Yamaha YP125R Service Manual Download

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FRONT BRAKE

4-25

2. Check:

• Brake caliper bracket

Cracks/damage

→

Replace.

EAS22400

ASSEMBLING THE FRONT BRAKE CALIPER

WARNING

EWA37P1011

• 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 brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.

• Whenever a brake caliper is disassembled,

replace the brake caliper piston dust seals
and brake caliper piston seals.

EAS22420

INSTALLING THE FRONT BRAKE CALIPER

1. Install:

• Front brake caliper “1”

(temporarily)

• Copper washers “2”
• Front brake hose “3”
• Brake hose union bolt “4”

WARNING

EWA37P1024

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING (YP125R)” on page 2-29 and “CA-
BLE ROUTING (YP250R)” on page 2-75.

NOTICE

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. Remove:

• Front brake caliper

3. Install:

• Brake pad support
• Brake pad spring
• Brake pads
• Brake pad pin
• Brake pad pin cap
• Front brake caliper
• Speed sensor lead guide

Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-23.

4. Fill:

• Brake master cylinder reservoir

(with the specified amount of the recom-
mended brake fluid)

WARNING

EWA37P1012

• 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 fluids
may result in a harmful chemical reaction,
leading to poor brake performance.

Recommended fluid

DOT 4

Front brake hose union bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

New

Brake pad pin

18 Nm (1.8 m·kgf, 13 ft·lbf)

Brake pad pin cap

3 Nm (0.3 m·kgf, 2.2 ft·lbf)

Front brake caliper bolt

40 Nm (4.0 m·kgf, 29 ft·lbf)

Recommended fluid

DOT 4

Summary of Contents for YP125R

Page 1: ...SERVICE MANUAL 2010 37P F8197 E0 YP125R YP250R...

Page 2: ...R 2010 SERVICE MANUAL 2009 by Yamaha Motor Espa a S A First edition November 2009 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Espa a S A is...

Page 3: ...ificant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable TIP Designs and specificat...

Page 4: ...b section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section...

Page 5: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Page 6: ......

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

Page 8: ......

Page 9: ...F THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 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 PL...

Page 10: ...CATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS20150 MODEL LABEL The model label 1 is affixed to the location shown This information wil...

Page 11: ...equirements 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 t...

Page 12: ...ed by the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air pressure sensor intake air temperature sensor...

Page 13: ...on display will appear and then disappear in order to test the electrical circuit Odometer and tripmeter modes Pushing the SELECT button switches the dis play between the odometer mode Odo and the tri...

Page 14: ...ith changes in the weather and engine load If the top segment and coolant temperature warning indicator flash stop the vehicle and let the en gine cool NOTICE ECA37P1034 Do not continue to operate the...

Page 15: ...e placement indicator comes on i e before the V belt replacement interval has been reached the indicator must be reset after the V belt replace ment for the next periodic V belt replacement to be indi...

Page 16: ...flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Ambient temperature display Pushing the SELECT button for at least two seconds swit...

Page 17: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Page 18: ...ease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembl...

Page 19: ...al times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 C...

Page 20: ...oid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890...

Page 21: ...dle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 52 4 54 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 54 Fork seal driver attachment 38 90890 01372 Replacement 38 mm YM...

Page 22: ...lve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 20 Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 20 Piston pin puller set 90890 01304 Piston pin p...

Page 23: ...5 94 5 97 Clutch spring holder arm 90890 01464 5 34 5 37 5 94 5 97 Oil seal guide 41 90890 01396 5 36 5 96 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 41 5 101 Digital circuit tester 90...

Page 24: ...58 5 59 5 119 5 120 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 58 5 59 5 119 5 120 Adapter M14 90890 01478 Adapter 6 YM 90066 5 58 5 59 5 119 Fork seal driver attachment 90890 01186 Replac...

Page 25: ...5 79 Valve guide installer 6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 79 Valve guide reamer 6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 79 Yamaha grease G 90793 40016 5 91 Spacer...

Page 26: ...890 04058 Bearing driver 40 mm YM 04058 6 6 6 15 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 15 Fuel sender wrench 90890 11098 7 3 7 4 Pressure gauge 90890 03153 YU 03...

Page 27: ...SPECIAL TOOLS 1 18 Test harness lean angle sensor 6P 90890 03209 8 84 Test harness 90890 03204 8 89 Tool name Tool No Illustration Reference pages...

Page 28: ...SPECIAL TOOLS 1 19...

Page 29: ...ND LUBRICANT TYPES YP125R 2 21 ENGINE 2 21 CHASSIS 2 23 LUBRICATION SYSTEM DIAGRAMS YP125R 2 25 COOLING SYSTEM DIAGRAMS YP125R 2 27 CABLE ROUTING YP125R 2 29 GENERAL SPECIFICATIONS YP250R 2 47 ENGINE...

Page 30: ...COOLING SYSTEM DIAGRAMS YP250R 2 73 CABLE ROUTING YP250R 2 75...

Page 31: ......

Page 32: ...D3 MBK Dimensions Overall length 2201 mm 86 7 in Overall width 776 mm 30 6 in Overall height 1337 mm 52 6 in Seat height 792 mm 31 2 in Wheelbase 1545 mm 60 8 in Ground clearance 134 mm 5 30 in Minimu...

Page 33: ...rade API service SG type or higher JASO standard MA Engine oil quantity Total amount 1 60 L 1 69 US qt 1 41 Imp qt Without oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter...

Page 34: ...ump Reduction ratio 16 38 0 42 Impeller shaft tilt limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK CPR9EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 9 90 10 50 cm 0 60...

Page 35: ...clearance cold Intake 0 10 0 14 mm 0 0039 0 0055 in Exhaust 0 22 0 26 mm 0 0087 0 0102 in Valve dimensions Valve head diameter A intake 19 40 19 60 mm 0 7638 0 7717 in Valve head diameter A exhaust 16...

Page 36: ...r head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve spring Free length int...

Page 37: ...in Offset direction Intake side Piston pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in Limit 14 043 mm 0 5529 in Piston pin outside diameter 13 995 14 000 mm 0 5510 0 5512 in Limit 13 975...

Page 38: ...h Clutch type Dry centrifugal automatic Automatic centrifugal clutch Clutch shoe thickness 2 0 mm 0 08 in Limit 1 0 mm 0 04 in Clutch shoe spring free length 33 0 mm 1 30 in Clutch housing inside diam...

Page 39: ...sor Input voltage at idle 5 V Output voltage at idle 0 40 0 90 V Fuel injection sensor Crankshaft position sensor resistance 248 372 at 20 C 68 F Intake air pressure sensor output voltage 3 57 3 71 V...

Page 40: ...ateral wheel runout limit 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70 15 M C 56P PIRELLI 120 70 15 M C 56S MICHELIN Manufacturer model MICHELIN GOLD ST...

Page 41: ...ng thickness outer 7 3 mm 0 29 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder inside diameter 32 00 mm 2 1 26 in 2 Recommended fluid DOT 4 Steering Steering b...

Page 42: ...led length 241 3 mm 9 50 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 17 30 N mm 1 76 kgf mm 98 78 lb in Spring stroke K1 0 47 5 mm 0 1 87 in Spring stroke K2 47 5 95 0 mm 1 87 3...

Page 43: ...magneto Standard output 14 0 V 245 W 5000 r min Stator coil resistance 0 28 0 42 at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifie...

Page 44: ...9 in Limit 16 6 mm 0 65 in Mica undercut depth 1 35 mm 0 05 in Starter relay Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Coil resistance 1 4 at 20 C 68 F Performance 105...

Page 45: ...ELECTRICAL SPECIFICATIONS YP125R 2 14 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 5 0 A Spare fuse 7 5 A...

Page 46: ...s manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torq...

Page 47: ...nce adjusting screw locknut M5 4 7 Nm 0 7 m kgf 5 1 ft lbf Coolant drain bolt cylinder M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case cover bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf V belt case bolt M6 8 10 Nm...

Page 48: ...lt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 5 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing plate 1 bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Fuel injector assembly bolt M6 1 12 Nm...

Page 49: ...lbf Mudguard bolt M6 3 11 Nm 1 1 m kgf 8 0 ft lbf Rear fender bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery box bolt M6 1 11 Nm 1 1 m kgf 8 0 f...

Page 50: ...kgf 7 2 ft lbf Grip end M16 2 26 Nm 2 6 m kgf 19 ft lbf Steering stem nut M20 1 120 Nm 12 0 m kgf 85 ft lbf Upper ring nut M25 1 75 Nm 7 5 m kgf 54 ft lbf See TIP Lower ring nut initial tightening tor...

Page 51: ...both ring nuts and then install the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kgf 54 ft lbf with a torque wrench and the steering nut wrench TIP...

Page 52: ...e and exhaust Valve stem ends intake and exhaust Rocker arm shaft and rocker arm Decompressor cam Oil pump driven gear shaft Oil pump rotors inner and outer Collar clutch housing Starter clutch idle g...

Page 53: ...LUBRICATION POINTS AND LUBRICANT TYPES YP125R 2 22 Timing chain tensioner bolt Yamaha bond No 1215 Lubrication point Lubricant...

Page 54: ...g point and metal to metal moving parts Rear brake pad pin Throttle cable end Throttle grip inner surface and throttle cables Handlebar grip inner surface Rubber adhesive Sidestand pivoting point and...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES YP125R 2 24...

Page 56: ...LUBRICATION SYSTEM DIAGRAMS YP125R 2 25 EAS37P1139 LUBRICATION SYSTEM DIAGRAMS YP125R 1 2 3 4 5 3...

Page 57: ...LUBRICATION SYSTEM DIAGRAMS YP125R 2 26 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter 5 Oil strainer...

Page 58: ...COOLING SYSTEM DIAGRAMS YP125R 2 27 EAS37P1128 COOLING SYSTEM DIAGRAMS YP125R B A B A 4 3 3 2 2 1 3 4 5 2 6 7 6...

Page 59: ...COOLING SYSTEM DIAGRAMS YP125R 2 28 1 Coolant reservoir 2 Coolant reservoir hose 3 Radiator cap 4 Radiator filler hose 5 Radiator 6 Radiator inlet hose 7 Radiator outlet hose...

Page 60: ...CABLE ROUTING YP125R 2 29 EAS37P1129 CABLE ROUTING YP125R Battery front view A B C D E F G H 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 11 11 15 12 15 14 13 17 16 13...

Page 61: ...lead to the front of the starter relay C Route the self diagnosis signal lead along the negative battery lead D Route the negative battery lead to the rear of the turn signal hazard relay lead lean a...

Page 62: ...CABLE ROUTING YP125R 2 31 Front fork front view A 1 1 1 1 2 2 2 3 4 5 6 7...

Page 63: ...nt brake hose 3 Rectifier regulator 4 Left front turn signal light coupler 5 Wire harness 6 Horn 7 Right front turn signal light coupler A Point the end of the plastic locking tie forward and then cut...

Page 64: ...CABLE ROUTING YP125R 2 33 Front brake hose right side view B 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 8 9 10 11 11 11 12 13 13 14 A C...

Page 65: ...rness 9 Rear brake pipe 10 Horn leads 11 Starter motor lead 12 Headlight relay 13 Rear brake hose 14 Throttle cables A Position the plastic locking tie above the frame cross member B Point the end of...

Page 66: ...CABLE ROUTING YP125R 2 35 Engine right side view A 7 3 2 2 2 1 3 4 5 6 7...

Page 67: ...lock cable 2 Wire harness 3 Ignition coil lead 4 Spark plug cap 5 O2 sensor 6 Starter motor lead 7 Rear brake hose A Point the end of the plastic locking tie to the right and then cut off the excess e...

Page 68: ...CABLE ROUTING YP125R 2 37 Throttle cables left side view A B C I J 1 2 3 3 3 4 5 5 5 6 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 D D E F H H G...

Page 69: ...he rear brake pipe B Route the sidestand switch lead to the inside of the frame C Route the sidestand switch lead to the outside of the frame D Position the connector cover as shown in the illustratio...

Page 70: ...CABLE ROUTING YP125R 2 39 Engine left side view 2 1 3 4 A 3...

Page 71: ...2 40 1 Wire harness 2 Intake air temperature sensor 3 Seat lock cable 4 Left tail brake light assembly A Point the end of the plastic locking tie to the left and then cut off the excess end of the tie...

Page 72: ...CABLE ROUTING YP125R 2 41 Handlebar top view A 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 73: ...l pump coupler 7 Fuel sender coupler 8 Fuel hose 9 Left handlebar switch lead 10 Rear brake hose 11 ECU engine control unit 12 Positive battery lead 13 Negative battery lead 14 Fuse box 1 15 Fuse box...

Page 74: ...CABLE ROUTING YP125R 2 43 Throttle body top view 3 1 3 4 6 10 11 9 2 2 2 3 3 C B A 18 17 13 15 16 12 11 14 3 5 7 8 10 11 12 16 15 7 19 4...

Page 75: ...r lead 12 Thermostat inlet hose 13 Intake air pressure lead 14 Fuel injector lead 15 Throttle position sensor lead 16 Coolant temperature sensor lead 17 ISC idle speed control unit lead 18 O2 sensor l...

Page 76: ...CABLE ROUTING YP125R 2 45 Tail brake light top view 2 1 3 4 B A 1 5 6...

Page 77: ...ake light assembly coupler 5 Left tail brake light assembly coupler 6 Seat lock cable A Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 2...

Page 78: ...A Dimensions Overall length 2201 mm 86 7 in Overall width 776 mm 30 6 in Overall height 1337 mm 52 6 in Seat height 792 mm 31 2 in Wheelbase 1545 mm 60 8 in Ground clearance 134 mm 5 30 in Minimum tur...

Page 79: ...20W 50 Recommended engine oil grade API service SF SG type or higher JASO standard MA Engine oil quantity Total amount 1 50 L 1 59 US qt 1 32 Imp qt Periodic oil change 1 30 L 1 37 US qt 1 14 Imp qt...

Page 80: ...limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK DPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 21 40 22 00 cm 1 31 1 34 cu in Warpage limit 0 05 mm 0 0020 in Camsh...

Page 81: ...ead diameter A intake 33 90 34 10 mm 1 3346 1 3425 in Valve head diameter A exhaust 28 40 28 60 mm 1 1181 1 1260 in Valve face width B intake 3 394 3 960 mm 0 1336 0 1559 in Valve face width B exhaust...

Page 82: ...0 mm 1 42 in Free length exhaust 38 10 mm 1 50 in Limit 36 10 mm 1 42 in Installed length intake 30 10 mm 1 19 in Installed length exhaust 30 10 mm 1 19 in Spring rate K1 intake 10 29 N mm 1 05 kgf mm...

Page 83: ...direction exhaust Clockwise Cylinder Bore 69 000 69 005 mm 2 7165 2 7167 in Wear limit 69 100 mm 2 7205 in Taper limit 0 030 mm 0 0012 in Out of round limit 0 030 mm 0 0012 in Warp limit 0 05 mm 0 00...

Page 84: ...clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 130 mm 0 0051 in Oil ring Dimensions B T 1 50 2 50 mm 0 06 0 10 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Ring side clearance 0 060 0 150 mm...

Page 85: ...40 14 2 857 Operation Centrifugal automatic type Gear ratio 2 440 0 830 1 Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Output pressure 250 0 kPa 2 50 kgf cm 36...

Page 86: ...ENGINE SPECIFICATIONS YP250R 2 55 Water temperature 85 0 95 0 C 185 00 203 00 F Oil temperature 75 0 85 0 C 167 00 185 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in...

Page 87: ...teral wheel runout limit 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70 15 M C 56P PIRELLI 120 70 15 M C 56S MICHELIN Manufacturer model MICHELIN GOLD STA...

Page 88: ...ng thickness outer 5 3 mm 0 21 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder inside diameter 22 22 mm 2 0 87 in 2 Recommended fluid DOT 4 Steering Steering b...

Page 89: ...led length 241 3 mm 9 50 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 17 30 N mm 1 76 kgf mm 98 78 lb in Spring stroke K1 0 47 5 mm 0 1 87 in Spring stroke K2 47 5 95 0 mm 1 87 3...

Page 90: ...magneto Standard output 14 0 V 260 W 5000 r min Stator coil resistance 0 32 0 48 at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier...

Page 91: ...it 22 4 mm 0 88 in Mica undercut depth 1 00 mm 0 04 in Starter relay Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Coil resistance 1 4 at 20 C 68 F Performance 105 118 dB...

Page 92: ...ELECTRICAL SPECIFICATIONS YP250R 2 61 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 5 0 A Spare fuse 7 5 A...

Page 93: ...manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque...

Page 94: ...3 ft lbf Camshaft retainer bolt M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Valve clearance adjusting screw locknut M6 2 14 Nm 1 4 m kgf 10 ft lbf V belt case cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case...

Page 95: ...bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt water pump M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump outlet pipe bolt M6 2 7 Nm...

Page 96: ...TIGHTENING TORQUES YP250R 2 65 Cylinder head tightening sequence Muffler tightening sequence 2 3 1...

Page 97: ...bf Mudguard bolt M6 3 11 Nm 1 1 m kgf 8 0 ft lbf Rear fender bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery box bolt M6 1 11 Nm 1 1 m kgf 8 0 ft...

Page 98: ...Nm 1 0 m kgf 7 2 ft lbf Grip end M16 2 26 Nm 2 6 m kgf 19 ft lbf Steering stem nut M20 1 120 Nm 12 m kgf 85 ft lbf Upper ring nut M25 1 75 Nm 7 5 m kgf 54 ft lbf See TIP Lower ring nut initial tighten...

Page 99: ...both ring nuts and then install the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kgf 54 ft lbf with a torque wrench and the steering nut wrench TIP...

Page 100: ...mshaft lobes Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts Rocker arm inner surface Impeller shaft gear Oil pump shaft Oil pump rotors inner and outer Oil pump ga...

Page 101: ...LUBRICATION POINTS AND LUBRICANT TYPES YP250R 2 70 Crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 Lubrication point Lubricant...

Page 102: ...and metal to metal moving parts Rear brake caliper retaining bolt Throttle cable end Throttle grip inner surface and throttle cables Handlebar grip inner surface Rubber adhesive Sidestand pivoting poi...

Page 103: ...LUBRICATION POINTS AND LUBRICANT TYPES YP250R 2 72...

Page 104: ...COOLING SYSTEM DIAGRAMS YP250R 2 73 EAS20420 COOLING SYSTEM DIAGRAMS YP250R A A 4 3 3 2 2 1 3 4 5 2 6 7...

Page 105: ...COOLING SYSTEM DIAGRAMS YP250R 2 74 1 Coolant reservoir 2 Coolant reservoir hose 3 Radiator cap 4 Radiator filler hose 5 Radiator 6 Radiator inlet hose 7 Radiator outlet hose...

Page 106: ...CABLE ROUTING YP250R 2 75 EAS20430 CABLE ROUTING YP250R Battery front view A B C D E F G H 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 12 13 14 15 15 11 11 13 16 17...

Page 107: ...lead to the front of the starter relay C Route the self diagnosis signal lead along the negative battery lead D Route the negative battery lead to the rear of the turn signal hazard relay lead lean a...

Page 108: ...CABLE ROUTING YP250R 2 77 Front fork front view 1 1 2 3 4 5 6 7 1 2 A 1 2...

Page 109: ...nt brake hose 3 Rectifier regulator 4 Left front turn signal light coupler 5 Wire harness 6 Horn 7 Right front turn signal light coupler A Point the end of the plastic locking tie forward and then cut...

Page 110: ...CABLE ROUTING YP250R 2 79 Front brake hose right side view 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 9 10 11 11 11 11 12 13 13 14 15 8 A B...

Page 111: ...or 7 Radiator fan motor lead 8 Wire harness 9 Rear brake pipe 10 Horn leads 11 Starter motor lead 12 Headlight relay 13 Rear brake hose 14 Throttle cables 15 Main switch immobilizer unit lead A Positi...

Page 112: ...CABLE ROUTING YP250R 2 81 Engine right side view A 7 3 2 2 2 1 3 4 5 6 7 8 B...

Page 113: ...ensor lead 6 O2 sensor 7 Starter motor lead 8 Rear brake hose A Fasten the wire harness starter motor lead crankshaft position sensor stator assembly lead and O2 sensor lead with a plastic locking tie...

Page 114: ...CABLE ROUTING YP250R 2 83 Throttle cables left side view A B C I J 1 2 3 3 3 4 5 5 5 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 D D E F H H G 6...

Page 115: ...he rear brake pipe B Route the sidestand switch lead to the inside of the frame C Route the sidestand switch lead to the outside of the frame D Position the connector cover as shown in the illustratio...

Page 116: ...CABLE ROUTING YP250R 2 85 Engine left side view 2 1 3 4 5 6 B A 3 7...

Page 117: ...brake light assembly 5 Safety protector 6 O2 sensor 7 Spark plug cap A Route the left tail brake light assembly lead and right tail brake light assembly lead over the safety protector B Point the end...

Page 118: ...CABLE ROUTING YP250R 2 87 Handlebar top view A 1 2 3 4 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17...

Page 119: ...l pump coupler 7 Fuel sender coupler 8 Fuel hose 9 Left handlebar switch lead 10 Rear brake hose 11 ECU engine control unit 12 Positive battery lead 13 Negative battery lead 14 Fuse box 1 15 Fuse box...

Page 120: ...CABLE ROUTING YP250R 2 89 Throttle body top view 3 3 1 2 3 A 6 7 8 8 9 13 C B D 11 10 10 11 4 5 4 4 4 4 4 12 12 12...

Page 121: ...nsor stator assembly lead 13 O2 sensor lead A Connect the breather hose air filter case to throttle body to the air filter case making sure to turn the white paint marks on the hose upward B Route the...

Page 122: ...CABLE ROUTING YP250R 2 91 Tail brake light top view 2 1 3 4 B A 1 5 6 8 7...

Page 123: ...ail brake light assembly coupler 6 Seat lock cable 7 Cylinder head breather hose 8 Intake air temperature sensor coupler A Point the end of the plastic locking tie to the right and then cut off the ex...

Page 124: ...CABLE ROUTING YP250R 2 93...

Page 125: ...V BELT CASE AIR FILTER ELEMENT 3 15 CHECKING THE THROTTLE BODY JOINT 3 16 CHECKING THE FUEL HOSE 3 16 CHECKING THE BREATHER HOSES 3 16 CHECKING THE EXHAUST SYSTEM 3 17 CHECKING THE COOLANT LEVEL 3 17...

Page 126: ...TEM 3 36 CHECKING AND ADJUSTING THE STEERING HEAD 3 37 CHECKING THE FRONT FORK 3 39 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3 39 CHECKING THE TIRES 3 39 CHECKING THE WHEELS 3 41 CHECKING AND LUBR...

Page 127: ......

Page 128: ...125R TIP The annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 30000 km 17500 mi repeat the mainten...

Page 129: ...peration and shock absorbers for oil leakage 17 Engine oil Change When the oil change indicator flashes 5000 km 3000 mi after the initial 1000 km 600 mi and every 6000 km 3500 mi thereafter Check oil...

Page 130: ...at the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills EAU1770C GENERA...

Page 131: ...ation Lubricate 14 Sidestand switch Check operation 15 Front fork Check operation and for oil leakage 16 Shock absorber assemblies Check operation and shock absorbers for oil leakage 17 Engine oil Cha...

Page 132: ...and the V belt air filter element needs to be ser viced more frequently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers...

Page 133: ...GENERAL CHASSIS on page 4 1 2 Remove V belt case cover 1 V belt case air duct 2 V belt case air filter element 3 Remove Spark plug cap Spark plug 1 Cylinder head cover 2 4 Remove Timing mark accessin...

Page 134: ...pecifica tion e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained...

Page 135: ...ing CO press the MODE but ton 8 Check that C1 appears on the LCD of the FI diagnostic tool and then press the MODE button 9 Start the engine NOTICE ECA37P1042 Perform the adjustment after the battery...

Page 136: ...idling speed to change EAS37P1091 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 1 2 Remove Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark p...

Page 137: ...ct Timing light 1 onto the spark plug lead 4 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that the station...

Page 138: ...NG EWA37P1019 To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and pist...

Page 139: ...Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again TIP Before checking the engine oil lev...

Page 140: ...drain bolt along with the gasket 8 Fill Crankcase with the specified amount of the recom mended engine oil 9 Install Engine oil filler cap 10 Start the engine warm it up for several min utes and then...

Page 141: ...indicator must be reset as soon as pos sible so that it comes on for the next periodic oil change EAS37P1095 CHANGING THE FINAL TRANSMISSION OIL 1 Stand the vehicle on a level surface TIP Place the v...

Page 142: ...d Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body tuning leading to poor engine pe...

Page 143: ...page 4 1 EAS37P1099 CHECKING THE FUEL HOSE 1 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hose 1 Cracks damage Replace the fuel injector assembly Loose connection Connect prop...

Page 144: ...olant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA37P1048 Adding water instead of c...

Page 145: ...rest board Bottom cover Storage box Refer to GENERAL CHASSIS on page 4 1 EAS37P1104 CHANGING THE COOLANT 1 Remove Bottom cover Refer to GENERAL CHASSIS on page 4 1 2 Remove Coolant reservoir cap 1 3 D...

Page 146: ...coolant is swallowed induce vomiting and get immediate medical attention NOTICE ECA37P1049 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of cool...

Page 147: ...rm it up for several min utes and then turn it off 15 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 17 TIP Before checking the coolant level wait a few minutes until the coolant h...

Page 148: ...3 Remove Spark plug cap 1 Spark plug Tappet covers 2 Camshaft sprocket cover 3 4 Remove Timing mark accessing plug 1 5 Measure Valve clearance Out of specification Adjust a Turn the primary sheave nu...

Page 149: ...alve clearance adjust ment steps until the specified clearance is obtained 7 Install Timing mark accessing plug along with the O ring Camshaft sprocket cover along with the O ring Tappet covers along...

Page 150: ...ss the MODE button 9 Start the engine NOTICE ECA37P1015 Perform the adjustment after the battery has been sufficiently charged 10 Change the CO adjustment volume by press ing the UP and DOWN buttons T...

Page 151: ...Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type...

Page 152: ...d en gine idling speed b Check that the stationary pointer a on the generator cover is within the firing range b on the generator rotor Incorrect firing range Check the ignition system TIP The ignitio...

Page 153: ...park plug bore and measure again Refer to the following table 8 Install Spark plug 9 Connect Spark plug cap 10 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS20740 CHECKING THE ENGINE OIL...

Page 154: ...rm 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...

Page 155: ...heck bolt to specification 13 Reset Oil change indicator a Set the main switch to ON b Push the OIL CHANGE button 1 for 15 to 20 seconds c Release the button and the oil change indica tor will go off...

Page 156: ...r filter element Damage Replace TIP Replace the air filter element every 20000 km of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 3 Install Ai...

Page 157: ...ge box Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle body joint 1 Cracks damage Replace 3 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL HOSE 1 Remove Stor...

Page 158: ...nt level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA37P1019 Adding water instead of cool...

Page 159: ...trest board Bottom cover Storage box Refer to GENERAL CHASSIS on page 4 1 EAS21130 CHANGING THE COOLANT 1 Remove Bottom cover Refer to GENERAL CHASSIS on page 4 1 2 Remove Coolant reservoir cap 1 3 Di...

Page 160: ...wallowed induce vomiting and get immediate medical attention NOTICE ECA37P1020 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check an...

Page 161: ...rm it up for several min utes and then turn it off 15 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 31 TIP Before checking the coolant level wait a few minutes until the coolant h...

Page 162: ...oil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In...

Page 163: ...RAKE on page 4 17 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose holder 2 Loose connection Connect 3 Hold the vehicle upright and apply the re...

Page 164: ...ontact the throttle grip or handlebar grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the p...

Page 165: ...binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 57 e Install the rubber washer f Install the center ring nut g Finger tighten the cente...

Page 166: ...following procedure applies to both of the rear shock absorber assemblies WARNING EWA37P1006 Securely support the vehicle so that there is no danger of it falling over Always adjust both rear shock a...

Page 167: ...injury from sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band...

Page 168: ...e placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA37P1008 A damaged outer cable may cause...

Page 169: ...CHASSIS 3 42 EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease...

Page 170: ...ad light bulb holder NOTICE 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 wi...

Page 171: ...loth moistened with alcohol or lacquer thinner 7 Attach Headlight bulb holder 8 Connect Headlight coupler 9 Install Headlight bulb cover 10 Install Front cowling assembly Refer to GENERAL CHASSIS on p...

Page 172: ...ELECTRICAL SYSTEM 3 45...

Page 173: ...SSEMBLING THE FRONT BRAKE CALIPER 4 25 INSTALLING THE FRONT BRAKE CALIPER 4 25 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 26 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 26 ASSEMBLING THE FRONT BRAKE MA...

Page 174: ...53 ASSEMBLING THE FRONT FORK LEGS 4 53 INSTALLING THE FRONT FORK LEGS 4 55 STEERING HEAD 4 57 REMOVING THE LOWER BRACKET 4 59 CHECKING THE STEERING HEAD 4 59 INSTALLING THE STEERING HEAD 4 59 REAR SH...

Page 175: ......

Page 176: ...e light coupler 1 Disconnect 9 Mudguard 1 10 Water guard 1 11 Seat lock cable 1 Disconnect 12 Storage box 1 13 Safety protector 1 For installation reverse the removal proce dure 4 4 3 2 1 5 6 6 7 7 8...

Page 177: ...n b Install the storage box seat lock cable water guard and mudguard to the vehicle c Pass the license plate light coupler license plate light side through the hole in the safety protector at the loca...

Page 178: ...htening the mudguard bolts tighten the center bolt a first and then tighten the side bolts b 3 Install Seat TIP Tighten the seat nuts in the proper tightening se quence as shown T R Seat nut 10 Nm 1 0...

Page 179: ...ndshield bracket 1 5 Headlight assembly coupler 1 Disconnect 6 Front cowling assembly 1 7 Headlight assembly 1 For installation reverse the removal proce dure 1 6 6 4 4 7 5 4 2 6 3 LT LT LT 7 Nm 0 7 m...

Page 180: ...ng the headlight assembly 1 Rearview mirror 2 2 Center handlebar cover 1 3 Upper handlebar cover 1 4 Lower handlebar cover 1 5 Storage compartment molding 1 6 Meter assembly coupler 1 Disconnect 7 Met...

Page 181: ...the seat and storage box Front cowling assembly Refer to Removing the headlight assembly 1 Front turn signal light coupler 2 Disconnect 2 Front upper panel 2 3 Front turn signal light 2 4 Footrest boa...

Page 182: ...to Removing the radiator cover 1 Radiator air duct 1 2 Bottom cover 1 3 Auxiliary DC jack coupler OPTION 1 Disconnect 4 Storage compartment 1 5 Footrest board 1 For installation reverse the removal p...

Page 183: ...ensor coupler 1 Disconnect 4 Intake air temperature sensor 1 5 Cylinder head breather hose 1 Disconnect 6 Breather hose air filter case to throttle body 1 Disconnect YP250R only 7 Air filter case join...

Page 184: ...e Q ty Remarks 1 Front wheel axle pinch bolt 1 Loosen 2 Front wheel axle 1 3 Front wheel 1 4 Speed sensor 1 5 Spacer 1 6 Front brake disc 1 For installation reverse the removal proce dure 5 1 2 3 6 4...

Page 185: ...FRONT WHEEL 4 10 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 2 3 LS New...

Page 186: ...event damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle R...

Page 187: ...4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or...

Page 188: ...eavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it s...

Page 189: ...talling the speed sensor make sure that the projection on the wheel hub does not damage the lip of the speed sensor oil seal Make sure that the slot c in the speed sensor fits over the stopper d on th...

Page 190: ...YP250R on page 5 61 Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 61 1 Air filter case mounting bolt 2 2 Rear fender 1 3 Rear wheel 1 4 Washer 1 YP125R 5 Spacer 1 YP250R 6...

Page 191: ...el or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STA...

Page 192: ...peed sensor lead guide 1 3 Front brake caliper 1 4 Brake pad pin cap 1 5 Brake pad pin 1 6 Front brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 For installation reverse the removal proce dure...

Page 193: ...inder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8...

Page 194: ...19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1...

Page 195: ...EEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Speed sensor lead guide 1 6 Front brake caliper 1 For ins...

Page 196: ...iper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 11 Brake caliper body 1 For assembly reverse the disassembly pro cedure S S S...

Page 197: ...1 Remove Front wheel Refer to FRONT WHEEL on page 4 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the br...

Page 198: ...w brake pad support 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 pist...

Page 199: ...careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seals and brake caliper piston sea...

Page 200: ...CE 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 Remove Front brake caliper 3 Install Brake pad support Br...

Page 201: ...e master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Front brake hose 3 TIP To collect any remaining brake fluid place a container un...

Page 202: ...e recom mended brake fluid WARNING EWA13540 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...

Page 203: ...FRONT BRAKE 4 28 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 a...

Page 204: ...Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad clip 1 4 Brake pad pin 1 5 Rear brake pad 2 6 Brake pad spring 1 For installation reverse the removal proce dure S 1 3 4 5 5...

Page 205: ...emarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 For installation reverse the removal proce dure 2 5 5 4 3 1 4 S S 6 Nm 0...

Page 206: ...nder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Rea...

Page 207: ...32 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF...

Page 208: ...o BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation reverse the remov...

Page 209: ...Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 3 5 Rear brake caliper 1 For inst...

Page 210: ...aliper YP125R Order Job Parts to remove Q ty Remarks 1 Brake pad clip 1 2 Brake pad pin 1 3 Rear brake pad 2 4 Brake pad spring 1 5 Bleed screw cap 1 1 For assembly reverse the disassembly pro cedure...

Page 211: ...er bracket 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 6 Brake caliper piston 2 7 Brake caliper piston dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw 1 10 Brake caliper body...

Page 212: ...isc Damage galling 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 22 4 Measur...

Page 213: ...Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 EAS22580 REPLACING THE REAR BRAKE PADS YP250R TIP When replacing the brake pads it is not neces sary to disconnect th...

Page 214: ...or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake flui...

Page 215: ...ING THE REAR BRAKE CALIPER YP250R 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brak...

Page 216: ...holding the brake hose tighten the union bolt within the angle range shown in the illustration 2 Remove Rear brake caliper 3 Install Brake pad spring Brake pads Brake pad pin Brake pad clip Rear brake...

Page 217: ...pper washers 2 Rear brake hose 3 Brake hose union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING YP250R on page 2 75 NOTICE ECA...

Page 218: ...the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 35 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page...

Page 219: ...right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended bra...

Page 220: ...evel mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 35 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer...

Page 221: ...r cylinder 1 5 Right handlebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Rear brake light switch connector 2 Disconnect 9 Rear brake master cylinder holder 1 10 Rear brake master cyli...

Page 222: ...proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 7 5 5 3 13 9 11 6 6 1 14 12 4 2 10 8 1 LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft...

Page 223: ...2 Install Handlebar Upper handlebar holders NOTICE ECA37P1031 First tighten the front bolt on each handle bar holder then the rear bolt TIP The upper handlebar holders should be installed with the arr...

Page 224: ...p based grease Align the projection a on the right handlebar switch with the hole b in the handlebar Be sure to slide the throttle cable rubber cover to its original position 7 Install Front brake mas...

Page 225: ...4 1 Front wheel Refer to FRONT WHEEL on page 4 9 1 Front brake caliper 1 2 Front fender 1 3 Cap bolt 1 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 For installation reverse the removal proc...

Page 226: ...es to both of the front fork legs 1 Fork spring 1 2 Dust seal 1 3 Oil seal clip 1 4 Damper rod bolt 1 5 Copper washer 1 6 Damper rod 1 7 Inner tube 1 8 Oil flow stopper 1 9 Oil seal 1 10 Outer tube 1...

Page 227: ...nch bolts WARNING EWA37P1022 Before loosening the lower bracket pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front f...

Page 228: ...FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and...

Page 229: ...efore installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits...

Page 230: ...nutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 10 Measure Front fork leg oil level a from the top of the inner tube with...

Page 231: ...stalling the cap bolt take care not to damage the rectifier regulator with the tools TIP Before installing the cap bolt lubricate its O ring with grease If the cap bolt is difficult to install slightl...

Page 232: ...1 Speed sensor lead holder bracket 1 2 Steering stem nut 1 3 Lower handlebar holder 1 4 Woodruff key 1 5 Upper ring nut 1 6 Lock washer 1 7 Center ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lo...

Page 233: ...bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 4 5 6 7 8 9 11 12 13 18 3 2 10 15 16 14 17 1 LS LS 9 Nm 0 9 m kgf...

Page 234: ...ce 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and h...

Page 235: ...ing nut 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 37 3 Install Woodruff key 1 Lower handlebar holder 2 Steering stem nut TIP Align the woodruff key with the groove a in the lower h...

Page 236: ...Rear wheel axle nut 1 2 Brake hose holder 1 3 Rear brake caliper 1 4 Rear shock absorber assembly 2 5 Swingarm 1 6 Spacer 1 7 Collar 1 8 Oil seal 2 9 Bearing 2 For installation reverse the removal pro...

Page 237: ...hose holder 1 3 Rear brake caliper 1 4 Rear shock absorber assembly 2 5 Swingarm 1 6 Spacer 1 7 Collar 1 8 Oil seal 1 9 Oil seal 1 10 Circlip 1 11 Bearing 1 For installation reverse the removal proce...

Page 238: ...liper 3 Remove Swingarm EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Oil leaks Replace t...

Page 239: ...nut 135 Nm 13 5 m kgf 98 ft lbf Swingarm mounting bolt upper side 28 Nm 2 8 m kgf 20 ft lbf YP125R 59 Nm 5 9 m kgf 43 ft lbf YP250R Swingarm mounting bolt lower side 28 Nm 2 8 m kgf 20 ft lbf YP125R 5...

Page 240: ...REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 65...

Page 241: ...E SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 INSTALLING THE VALVES 5 23 CYLINDER AND PISTON YP125R 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDER AND PISTON 5 26 CHECKING THE PISTON RINGS 5 27 CH...

Page 242: ...HAFT ASSEMBLY 5 56 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 56 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 56 CHECKING THE CRANKCASE 5 57 CHECKING THE BEARING AND OIL SEAL 5 57 CHECKING THE...

Page 243: ...CH SHOES 5 94 CHECKING THE V BELT 5 94 CHECKING THE PRIMARY SHEAVE 5 95 CHECKING THE PRIMARY SHEAVE WEIGHTS 5 95 CHECKING THE PRIMARY SHEAVE SLIDERS 5 95 CHECKING THE SECONDARY SHEAVE 5 95 ASSEMBLING...

Page 244: ...SSEMBLY 5 117 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 118 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 118 CHECKING THE CRANKCASE 5 119 CHECKING THE BEARING AND OIL SEAL 5 119 CHECKING THE...

Page 245: ......

Page 246: ...s to remove Q ty Remarks 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 New New 14 Nm 1 4...

Page 247: ...duct joint Refer to V BELT AUTOMATIC TRANSMIS SION YP125R on page 5 30 Fuel injector assembly Throttle body Intake manifold Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 1 Disconnect 2 Coolant t...

Page 248: ...OVAL YP125R 5 3 8 Ground lead 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 3 5 1 2 4 8 7 6 7 Nm 0 7 m kgf 5 1 f...

Page 249: ...orber 2 3 Engine mounting nut washer bolt 1 1 1 4 Spacer 1 5 Engine bracket rod nut washer bolt 2 2 2 6 Engine bracket rod 2 7 Engine 1 8 Engine bracket nut bolt 2 2 9 Engine bracket 1 For installatio...

Page 250: ...r shock absorber assembly upper nuts Rear shock absorber assembly lower bolts 4 Install Gasket Exhaust pipe Exhaust pipe nuts temporarily tighten 5 Install Muffler Muffler mounting bolts temporarily t...

Page 251: ...ng bolts in the proper tightening sequence as shown 7 Tighten Exhaust pipe nuts 8 Tighten Muffler joint bolt O2 sensor T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler joint bolt 14 Nm 1 4 m...

Page 252: ...case air duct 1 6 V belt case air filter element 1 7 Cylinder head cover 1 8 Cylinder head cover gasket 1 9 Timing chain tensioner 1 10 Timing chain tensioner gasket 1 11 Camshaft sprocket 1 10 Nm 1 0...

Page 253: ...arks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 13 Nm 1 3 m...

Page 254: ...haft sprocket bolt 1 TIP While holding the primary sheave nut with a wrench remove the camshaft sprocket bolt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sp...

Page 255: ...urface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS37P1004 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket M...

Page 256: ...n the generator rotor with the stationary pointer b on the genera tor cover c Install the timing chain 1 onto the camshaft sprocket 2 then the camshaft sprocket onto the camshaft and then finger tight...

Page 257: ...gasket TIP Apply sealant to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then install the...

Page 258: ...ten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTI...

Page 259: ...YP125R on page 5 7 1 Locknut 4 2 Adjusting screw 4 3 Decompression cam 1 4 Camshaft retainer 1 5 Camshaft 1 6 Rocker arm shaft 2 7 Intake rocker arm 1 8 Exhaust rocker arm 1 For installation reverse t...

Page 260: ...ft sprocket and the decompression cam installed to the camshaft b Check that the decompression lever 1 moves smoothly c Without operating the decompression lever check that the decompression cam 2 pro...

Page 261: ...ion Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance TIP Calculate the clearance by subtracting the rock er arm s...

Page 262: ...illustration Make sure the rocker arm shafts intake and exhaust are completely pushed into the cylin der head 4 Install Camshaft 1 TIP Make sure that the camshaft projections a and hole b are positio...

Page 263: ...ER HEAD YP125R on page 5 7 Rocker arms Camshaft Refer to CAMSHAFT YP125R on page 5 14 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 L...

Page 264: ...cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3...

Page 265: ...roper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in...

Page 266: ...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...

Page 267: ...s lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be...

Page 268: ...cant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve spr...

Page 269: ...pring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damag...

Page 270: ...s Cylinder head Refer to CYLINDER HEAD YP125R on page 5 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring...

Page 271: ...ng open the end gap with your fingers and lift the other side of the ring over the piston crown EAS37P1021 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore...

Page 272: ...n Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring int...

Page 273: ...G CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS37P1024 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower...

Page 274: ...ankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While compressing the piston rings wit...

Page 275: ...AL CHASSIS on page 4 1 1 V belt case cover 1 2 V belt case air duct joint 1 3 V belt case air duct 1 4 V belt case air filter element 1 5 V belt case 1 6 V belt case gasket 1 1 7 V belt case gasket 2...

Page 276: ...1 1 2 Primary fixed sheave 1 3 Washer 1 4 Secondary sheave nut 1 5 Spacer 1 6 Clutch housing 1 7 Secondary sheave assembly 1 8 V belt 1 9 Primary sliding sheave 1 10 Oil seal 2 11 Spacer 1 12 Cam 1 13...

Page 277: ...2 Clutch carrier 1 3 Clip 3 4 Clutch carrier plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 3 9 Secondary sliding sheave 1 10 O ring 2 11 Oil seal 2 12 Oil seal 1 1...

Page 278: ...ousing 2 TIP While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut 2 Loosen Clutch carrier nut 1 NOTICE ECA13860 Do not remove the clutch carrier nut at this stage...

Page 279: ...all of the clutch shoes 1 Check Clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per TIP After sanding the glazed areas clean the clutch with...

Page 280: ...ck Primary sheave slider Cracks damage wear Replace EAS37P1034 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and...

Page 281: ...econdary sliding sheave inner surface 2 Oil seals Bearing with the recommended lubricant 2 Install Oil seal Secondary sliding sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed...

Page 282: ...ary sheave side 2 Tighten Clutch carrier nut 1 TIP While holding the clutch carrier with the sheave holder 2 tighten the clutch carrier nut with the locknut wrench 3 3 Install Clutch housing 1 Spacer...

Page 283: ...TICE ECA37P1014 Do not allow grease to contact the primary sheave assembly 5 Tighten Primary sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary s...

Page 284: ...r to ENGINE REMOVAL YP125R on page 5 1 1 Crankshaft position sensor coupler Stator as sembly coupler 1 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Crankshaft position s...

Page 285: ...marks 1 Circlip 1 2 Washer 1 3 Starter clutch idle gear shaft 1 4 Starter clutch idle gear 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Starter clutch 1 For installation reverse th...

Page 286: ...aft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS37P1040 REMOVING THE ST...

Page 287: ...generator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS37P1043 INSTALLING THE GENERATOR 1 Install...

Page 288: ...ll Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No...

Page 289: ...arter motor Order Job Parts to remove Q ty Remarks Storage box Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For i...

Page 290: ...otor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor yoke 1 3 O ring 1 4 Armature assembly 1 5 Shim 6 Brush 2 7 Spring 2 8 Front bracket brush holder set 1 For assembly reverse the d...

Page 291: ...on Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 M...

Page 292: ...ELECTRIC STARTER YP125R 5 47 7 Check Gear teeth Damage wear Replace the gear 8 Check Bearing Oil seal Bushing Damage wear Replace the defective part s...

Page 293: ...CLUTCH AND GENER ATOR YP125R on page 5 39 1 Oil pump plate 1 2 Oil pump assembly 1 3 Oil pump housing cover 1 4 Pin 1 5 Oil pump driven gear 1 6 Oil pump inner rotor 1 7 Oil pump outer rotor 1 8 Oil p...

Page 294: ...s EAS37P1048 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor 2 Lubricate Oil pump shaft with the recommended lubricant 3 Install Oil pump driven gear Oil pump housing 1 Oil pump outer rot...

Page 295: ...groove a in the inner rotor 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 49 EAS37P1049 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA37P1006 After tightening the...

Page 296: ...ISSION OIL on page 3 14 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION YP125R on page 5 30 1 Transmission case cover 1 2 Gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 1 6 C...

Page 297: ...axle 1 For installation reverse the removal proce dure Removing the transmission Order Job Parts to remove Q ty Remarks 11 7 10 9 6 5 3 3 4 6 5 2 1 6 8 8 11 7 9 E E E E E E E New New New New LS A B A...

Page 298: ...discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check Transmission gear engagement each pinion gear to its res...

Page 299: ...n page 5 30 Oil pump assembly Refer to OIL PUMP YP125R on page 5 48 Transmission Refer to TRANSMISSION YP125R on page 5 51 1 Oil filter element cover 1 2 Oil filter element 1 3 Oil strainer cover 1 4...

Page 300: ...Oil seal 1 For installation reverse the removal proce dure Removing the crankshaft Order Job Parts to remove Q ty Remarks 5 4 3 11 9 9 13 12 14 10 7 2 1 15 6 8 3 3 5 New New New New New New New LS LS...

Page 301: ...nkshaft assembly with the crankcase separating tool 2 and M6 bolts 3 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA37P1008 To protect the end of the c...

Page 302: ...HECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil deli...

Page 303: ...he oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt...

Page 304: ...nkcase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pattern M6 110 mm 4 33 in bolts 1 M6 80 mm 3 15 in bolts 2 M6 70 mm 2 76 in bolts 3 5 Install Oil filter element cover 1 TIP...

Page 305: ...CRANKSHAFT YP125R 5 60 a 1...

Page 306: ...s to remove Q ty Remarks 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 For installation reverse the removal proce dure 3 4 5 2 1 6 New New 14 Nm 1 4...

Page 307: ...GENERAL CHASSIS on page 4 1 Fuel injector assembly Throttle body Intake manifold Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Cr...

Page 308: ...OVAL YP250R 5 63 8 Ground lead 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 8 7 3 2 1 4 6 5 7 Nm 0 7 m kgf 5 1...

Page 309: ...orber 2 3 Engine mounting nut washer bolt 1 1 1 4 Spacer 1 5 Engine bracket rod nut washer bolt 2 2 2 6 Engine bracket rod 2 7 Engine 1 8 Engine bracket nut bolt 2 2 9 Engine bracket 1 For installatio...

Page 310: ...r shock absorber assembly upper nuts Rear shock absorber assembly lower bolts 4 Install Gasket Exhaust pipe Exhaust pipe nuts temporarily tighten 5 Install Muffler Muffler mounting bolts temporarily t...

Page 311: ...ng bolts in the proper tightening sequence as shown 7 Tighten Exhaust pipe nuts 8 Tighten Muffler joint bolt O2 sensor T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler joint bolt 14 Nm 1 4 m...

Page 312: ...ket cover 1 7 Tappet cover 2 8 Timing chain tensioner 1 9 Timing chain tensioner gasket 1 10 Camshaft sprocket plate 1 11 Camshaft sprocket 1 12 Dowel pin 1 13 Cylinder head 1 3 4 1 4 7 2 8 14 15 9 12...

Page 313: ...4 7 2 8 14 15 9 12 11 10 13 7 5 6 E New New New New New New New LS LS New New LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft...

Page 314: ...ve nut with a wrench remove the camshaft sprocket bolt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket plate 2 Camshaft sprocket TIP To prevent the tim...

Page 315: ...ead using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS23870 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear...

Page 316: ...amshaft sprocket and then install the camshaft sprocket onto the camshaft TIP When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side Align the...

Page 317: ...mshaft sprocket is aligned with the stationary pointer d on the cylinder head Out of alignment Correct Refer to the installation steps above 6 Tighten Camshaft sprocket bolt NOTICE ECA37P1010 Be sure...

Page 318: ...0R on page 5 67 1 Locknut 2 Loosen 2 Adjusting screw 2 Loosen 3 Lock plate 1 4 Camshaft retainer 1 5 Intake rocker arm shaft 1 6 Exhaust rocker arm shaft 1 7 Rocker arm 2 8 Camshaft 1 For installation...

Page 319: ...CKING THE CAMSHAFT 1 Check Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft Slide hammer b...

Page 320: ...shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defective part s EAS24040 INSTALL...

Page 321: ...Intake rocker arm shaft 1 TIP Insert a guide stud 8 mm 2 into the stud bolt hole in the cylinder head and install the intake rocker arm shaft as shown NOTICE ECA13780 Make sure the threaded part of th...

Page 322: ...HEAD YP250R on page 5 67 Rocker arms Camshaft Refer to CAMSHAFT YP250R on page 5 73 1 Valve cotter 4 2 Upper spring seat 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valv...

Page 323: ...IP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Outer valve spring 2 Inner valve...

Page 324: ...the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear...

Page 325: ...seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve...

Page 326: ...face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valv...

Page 327: ...6 88 N 7 75 8 97 kgf 17 08 19 78 lbf Installed compression spring force exhaust 76 88 N 7 75 8 97 kgf 17 08 19 78 lbf Installed length intake 30 10 mm 1 19 in Installed length exhaust 30 10 mm 1 19 in...

Page 328: ...tall Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 5 To secure the valve cotters onto the...

Page 329: ...to CYLINDER HEAD YP250R on page 5 67 1 Water pump outlet pipe 1 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Clip 2 7 Piston pin 1 8 Piston 1 9 Top ring 1 10 2...

Page 330: ...ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore...

Page 331: ...Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into...

Page 332: ...G CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oi...

Page 333: ...o the crankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder TIP While compressing the piston rin...

Page 334: ...filter case Refer to GENERAL CHASSIS on page 4 1 1 V belt case air filter cover 1 2 V belt case air filter element 1 3 V belt case cover 1 4 V belt case 1 5 V belt case gasket 1 6 Dowel pin 2 For ins...

Page 335: ...ry sheave bracket 1 4 Secondary sheave nut 1 5 Spacer 1 6 Clutch housing 1 7 Secondary sheave assembly 1 8 V belt 1 9 Primary sliding sheave 1 10 Spacer 1 11 Primary sheave cap 1 12 Cam 1 13 Weight 8...

Page 336: ...removal proce dure Yamaha grease G 90793 40016 Removing the V belt primary sheave and secondary sheave Order Job Parts to remove Q ty Remarks LS LS LS LS LT LT E 4 11 14 15 12 13 9 New New New 10 2 1...

Page 337: ...rier nut 1 2 Clutch carrier 1 3 Clip 3 4 Clutch carrier plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 4 9 Secondary sliding sheave 1 10 O ring 2 11 Oil seal 2 12 Se...

Page 338: ...sing 2 TIP While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut 2 Loosen Clutch carrier nut 1 NOTICE ECA13860 Do not remove the clutch carrier nut at this stage TI...

Page 339: ...ll of the clutch shoes 1 Check Clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per TIP After sanding the glazed areas clean the clutch with a...

Page 340: ...k Primary sheave slider Cracks damage wear Replace EAS24710 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sl...

Page 341: ...sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 3 Install Guide pins 1 4 Lubricate Guide pin grooves 2 O rings 3 with the recommended lub...

Page 342: ...1 TIP While holding the clutch carrier with the sheave holder 2 tighten the clutch carrier nut with the locknut wrench 3 3 Install Clutch housing 1 Spacer Secondary sheave nut 2 TIP While holding the...

Page 343: ...hen the pulley is at its narrowest position and make sure the V belt is tight 5 Tighten Primary sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primar...

Page 344: ...to ENGINE REMOVAL YP250R on page 5 61 1 Crankshaft position sensor coupler Stator as sembly coupler 1 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Crankshaft position s...

Page 345: ...s to remove Q ty Remarks 1 Circlip 1 2 Washer 1 3 Starter clutch idle gear shaft 1 4 Starter clutch idle gear 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Starter clutch 1 For inst...

Page 346: ...protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator r...

Page 347: ...le holding the generator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS24500 INSTALLING THE GENERAT...

Page 348: ...embly lead grommet 4 Install Oil seal 1 5 Install Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 90890 85505 Three Bond No 1215 Install...

Page 349: ...arter motor Order Job Parts to remove Q ty Remarks Storage box Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For i...

Page 350: ...3 Shim 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Starter motor yoke 1 8 Armature assembly 1 9 O ring 1 10 Shim 11 Brush holder set 1 12 Starter motor rear cover 1 13 Bushing 1 For assembly reverse th...

Page 351: ...nsulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter mo...

Page 352: ...Bearing Damage wear Replace the bearing EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the match marks a on the...

Page 353: ...YP250R on page 5 99 1 Oil baffle plate 1 2 Oil pump assembly 1 3 Oil pump gasket 1 4 Circlip 1 5 Washer 1 6 Oil pump driven gear 1 7 Pin 1 8 Oil pump housing cover 1 9 Pin 2 10 Pin 1 11 Oil pump shaft...

Page 354: ...housing 1 For installation reverse the removal proce dure Removing the oil pump Order Job Parts to remove Q ty Remarks New New 4 1 5 6 7 9 9 2 8 13 11 14 12 10 3 LS E E M 7 Nm 0 7 m kgf 5 1 ft Ibf T...

Page 355: ...ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor 2 Lubricate Oil pump shaft with the recommended lubricant 3 Install Oil pump shaft 1 Pin 2 TIP When installing the oil pump shaft align the...

Page 356: ...n Refer to CHECKING THE OIL PUMP on page 5 110 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pum...

Page 357: ...r to CHANGING THE FINAL TRANS MISSION OIL on page 3 28 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION YP250R on page 5 89 1 Transmission case cover 1 2 Gasket 1 3 Dowel pin 2 4 Prim...

Page 358: ...ON YP250R 5 113 12 Primary driven gear 1 For installation reverse the removal proce dure Removing the transmission Order Job Parts to remove Q ty Remarks E E E E E A B LS New 5 3 16 Nm 1 6 m kgf 11 ft...

Page 359: ...scoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check Transmission gear engagement each pinion gear to its respe...

Page 360: ...R on page 5 84 Belt drive Refer to V BELT AUTOMATIC TRANSMIS SION YP250R on page 5 89 Oil pump assembly Refer to OIL PUMP YP250R on page 5 108 Transmission Refer to TRANSMISSION YP250R on page 5 112 1...

Page 361: ...in 1 12 Left crankcase 1 13 Oil seal 1 For installation reverse the removal proce dure Removing the crankshaft Order Job Parts to remove Q ty Remarks New New 2 7 11 13 6 1 12 3 4 5 9 9 LS LS E E LS 8...

Page 362: ...t EAS26020 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove Timing chain 1 TIP Before removing the crankshaft assembly re move the timing chain from the crankshaft sprocket The crankshaft assembly cannot be...

Page 363: ...2 Measure Big end side clearance Out of specification Replace the crank shaft 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket 1 Damage wear Replace...

Page 364: ...NKSHAFT 1 Lubricate Oil seals Bearings Oil pump drive gear 2 Install Oil seal 1 to the left crankcase 3 Install Timing chain 1 TIP Install the timing chain so it is not visible through the opening a i...

Page 365: ...ting surfaces 2 Apply Sealant onto the crankcase mating surfaces TIP Do not allow any sealant to come into contact with the oil gallery 3 Install Right crankcase 1 TIP Install the crankshaft assembly...

Page 366: ...CRANKSHAFT YP250R 5 121...

Page 367: ...E WATER PUMP 6 6 CHECKING THE WATER PUMP 6 6 ASSEMBLING THE WATER PUMP 6 6 INSTALLING THE WATER PUMP 6 7 RADIATOR YP250R 6 8 CHECKING THE RADIATOR 6 9 INSTALLING THE RADIATOR 6 9 THERMOSTAT YP250R 6 1...

Page 368: ...G THE COOLANT on page 3 18 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator filler hose 1 5 Radiator inlet hose 1 6 Radiator outlet hose 1 7 Radiator fan motor coupler 1 Di...

Page 369: ...3 Check Radiator fan motor Damage Replace Malfunction Check and repair Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 87 EAS37P1107 INSTALLING THE RADIATOR 1 Install Radiator outlet hose screw cl...

Page 370: ...y Remarks Storage box Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 18 1 Radiator inlet hose 1 Disconnect 2 Thermostat inlet hose 1 3 Thermostat cover 1 4...

Page 371: ...e TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS37P1110 INSTALLING...

Page 372: ...Water pump housing cover 1 4 Water pump housing cover gasket 1 5 Cylinder head breather hose 1 Disconnect 6 Water pump housing 1 7 Water pump housing plate 1 1 8 Water pump housing plate 2 1 9 Water...

Page 373: ...ER PUMP 1 Install Water pump seal 1 into the water pump housing 2 TIP Install the water pump seal with the special tools to the specified depth as shown in the illustra tion 2 Lubricate Water pump sea...

Page 374: ...PUMP 1 Install O rings Water pump assembly 1 TIP Lubricate the O rings with a thin coat of lithium soap based grease Align the projection a on the impeller shaft with the slot b in the camshaft sproc...

Page 375: ...THE COOLANT on page 3 32 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator filler hose 1 5 Radiator inlet hose 1 6 Radiator outlet hose 1 7 Radiator fan motor coupler 1 Dis...

Page 376: ...3 Check Radiator fan motor Damage Replace Malfunction Check and repair Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 87 EAS26400 INSTALLING THE RADIATOR 1 Install Radiator outlet hose screw clam...

Page 377: ...ge box Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 1 Radiator inlet hose 1 Disconnect 2 Thermostat inlet hose 1 3 Thermostat cover 1 4 Thermostat 1 Fo...

Page 378: ...re TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26460 INSTALLING T...

Page 379: ...r rotor Refer to STARTER CLUTCH AND GENER ATOR YP250R on page 5 99 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 1 Oil baffle plate 1 2 Impeller shaft gear 1 3 Washer 1 4 Radiator outlet ho...

Page 380: ...il seal 1 For installation reverse the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks New LS LS 12 11 13 New New New 7 8 10 9 5 6 4 3 2 1 LS LS A LT M 10 Nm 1 0 m kg...

Page 381: ...1 Check Water pump housing cover Water pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26570 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the wa...

Page 382: ...all Impeller shaft gear 1 TIP Align the slot on the impeller shaft with the pro jection on the impeller shaft gear when installing 2 Fill Cooling system with the specified amount of the recom mended c...

Page 383: ...7 5 REMOVING THE FUEL HOSE 7 9 CHECKING THE FUEL INJECTOR 7 9 CHECKING THE THROTTLE BODY 7 9 INSTALLING THE INTAKE MANIFOLD YP125R 7 9 INSTALLING THE INTAKE MANIFOLD YP250R 7 9 INSTALLING THE FUEL HOS...

Page 384: ...6 Plastic locking tie 1 YP250R only 7 Tube 1 YP250R only 8 Fuel hose connector cover 1 9 Fuel hose 1 Disconnect 10 Fuel sender 1 11 Fuel tank bracket 1 12 Radiator fan motor coupler 1 Disconnect 13 C...

Page 385: ...he fuel tank Order Job Parts to remove Q ty Remarks New New LT 16 13 13 14 12 16 1 15 11 4 4 10 8 9 3 7 6 2 5 17 4 13 Nm 1 3 m kgf 9 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 386: ...nder where it will be removed 4 Remove Fuel sender 1 TIP Remove the fuel sender with the fuel sender wrench 2 5 Remove Fuel tank TIP To remove the fuel tank lower the radiator 1 NOTICE ECA37P1021 When...

Page 387: ...ose connector cover NOTICE ECA37P1022 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover is in the correct posi tion otherwise the fuel hose w...

Page 388: ...er 1 Disconnect 7 Throttle position sensor 1 8 Throttle cable 2 Disconnect 9 Air filter case joint clamp screw 1 Loosen 10 Throttle body joint clamp screw 1 Loosen 11 Throttle body 1 12 Fuel injector...

Page 389: ...s to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1...

Page 390: ...Throttle position sensor 1 8 Throttle cable 2 Disconnect 9 Breather hose air filter case to throttle body 1 10 Air filter case joint clamp screw 1 Loosen 11 Throttle body joint clamp screw 1 Loosen 12...

Page 391: ...250R Order Job Parts to remove Q ty Remarks 12 3 4 1 9 5 10 16 13 8 8 17 15 11 7 6 14 2 LS New New New E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Page 392: ...EAS26990 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent Do not...

Page 393: ...aining in the recess a in the fuel pump with a dry rag 1 After installing the fuel hose connector cover 2 make sure that it is installed securely EAS37P1076 INSTALLING THE THROTTLE BODY 1 Install Thro...

Page 394: ...THROTTLE BODY 7 11...

Page 395: ...CUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING M...

Page 396: ...84 CHECKING THE STARTER MOTOR OPERATION 8 84 CHECKING THE STATOR COIL 8 85 CHECKING THE RECTIFIER REGULATOR 8 85 CHECKING THE HORN 8 85 CHECKING THE FUEL SENDER 8 86 CHECKING THE FUEL LEVEL WARNING LI...

Page 397: ......

Page 398: ...R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R...

Page 399: ...M 8 2 2 Crankshaft position sensor 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 18 Sidestand switch 29 Lean angle sensor 31 ECU engine control unit 32 Ignition coil...

Page 400: ...page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 24 Re gap or replace the spark plug 4 Check the ignition spark...

Page 401: ...the sidestand switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the sidestand switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 84 Replace the lean angl...

Page 402: ...1 Sb Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L R B B W Y L R L G L G L...

Page 403: ...gnition fuse 11 Signaling system fuse 12 Battery 13 Main fuse 14 Starter relay 15 Starter motor 16 Diode 17 Frame ground 18 Sidestand switch 20 Starting circuit cut off relay 22 Start switch 24 Front...

Page 404: ...osed 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...

Page 405: ...tery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Starting circuit cut off relay 6 Sidestand switch 7 Signaling system fuse 8 Front brake light switch 9 Rear brake light switch 10 Start switch 11 Diode...

Page 406: ...y 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 84 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check...

Page 407: ...ont and rear Refer to CHECKING THE SWITCHES on page 8 73 Replace the brake light switch es 10 Check the start switch Refer to CHECKING THE SWITCHES on page 8 73 The start switch is faulty Replace the...

Page 408: ...W W W2 W3 R W Gy B W R R L R B G L Y L B W L W Dg W Y Br Br W Ch G Y Dg Br Ch G Y L W Br W W Y R W3 W2 W B L W BLACK B R ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br LBr R R R G R W R B R Y R Br R Br...

Page 409: ...CHARGING SYSTEM 8 12 1 AC magneto 3 Rectifier regulator 12 Battery 13 Main fuse 17 Frame ground...

Page 410: ...AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 85 Replace the crankshaft position...

Page 411: ...CHARGING SYSTEM 8 14...

Page 412: ...R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R...

Page 413: ...use 10 Headlight fuse 11 Signaling system fuse 12 Battery 13 Main fuse 17 Frame ground 31 ECU engine control unit 40 Headlight relay 42 Dimmer switch 43 Pass switch 49 Tail brake light 55 Headlight 56...

Page 414: ...l hazard and signaling sys tem Refer to CHECKING THE FUS ES on page 8 77 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Rech...

Page 415: ...LIGHTING SYSTEM 8 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or repair the lighting sys tem wiring Replace the ECU or meter assembly...

Page 416: ...g R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L...

Page 417: ...rd relay 44 Turn signal switch 45 Horn switch 46 Rear brake light switch 48 Right rear turn signal light 49 Tail brake light 51 Left rear turn signal light 52 Right front turn signal light 53 Left fro...

Page 418: ...he fuses Main signaling system ignition ECU and turn signal hazard Refer to CHECKING THE FUS ES on page 8 77 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8...

Page 419: ...efer to CHECKING THE BULBS AND BULB SOCKETS on page 8 76 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the f...

Page 420: ...heck the turn signal hazard relay Refer to CHECKING THE TURN SIGNAL HAZARD RELAY on page 8 81 Replace the turn signal hazard relay 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM o...

Page 421: ...sor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the ECU or meter assembly 1 Check the crankshaft pos...

Page 422: ...eck the V belt replacement indi cator reset coupler Refer to CHECKING THE V BELT REPLACEMENT INDICATOR RE SET COUPLER on page 8 90 Replace the V belt replacement indicator reset coupler 2 Check the en...

Page 423: ...SIGNALING SYSTEM 8 26...

Page 424: ...R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R...

Page 425: ...28 5 Main switch 6 ECU fuse 7 Radiator fan motor fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 25 Coolant temperature sensor 31 ECU engine control unit 73 Radiator fan motor 74 Radiator...

Page 426: ...or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN...

Page 427: ...COOLING SYSTEM 8 30...

Page 428: ...Sb Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L...

Page 429: ...el pump 25 Coolant temperature sensor 26 Throttle position sensor 27 Intake air pressure sensor 28 Intake air temperature sensor 29 Lean angle sensor 30 Speed sensor 31 ECU engine control unit 32 Igni...

Page 430: ...isted below is present and the start switch is pushed Checking for a defective engine trouble warning light The engine trouble warning light comes on for 2 0 seconds after the main switch has been set...

Page 431: ...iagnos tic mode Refer to DIAGNOSTIC CODE TA BLE on page 8 54 Diagnostic code No 62 TIP Setting the main switch to OFF will not erase the malfunction history The engine operation is not normal but the...

Page 432: ...elected diagnostic code number press the DOWN button Press the DOWN but ton for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number...

Page 433: ...Fault code No 12 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No...

Page 434: ...sensor coupler and ECU coupler gray red gray red pink white pink white gray black gray black 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer t...

Page 435: ...ly closed Check with throttle fully opened Probable cause of malfunction Check or maintenance job 1 Installed condition of throttle position sensor Check for looseness or pinching Check that the senso...

Page 436: ...ENSOR on page 8 88 Reinstatement method Turning the main switch to ON Fault code No 19 Item Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected Fail safe system Un...

Page 437: ...ction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU coupl...

Page 438: ...h to ON Fault code No 24 Item O2 sensor no normal signal is received from the O2 sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI diagnostic tool display Checki...

Page 439: ...or coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securel...

Page 440: ...The amount of air fuel ratio feedback compensa tion is maintained continuously in the vicinity of the lower lim it Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI dia...

Page 441: ...enance job 1 Connections Ignition coil connector primary coil side Wire harness ECU coupler Check the connector and coupler for any pins that may be pulled out Check the locking condition of the conne...

Page 442: ...by the ECU Check that the ISC unit coupler is not discon nected The ISC valve is stuck fully open if it does not operate when the main switch is turned OFF Touch the ISC unit with your hand and check...

Page 443: ...able to start engine Unable to drive vehicle Diagnostic code No 08 FI diagnostic tool display Lean angle sensor 0 4 1 4 upright 3 7 4 4 overturned Checking method Remove the lean angle sensor and incl...

Page 444: ...f there is an open or short circuit Between speed sensor coupler and ECU cou pler gray red gray red gray gray gray black gray black 3 Defective speed sensor Execute the diagnostic mode Code No 07 Repl...

Page 445: ...Between ignition fuse terminal and ECU cou pler red black red black 3 Malfunction or open circuit in fuel sys tem Execute the diagnostic mode Code No 09 Reinstatement method Starting the engine and op...

Page 446: ...gulator Replace if defective Refer to CHARGING SYSTEM on page 8 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery terminal and ECU fuse...

Page 447: ...ly 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ISC idle speed control unit and ECU coupler pink pink light green light green green green sky...

Page 448: ...er display Checking method Probable cause of malfunction Check or maintenance job 1 Connections Meter assembly coupler Wire harness ECU coupler Self diagnosis signal coupler Check the coupler for any...

Page 449: ...Between meter assembly coupler and self di agnosis signal coupler yellow blue yellow blue Between self diagnosis signal coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly...

Page 450: ...coupler yellow blue yellow blue Between self diagnosis signal coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace t...

Page 451: ...ctuates five times by listening for the operating sound 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates the WARNING LED on the F...

Page 452: ...onnection in connecting lead The main switch is set to OFF Malfunction in FI diagnostic tool Malfunction in ECU ERROR 4 Commands from the FI diagnostic tool are not accepted by the ECU Set the main sw...

Page 453: ...FUEL INJECTION SYSTEM 8 56...

Page 454: ...g R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L...

Page 455: ...FUEL PUMP SYSTEM 8 58 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 19 Fuel pump 31 ECU engine control unit...

Page 456: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Repl...

Page 457: ...FUEL PUMP SYSTEM 8 60...

Page 458: ...Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G...

Page 459: ...r unit and meter assembly 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 31 ECU engine control unit 61 Immobilizer system indicator light 62 Multifunction meter 75 Se...

Page 460: ...is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made...

Page 461: ...andby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours A...

Page 462: ...h then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key r...

Page 463: ...Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Im...

Page 464: ...ean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the entire immobilizer sy...

Page 465: ...it mal function 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the imm...

Page 466: ...IMMOBILIZER SYSTEM 8 69 a Light on b Light off...

Page 467: ...IMMOBILIZER SYSTEM 8 70...

Page 468: ...ELECTRICAL COMPONENTS 8 71 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 22 23 24 25 26 28 29 30 27 21 14...

Page 469: ...ture sensor 11 Intake air pressure sensor 12 Throttle position sensor 13 ISC idle speed control unit 14 Crankshaft position sensor 15 Stator coil 16 Coolant temperature sensor 17 O2 sensor 18 Sidestan...

Page 470: ...EAS27980 CHECKING THE SWITCHES 1 2 3 4 Br W Ch Dg P B B B BLUE 10 5 7 6 8 9 Br G Y ON R Br L Br R OFF OPEN LOCK P Br R R Br L G Y Br R Y L B B P Dg Y G Br W Ch L B G Y R Y Y Dg Ch Br W G Y Br L W W Y...

Page 471: ...RICAL COMPONENTS 8 74 1 Start switch 2 Hazard switch 3 Front brake light switch 4 Main switch 5 Dimmer switch 6 Pass switch 7 Turn signal switch 8 Horn switch 9 Rear brake light switch 10 Sidestand sw...

Page 472: ...er to 0 and to the 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following e...

Page 473: ...bs 1 Remove Bulb WARNING EWA37P1018 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA37P1039 Be sure to hold the sock...

Page 474: ...behind the front cowling assembly NOTICE ECA37P1040 To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Upper panel and or front cowling assembly Ref...

Page 475: ...XTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or veg...

Page 476: ...removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and t...

Page 477: ...battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals NOTICE ECA13630 First connect the positive battery lead 1 and then the negative battery lead...

Page 478: ...tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive batt...

Page 479: ...1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coi...

Page 480: ...own c Set the main switch to ON d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRA...

Page 481: ...ting starting with step 4 Refer to TROUBLESHOOTING on page 8 9 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper...

Page 482: ...roximate ly 5000 r min d Measure the charging voltage EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn connectors from the horn terminals b Connect...

Page 483: ...The warning light comes on for a few sec onds then goes off The warning light is OK The warning light does not come on Re place the meter assembly All LCD segments of the fuel meter 2 and the fuel lev...

Page 484: ...on page 5 7 and CYLINDER HEAD YP250R on page 5 67 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolan...

Page 485: ...ace the throttle position sen sor Out of specification closed position Re place the throttle position sensor EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output...

Page 486: ...t get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the spec ified temperature e Measure the intake air temperature sensor resistance EAS37P1083 CHECKING THE AIR TEM...

Page 487: ...c Measure the ISC unit resistance Out of specification Replace the throttle body EAS37P1084 CHECKING THE V BELT REPLACEMENT INDICATOR RESET COUPLER 1 Remove V belt replacement indicator reset coupler...

Page 488: ...91 a Connect the pocket tester 1 to the V belt replacement indicator reset coupler ter minals b Check the V belt replacement indicator reset coupler for continuity Pocket tester 90890 03112 Analog po...

Page 489: ...FAILURE HARD STARTING 9 1 INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK...

Page 490: ...damaged fuel hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2...

Page 491: ...imary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation 3 Clutch shoe s Bent damaged or...

Page 492: ...AS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed lower handlebar holder Improperly installed lower bracket improperly tighte...

Page 493: ...relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signals flash slowly Faulty turn si...

Page 494: ...ht assembly 51 Left rear turn signal light 52 Right front turn signal light 53 Left front turn signal light 54 Headlight assembly 55 Headlight 56 Auxiliary light 57 License plate light 58 Fuel sender...

Page 495: ......

Page 496: ...YAMAHA MOTOR ESPA A S A...

Page 497: ...B O B Y L O P W B W W R L Y L W L R B R W B B1 Sb Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P...

Page 498: ...BLUE BLUE BLACK GREEN P BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK Y A WIRE HARNESS SUB WIRE HARNESS BLACK BLACK BLACK A ON OFF OPEN LOCK P A A A 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69...

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Yamaha YP125R, Service Manual

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