 Horn switch 47 Left handlebar switch 48 Rear brake switch 49 Front brake light switch 50 Tail brake light 51 License plate light 52 Radiator fan motor relay 53 Radiator fan motor 54 Headlight fuse 55 Signal fuse 56 Ignition fuse 57 Radiator fan fuse 58 Fuel...

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Page 362: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 363: ...XX 2008 WIRING DIAGRAM WR250RX WR250XX 2008 SCHÉMA DE CÂBLAGE WR250RX WR250XX 2008 SCHALTPLAN SCHEMA ELETTRICO WR250RX WR250XX 2008 DIAGRAMA ELÉCTRICO DE LA WR250RX WR250XX 2008 32D 7 E0 W D 30 10 07 2 09 PM Page 1 ...

Page 364: ...XX 2008 WIRING DIAGRAM WR250RX WR250XX 2008 SCHÉMA DE CÂBLAGE WR250RX WR250XX 2008 SCHALTPLAN SCHEMA ELETTRICO WR250RX WR250XX 2008 DIAGRAMA ELÉCTRICO DE LA WR250RX WR250XX 2008 32D 7 E0 W D 30 10 07 2 09 PM Page 2 ...

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