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Yamaha YZ 2015 Series, Owner'S Service Manual


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CYLINDER AND PISTON

5-32

EASB291232

CYLINDER AND PISTON

Removing the cylinder and piston

Order

Part name

Q’ty

Remarks

Cylinder head

Refer to “CYLINDER HEAD” on page 5-20.

1

Cylinder body

1

2

Gaskets

1

3

Dowel pin

2

4

Piston pin clip

2

5

Piston pin

1

6

Piston

1

7

Piston ring set

1

For installation, reverse the removal proce-

dure.

1

2

3

4

4

5

6

7

10 Nm (1.0 m kgf, 7.2 ft Ibf)

T.R.

10 Nm (1.0 m kgf, 7.2 ft Ibf)

T.R.

E

E

New

New

New

LT

E

Summary of Contents for YZ 2015 Series

Page 1: ...UAL YZ250FXF B29 28199 10 LIT 11626 28 51 YZ250FXF 2015 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014 09 0 8 1 E B29 28199 10_cover_12mm in...

Page 2: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Page 3: ...14 by Yamaha Motor Corporation U S A 1st Edition September 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly pro...

Page 4: ...ANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YO...

Page 5: ...HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or ex haust system Never refuel in the vicinity of an open flame or while smoking GASOLIN...

Page 6: ...EASB291006 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 7: ...he section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in t...

Page 8: ...FINITION 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...

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

Page 10: ......

Page 11: ...PART 1 6 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1...

Page 12: ...1 22 AIR FILTER MAINTENANCE 1 22 STARTING A COLD ENGINE 1 22 STARTING A WARM ENGINE 1 23 BREAK IN PROCEDURES 1 24 MAINTENANCE AFTER BREAK IN 1 25 MAJOR MAINTENANCE 1 25 TORQUE CHECK POINTS 1 26 MOTOR...

Page 13: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D...

Page 14: ...those for the vehicle you have pur chased 1 Clutch lever 10 Radiator 2 Front brake lever 11 Coolant drain bolt 3 Throttle grip 12 Rear brake pedal 4 Start switch 13 Air filter 5 Radiator cap 14 Drive...

Page 15: ...ositive iden tification of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EASB291012 VEHICLE IDENTIFICATION NUMBER The vehic...

Page 16: ...n under a heavy load The carburetor that mea sures fuel through the use of jets are provided with various auxiliary devices so that the optimum air fuel ratio can be obtained to accommodate frequent c...

Page 17: ...the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals input from the throt tle position sensor the coolant temperature senso...

Page 18: ...sed to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EASB291021 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting th...

Page 19: ...ach section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the li...

Page 20: ...ASB291026 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces...

Page 21: ...ry lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water ECA NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the b...

Page 22: ...en push the starter switch Be sure to wait for five seconds or lon ger before pushing the start switch after the en gine is stopped Checking the electrical system TIP Before checking the electrical sy...

Page 23: ...e to check the type of cou pler lock before disconnecting the cou pler ECA NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector and then disconnect the con n...

Page 24: ...terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a q...

Page 25: ...use tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This...

Page 26: ...This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 This tool is used to remove or tighten the base valve Cap bolt ring wrench 90890 01501 Cap...

Page 27: ...essure gauge Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 This tool is used to check the throttle position sensor input voltage Test harness lean angle sens...

Page 28: ...older YM 91042 This tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is used t...

Page 29: ...guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 This tool is u...

Page 30: ...90 06760 Digital tachometer YU 39951 B This tool is used to measure the engine speed Yamaha bond No 1215 90890 85505 Three bond No 1215 This sealant Bond is used for crankcase mating sur face etc Tool...

Page 31: ...clutch Pull the clutch lever toward the handlebar to disengage the clutch and release the lever to engage the clutch EASB291035 SHIFT PEDAL The shift pedal 1 has adopted a method of 1 down 5 ups pres...

Page 32: ...TING SCREW Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob idle screw 1 Pulling the knob toward a turns ON the start er resulting in a larger amount...

Page 33: ...CONTROL FUNCTIONS 1 21 a 2...

Page 34: ...well ventilated area ECA NOTICE Unlike a two stroke engine this engine cannot be kick started when the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel...

Page 35: ...ne stop switch till the engine comes to a full stop Starting with the kickstarter When using the kickstarter to start the engine follow the procedures as described below 1 Fold out the kickstarter lev...

Page 36: ...reas for looseness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spok...

Page 37: ...is connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets...

Page 38: ...absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tighten...

Page 39: ...2 Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fend...

Page 40: ...may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or...

Page 41: ...ill wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EASB291055 STORAGE Short term Always store your motorcycle in a cool dry place and if necessary protect it agains...

Page 42: ...es from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charg...

Page 43: ...FICATIONS 2 11 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2...

Page 44: ...3 EUR B294 AUS NZL ZAF B295 JPN Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1465 mm 57 7 in Ground cleara...

Page 45: ...ent replacement 0 83 L 0 88 US qt 0 73 Imp qt With oil filter element replacement 0 85 L 0 90 US qt 0 75 Imp qt Oil filter Oil filter type Paper Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 k...

Page 46: ...shaft lobe dimensions Intake A 31 730 31 830 mm 1 2492 1 2531 in Limit 31 630 mm 1 2453 in Intake B 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Exhaust A 33 370 33 470 mm 1 3138 1 3177...

Page 47: ...in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 003...

Page 48: ...3 0303 in Measuring point from piston skirt bottom 6 0 mm 0 24 in Offset 0 00 mm 0 0000 in Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in Limit 16 043 mm 0 6316 in Piston pin outsid...

Page 49: ...in Clutch spring free length 47 80 mm 1 88 in Limit 46 80 mm 1 84 in Spring quantity 5 pcs Push rod bending limit 0 10 mm 0 004 in Transmission Transmission type Constant mesh 6 speed Primary reducti...

Page 50: ...on sensor Crankshaft position sensor resistance 228 342 Gy B Intake air pressure sensor output voltage 3 61 3 67 V at 101 3 kPa 3 61 3 67 V at 1 01 kgf cm2 3 61 3 67 V at 14 7 psi Intake air temperatu...

Page 51: ...0 02 in Front tire Type With tube Size 90 90 21 54M Manufacturer model DUNLOP AT81F Rear tire Type With tube Size 110 100 18 64M Manufacturer model DUNLOP AT81 Tire air pressure measured on cold tires...

Page 52: ...Coil spring oil damper Front fork travel 310 0 mm 12 20 in Fork spring free length 470 0 mm 18 50 in Limit 465 0 mm 18 31 in Fork spring installed length 470 0 mm 18 50 in Spring rate K1 4 40 N mm 0...

Page 53: ...n in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Position in which the adjuster is turned in finger tight Minimum 30 click s out Standard 11 cl...

Page 54: ...emi conductor short circuit No load regulated voltage 14 1 14 9 V Rectifier capacity DC 23 0 A Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah Specific gravity 1 31 Manufacturer GS YUASA Ten hour r...

Page 55: ...To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 56: ...bf Timing chain guide stopper plate exhaust side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft...

Page 57: ...M6 12 12 Nm 1 2 m kgf 8 7 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft end accessing screw M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing mark accessing screw M14 1 6 Nm 0 6 m...

Page 58: ...bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Damper assembly cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch bolt M6 6 16 Nm 1 6 m kgf 12 ft lbf Starter motor bolt M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Co...

Page 59: ...m 0 13 m kgf 0 94 ft lbf Front fork protector bolt M6 6 5 Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 3...

Page 60: ...lt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft lbf Engine mounting bolt front side M10...

Page 61: ...0 40 m kgf 2 9 ft lbf Seat set bracket and fuel tank screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Seat bolt M8 2 22 Nm 2 2 m kgf 16 ft lbf Left side cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Right side cover...

Page 62: ...il passage gasket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear nut threads and contact...

Page 63: ...her surface both sides Relay arm collar outer surface and bolt outer surface Relay arm bolt threads swingarm side Connecting arm bearing and oil seal lip Connecting arm collar outer surface and bolt o...

Page 64: ...e caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston seal Rear brake caliper dust seal Rear brake ca...

Page 65: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22 EASB291066...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS EASB291067 LUBRICATION DIAGRAMS...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Page 74: ...CABLE ROUTING DIAGRAM 2 31 EASB291068 CABLE ROUTING DIAGRAM...

Page 75: ...the vehicle L Insert the plastic locking tie into the bracket hole and clamp the clutch cable Clamp it so that the lock of the plastic locking tie faces downward and then cut off the end of the plast...

Page 76: ...CABLE ROUTING DIAGRAM 2 33...

Page 77: ...eet metal of the radiator B Route each lead so that the leads are not pinched between the tank rail and air filter joint C Insert the projection of the wire harness into the hole in the frame D Route...

Page 78: ...CABLE ROUTING DIAGRAM 2 35...

Page 79: ...throttle position sensor lead to the out side of the tension arm the outside of the vehi cle D After connecting the throttle position sensor cou pler attach the cover E Pass the radiator breather hos...

Page 80: ...CABLE ROUTING DIAGRAM 2 37...

Page 81: ...vehicle E Insert the protruding end of the wire harness into the battery bracket hole and holder plate hole F After connecting the negative lead coupler place it on the right side of the battery G Af...

Page 82: ...CABLE ROUTING DIAGRAM 2 39...

Page 83: ...ber plate band D Pass the engine stop switch lead between the head pipe and the cable guide E Pass the front brake hose to the front of the num ber plate F Pass the start switch lead and clutch switch...

Page 84: ...CABLE ROUTING DIAGRAM 2 41...

Page 85: ...all the two breather hoses so that the yellow paint mark is pointing forwards C Align the white paint mark to the protruding por tion of the pipe to install breather hose 3 D Protruding portion of the...

Page 86: ...CABLE ROUTING DIAGRAM 2 43...

Page 87: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

Page 88: ...CABLE ROUTING DIAGRAM 2 45...

Page 89: ...CKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 21 BLEEDING THE BRAKE SYSTEM 3 21 CHECKING THE BRAKE HO...

Page 90: ...34 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDAL 3 34 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 35 CHECKING THE CHASSIS FASTENERS 3 35 ELECTRICAL SYSTEM 3 36 CHECKING THE SPARK...

Page 91: ...to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold...

Page 92: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Page 93: ...air filter oil or equiv alent oil Replace BREATHER SYS TEM Inspect Check ventilation hose for cracks or damage and drain any deposits Replace Every two years SPARK PLUG Inspect and clean Check the el...

Page 94: ...d adjust Replace oil Replace oil seal Clean and grease oil seals and dust seals Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grea...

Page 95: ...lfide grease RELAY ARM CON NECTING ROD Inspect lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium soap based grease STEERING HEAD Inspect free play and retighten Check for tigh...

Page 96: ...nd clean throttle cable Check throttle cables on the throttle body for dirt and wear LEVERS Adjust clutch lever free play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Reti...

Page 97: ...es Check the play of front brake and effect of front and rear brake 3 21 27 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 27 4 67 68 Wheels Chec...

Page 98: ...minutes until the coolant has settled EASB291075 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer t...

Page 99: ...t level Refer to CHECKING THE COOLANT LEV EL on page 3 8 EASB291077 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replac...

Page 100: ...moved coolant will spout therefore cover it with a cloth beforehand EASB291080 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever...

Page 101: ...adjuster 2 until the specified free play is obtained c Tighten the locknut EWA WARNING After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this d...

Page 102: ...e Air filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air filter element 3 Wash Air filter element EWA WARNING Do not use gasoline or organic acid alka line volatile oil for wa...

Page 103: ...properly ECA NOTICE Make sure the cylinder head breather hose is routed correctly EASB291086 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer...

Page 104: ...s up for 3 minutes and then stop the engine and wait about 5 minute 3 Check Oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level m...

Page 105: ...ter element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil strainer 1 b Check the oil strainer Damage Replace Clogging due to dirt Wash with kerosene c Replace th...

Page 106: ...EASB291090 ADJUSTING THE ENGINE IDLING SPEED TIP Because the air pressure is lower at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the starter knob idle scr...

Page 107: ...e the engine is cold at room temperature While the valve clearance is checked or ad justed make sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air sc...

Page 108: ...ter 2 and the adjusting pad 3 with a valve lapper 1 TIP Place a cloth in the timing chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad...

Page 109: ...Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lift...

Page 110: ...40 1 25 1 29 230 235 240 1 30 1 34 235 240 1 35 1 39 240 0 19 0 12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145...

Page 111: ...the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the br...

Page 112: ...b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA WARNING A soft or spongy feeling in the brake lever can indicate the pre...

Page 113: ...ing performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EASB291097 CHECKING THE FRONT BRAKE PADS 1 Measure Brake pad thickness a Out of...

Page 114: ...jections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid lev...

Page 115: ...pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper piston in EWA WARNING Do not reuse...

Page 116: ...PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 22 2 Check Rear brake pad insulator 1 Damage Replace EASB291100 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a level...

Page 117: ...suitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull...

Page 118: ...ification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EASB291104 CLEANING THE FRONT FORK OIL SEAL AND DUST...

Page 119: ...range 1 Adjust Compression damping force a Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 Nm 0 13 m kgf 0 94 ft lbf Direction a Rebound damping force is incr...

Page 120: ...TING THE REAR SHOCK ABSORB ER ASSEMBLY Use a suitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload...

Page 121: ...ust High compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping force is increased suspension is harde...

Page 122: ...s found tilted the tire is considered to be slipping off its position Cor rect the tire position EASB291111 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A ti...

Page 123: ...CHECKING AND ADJUSTING THE STEER ING HEAD 1 Use a suitable stand to raise the front wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Check...

Page 124: ...e in ner and outer cables EWA WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner ca bles as soon as possible 1 Check Outer...

Page 125: ...fore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubrican...

Page 126: ...oving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan...

Page 127: ...left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EASB291124 CHECKING AND CHARGING...

Page 128: ...ELECTRICAL SYSTEM 3 38...

Page 129: ...PER 4 16 CHECKING THE FRONT BRAKE CALIPER 4 17 ASSEMBLING THE FRONT BRAKE CALIPER 4 17 INSTALLING THE BRAKE CALIPER PISTON 4 17 INSTALLING THE FRONT BRAKE CALIPER 4 18 REMOVING THE FRONT BRAKE MASTER...

Page 130: ...MBLY 4 56 HANDLING THE REAR SHOCK ABSORBER 4 59 DISPOSING OF A REAR SHOCK ABSORBER 4 59 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 59 REMOVING THE BEARING 4 59 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 131: ...this manual It may lead to servicing trouble and mechanical damage EASB291126 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop rig...

Page 132: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 20 2 Remove Seat 1 EASB291129 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 133: ...wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm...

Page 134: ...CHECKING THE WHEELS on page 3 33 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Ti...

Page 135: ...2 Bearing right side 3 Oil seals 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with i...

Page 136: ...l Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA NOTICE Before tightening the front wheel axle nut push down hard on the handle...

Page 137: ...el axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m...

Page 138: ...2 Check Tire s Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spokes Refer to CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radia...

Page 139: ...um soap based grease to the bearing and the oil seal lip when installing Install the bearing with seal facing outward Right side of bearing shall be installed first Install the oil seal with its manuf...

Page 140: ...the drive chain 3 Install Left drive chain puller 1 Rear wheel axle 2 TIP Install the left drive chain puller and insert the rear wheel axle from the left side Apply the lithium soap based grease to...

Page 141: ...REAR WHEEL 4 11 6 Tighten Rear wheel axle nut 1 Locknut 2 Wheel axle nut 125 Nm 12 5 m kgf 90 ft lbf Locknut 21 Nm 2 1 m kgf 15 ft lbf T R T R 1 2...

Page 142: ...washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Page 143: ...ke caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Page 144: ...Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake mas...

Page 145: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Page 146: ...ion EASB291145 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc...

Page 147: ...clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When t...

Page 148: ...the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA WARNING U...

Page 149: ...cylinder and the end of the brake hose EASB291153 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cy...

Page 150: ...291155 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the...

Page 151: ...poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vap...

Page 152: ...pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse...

Page 153: ...brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2...

Page 154: ...age 3 21 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cy...

Page 155: ...5 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Page 156: ...ion EASB291158 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thicknes...

Page 157: ...61 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brake...

Page 158: ...th its side a facing the brake caliper Never force to insert EASB291164 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHE...

Page 159: ...CHECKING THE BRAKE FLUID LEVEL on page 3 26 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 21 EASB291165 REMOVING THE REA...

Page 160: ...shown Wrong orientation in installation causes poor braking perfor mance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the...

Page 161: ...result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point...

Page 162: ...e 1 Disconnect 2 Clutch switch 1 3 Clutch lever holder 1 4 Engine stop switch 1 5 Brake master cylinder 1 6 Throttle cable cap 1 7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect...

Page 163: ...HANDLEBAR 4 33 16 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Page 164: ...291172 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower handlebar...

Page 165: ...ll Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive w...

Page 166: ...ner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 7 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium soap based grease on t...

Page 167: ...lder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt...

Page 168: ...HANDLEBAR 4 38 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in...

Page 169: ...rake caliper Refer to FRONT BRAKE on page 4 12 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bol...

Page 170: ...n metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New N...

Page 171: ...olt ring wrench 2 3 Remove Front fork leg s EASB291175 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bol...

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

Page 173: ...k leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seals Copper washers Before assembling the front fork leg make sure that all of the components are clean 1 Stretc...

Page 174: ...1 TIP Before loosening the damping force adjuster record the setting position Unless the damping force adjuster is fully loosened correct damping characteristic can not be obtained after installation...

Page 175: ...to damage the damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 8 cm3 0 27 US oz 0 28 lmp oz 13 Check Damper assembly smooth...

Page 176: ...ork oil applied to protect the oil seal lip 15 Install Inner tube bushing 1 TIP Install the inner tube bushing onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Inner...

Page 177: ...rease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1...

Page 178: ...Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto t...

Page 179: ...to the outer tube TIP Temporarily tighten the damper assembly 32 Install Protector guide 1 EASB291178 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lowe...

Page 180: ...rk to malfunction 5 Install Protector 1 Bolt protector 2 6 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Damper assembly...

Page 181: ...FRONT FORK 4 51 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1 1...

Page 182: ...3 Front fork leg s 2 Refer to FRONT FORK on page 4 39 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing lower side 1 10 Bearing races 2 For...

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

Page 184: ...e steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 33 5 Check the steering st...

Page 185: ...steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued...

Page 186: ...1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear sho...

Page 187: ...14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Part name Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3...

Page 188: ...arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2...

Page 189: ...km of run ning EASB291185 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA WARNING Wear protective glasses to prevent...

Page 190: ...ng Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EASB291189 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay ar...

Page 191: ...ck absorber assembly lower side TIP Install the dust seals with their lips facing in ward 5 Lubricate Connecting arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circum...

Page 192: ...m side Rear shock absorber assembly lower bolt Rear shock absorber assembly upper bolt 56 Nm 5 6 m kgf 41 ft lbf Connecting arm bolt frame side 80 Nm 8 0 m kgf 58 ft lbf Connecting arm bolt relay arm...

Page 193: ...ake hose holder Refer to REAR BRAKE on page 4 22 Rear brake caliper Refer to REAR BRAKE on page 4 22 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Page 194: ...the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EASB291194 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 195: ...3 Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Reco...

Page 196: ...ving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m...

Page 197: ...gth b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Che...

Page 198: ...eel sprocket as a set EASB291199 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EASB291200 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NO...

Page 199: ...TICE Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3...

Page 200: ...CHAIN DRIVE 4 70...

Page 201: ...NG THE DECOMPRESSION SYSTEM 5 17 INSTALLING THE CAMSHAFTS 5 17 CYLINDER HEAD 5 20 REMOVING THE CYLINDER HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTA...

Page 202: ...2 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 5 52 INSTALLING THE KICK SHAFT ASSEMBLY 5 52 INSTALLING THE KICK IDLE GEAR 5 53 SHIFT SHAFT 5 54 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSE...

Page 203: ...IDE OIL STRAINER 5 73 CHECKING THE CRANKCASE 5 73 INSTALLING THE OIL SEAL 5 74 ASSEMBLING THE CRANKCASE 5 74 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 75 REMOVING THE CRANKSHAFT ASSEMBLY 5 76 CHECKING...

Page 204: ...arks Side cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 56 Connecting arm bolt frame side Refer to REAR SHOC...

Page 205: ...pipe Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New 10 Nm 1...

Page 206: ...S on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Neutral switc...

Page 207: ...e 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTLE BODY on page 7 5 Throttle body Refer to THROTTLE BODY on...

Page 208: ...r engine bracket 2 9 Washer 1 Thickness 2 3 mm 0 09 in 10 Washer 1 Thickness 1 0 mm 0 04 in 11 Lower engine bracket 2 12 Pivot shaft 1 13 Engine 1 For installation reverse the removal proce dure Remov...

Page 209: ...silencer EASB291204 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EASB291205 REMOVING THE DRIVE SPROCKET 1 St...

Page 210: ...e TIP Make sure that the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EASB291207 CHECKING THE SILENCER AND...

Page 211: ...f sealant Take care not to allow the fiber out of place when installing the silencer body 3 EASB291209 INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from the right side Pivot shaft 2 Eng...

Page 212: ...PROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 TIP Tighten the nut while applying the rear b...

Page 213: ...0 m kgf 14 ft lbf 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1 3 I...

Page 214: ...4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2 20 Nm 2 0 m kgf 14 ft lbf Clamp 12 Nm 1 2 m kgf 8 7 ft lbf...

Page 215: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder...

Page 216: ...4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T...

Page 217: ...ft sprocket and the alignment mark d on the intake camshaft sprocket with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camsha...

Page 218: ...ut Out of specification Replace 4 Measure Camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaft journal diameter Camshaft lobe dimensions Intake A 31 730 31 830 mm 1 2...

Page 219: ...TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft and...

Page 220: ...lockwise with a wrench TIP Apply molybdenum disulfide oil to the cam shafts Apply the engine oil on the decompression system b Align the top dead center TDC mark a on the rotor with the alignment mark...

Page 221: ...ockwise b With the tensioner rod fully wound and the chain tensioner UP mark a facing upward install the gasket 1 the timing chain ten sioner 2 and the gasket 3 and tighten the bolt 4 c Release the sc...

Page 222: ...CAMSHAFT 5 19 inder head cover gasket 6 Install Cylinder head breather hose Spark plug Yamaha bond No 1215 90890 85505 Three bond No 1215 Spark plug 13 Nm 1 3m kgf 9 4 ft lbf 4 4 3 2 1 T R...

Page 223: ...pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAF...

Page 224: ...HEAD 5 21 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft...

Page 225: ...trument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE V...

Page 226: ...he cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the...

Page 227: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 228: ...e the valve seat and the valve seat width Refer to CHECKING THE VALVE SEATS on page 5 27 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Chec...

Page 229: ...ide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 c After installing the valve guide expand the hole in the valve guide with the valve guide r...

Page 230: ...THE 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 C a Out of specification Replace th...

Page 231: ...he valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face ECA NOTICE Do not let the lapping compound enter the g...

Page 232: ...essed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 36 69 mm 1 44 in Limit 35 69 mm...

Page 233: ...l the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring com...

Page 234: ...sting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjust ing pad are...

Page 235: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the remov...

Page 236: ...fingers and lift the opposite end gap of the piston ring over the piston crown EASB291234 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cyl...

Page 237: ...side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP Level the piston ring into the cylinder with the piston 3 Measure Piston ring en...

Page 238: ...install the piston ring so that the manufacturer s marks or numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the F m...

Page 239: ...inder TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring...

Page 240: ...ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure 1...

Page 241: ...mbling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly rever...

Page 242: ...re assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of spec...

Page 243: ...he part that has a smaller step differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark a on the starter motor yoke with the match mark b...

Page 244: ...ELECTRIC STARTER 5 41...

Page 245: ...dal Refer to ENGINE REMOVAL on page 5 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push...

Page 246: ...7 Thrust washer 1 18 Primary driven gear 1 19 Spacer 1 20 Bearing 1 21 Washer 1 22 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks N...

Page 247: ...Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 42 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe...

Page 248: ...91244 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace t...

Page 249: ...place EASB291249 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EASB291250 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks...

Page 250: ...NG THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithium soap based grease on the O ring 2 Install Right crankcase cover 1 Right crankcase cover bolt 2 TIP A...

Page 251: ...te 1 1 Clutch plate 2 Cushion spring 3 Friction plate 2 4 TIP Install the clutch plates and friction plates al ternately on the clutch boss starting with a friction plate and ending with a friction pl...

Page 252: ...ush rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install Gasket 1 11 Install Clutch cover 1 Clu...

Page 253: ...r Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right crankca...

Page 254: ...haft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 42 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick...

Page 255: ...Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EASB291261 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Page 256: ...kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Ins...

Page 257: ...llar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15 Segment 1 For inst...

Page 258: ...oosen the bolt ECA NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EASB291266 CHECKING THE SHIFT SHAFT 1 Check Shift...

Page 259: ...ged Take care not to give an impact to it when tightening the bolt EASB291271 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply th...

Page 260: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EASB291273 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift sh...

Page 261: ...Refer to CLUTCH on page 5 42 Right crankcase cover Refer to CLUTCH on page 5 42 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Rotor...

Page 262: ...OR AND STARTER CLUTCH on page 5 64 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9...

Page 263: ...NG THE BALANCER 1 Check Balancer Crack damage Replace EASB291278 CHECKING THE OIL PUMP 1 Check Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump housing cover Cracks damage wear Repla...

Page 264: ...rotor Fit the dowel pin into the groove in the inner rotor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EASB291280 INSTALLING T...

Page 265: ...each other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the c...

Page 266: ...OIL PUMP AND BALANCER GEAR 5 63 c d 6 6 7 8 8 b...

Page 267: ...k Refer to GENERAL CHASSIS on page 4 1 and FUEL TANK on page 7 1 Disconnect the AC magneto lead Clutch cable Shift pedal Refer to SHIFT SHAFT on page 5 54 1 Cover Damper assembly 1 2 Damper assembly 1...

Page 268: ...clutch 1 13 Starter clutch drive gear 1 14 Crankshaft position sensor 1 15 Stator 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks T R T...

Page 269: ...h gear 4 Check Damper assembly Damage pitting wear Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive gear 1...

Page 270: ...3 Install Starter clutch 1 To generator rotor 2 EASB291285 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the crankshaf...

Page 271: ...aring and idle gear inner circumfer ence 4 Install Dowel pin Crankcase cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under...

Page 272: ...AND STARTER CLUTCH 5 69 6 Install Cover damper assembly 1 Bracket 2 Bolt 3 Breather hose 2 4 TIP Install the cover damper assembly with its mark a facing upward Bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R 1...

Page 273: ...Segment Refer to SHIFT SHAFT on page 5 54 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 64 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4...

Page 274: ...assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1...

Page 275: ...Transmission Refer to TRANSMISSION on page 5 78 Shift cam and shift fork Refer to TRANSMISSION on page 5 78 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT L...

Page 276: ...lf Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining ca...

Page 277: ...e left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two...

Page 278: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 70 Transmission Refer to TRANSMISSION on page 5 78 1 Balancer s...

Page 279: ...ication Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance D a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3...

Page 280: ...ent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn...

Page 281: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 70 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift for...

Page 282: ...on of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EASB291300 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift...

Page 283: ...heck Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement...

Page 284: ...the O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on the spl...

Page 285: ...th the 5th wheel gear 5 and 3 R with the 6th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shift f...

Page 286: ...TRANSMISSION 5 83...

Page 287: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WA...

Page 288: ...vicing trouble and mechanical damage EASB291305 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 8 Seat Refer to GENERAL CHASSIS on pag...

Page 289: ...9 Radiator breather hose 1 10 Left radiator 1 11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 For installation reverse the removal proce dure Removing the radiator Order Par...

Page 290: ...ra diator cap EASB291307 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins with...

Page 291: ...fer to CHANGING THE ENGINE OIL on page 3 15 Right crankcase cover Refer to CLUTCH on page 5 42 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Washer 2 5 Collar 1 6 Gear 1 7 Pin 1 8 Impeller shaft a...

Page 292: ...or installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New E...

Page 293: ...91312 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right crankcase...

Page 294: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2...

Page 295: ...2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8...

Page 296: ...icing trouble and mechanical damage EASB291315 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fuel...

Page 297: ...ign ma terials from entering the fuel pump install the included fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover left...

Page 298: ...L CHASSIS on page 4 1 EASB291321 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the side cover left right the seat and the air scoop left right Refer to GENERAL CHASSIS on page 4 1 b Remove...

Page 299: ...nd 3 with the arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EASB291323 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear da...

Page 300: ...AL on page 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Breather hose 3 1 3 Air filter case 1 4 Fuel injector coupler 1 Disconnect 5 Int...

Page 301: ...int 1 For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T...

Page 302: ...ks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5...

Page 303: ...eign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly...

Page 304: ...YAMAHA DIAGNOSTIC TOOL on page 8 22 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set th...

Page 305: ...8 ELECTRICAL COMPONENTS 8 50 CHECKING THE SWITCHES 8 54 CHECKING THE FUSES 8 57 CHECKING AND CHARGING THE BATTERY 8 57 CHECKING THE RELAYS 8 60 CHECKING THE DIODE 8 61 CHECKING THE IGNITION SPARK GAP...

Page 306: ...CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 67 CHECKING THE FUEL INJECTOR 8 68...

Page 307: ...servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas semb...

Page 308: ...G W Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B...

Page 309: ...nnector 2 Joint connector 4 AC magneto 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 17 Ignition coil 18 Spark plug 24 Joint connector 29 Lean angle sensor 30 Engin...

Page 310: ...terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE FUSES on page 8 57 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING TH...

Page 311: ...Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 63 NG Replace the lean angle sensor OK 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 2 NG Properly connect or repair...

Page 312: ...B L G W G W Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br...

Page 313: ...Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 12 Starter motor 13 Starter relay diode 16 ECU engine control unit 24 Joint connector 30 Engine stop switch 31 Neutral switch 32 Diod...

Page 314: ...er is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance t...

Page 315: ...E TRANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Starting circuit cut off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral sw...

Page 316: ...battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 64 OK Starter motor is OK Perform the electric starting system troubleshooting starting with st...

Page 317: ...ch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the start switch OK 12 Check the s...

Page 318: ...W Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B...

Page 319: ...CHARGING SYSTEM 8 13 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse...

Page 320: ...HARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 64 NG Replace the stator assembl...

Page 321: ...CHARGING SYSTEM 8 15 EASB291338...

Page 322: ...W G W Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy...

Page 323: ...ctor 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 21 Radiator fan motor relay 22 Radiator fan motor fuse 23 Radiator fan motor 24 Jo...

Page 324: ...main relay Refer to CHECKING THE RE LAYS on page 8 60 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR For JPN on page 8 65 NG Replace the radiator...

Page 325: ...COOLING SYSTEM For JPN 8 19 EASB291341...

Page 326: ...G W Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy...

Page 327: ...ter relay 11 Main fuse 16 ECU engine control unit 19 Injector 24 Joint connector 25 Intake air temperature sensor 26 Coolant temperature sensor 27 Throttle position sensor 28 Intake air pressure senso...

Page 328: ...e diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting setting to...

Page 329: ...to connect and use the Yamaha diagnostic tool refer to YAMAHA DIGNO STIC TOOL OPERATION MANUAL FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 1 Vehicle 2 Coupler for conn...

Page 330: ...the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctio...

Page 331: ...d service the items or components that are the probable cause of the malfunction following the or der given After the check and service of the malfunctioning part have been completed reset the diagnos...

Page 332: ...finished Fault code number is dis played Go to item 4 4 Installed condition of crank shaft position sensor Check for looseness or pinching Check the gap between the crankshaft position sensor and the...

Page 333: ...replace the wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the...

Page 334: ...ge 8 67 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 14 Item Intake air...

Page 335: ...nsor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Diagnostic tool display Throttle position sensor signal 11 14 fully closed positio...

Page 336: ...ION SEN SOR on page 7 9 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Applied voltage of throttle po sition sensor lead C...

Page 337: ...sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Push the start switch Fault code number...

Page 338: ...e har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking conditi...

Page 339: ...intake air temperature Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value Item Probable cause of malfunc tion and check Maintenance job Confi...

Page 340: ...ambient temper ature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENS...

Page 341: ...coil is actuated Procedure Check that a spark is generated five times Connect an ignition checker Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Co...

Page 342: ...played Service is finished Fault code number is dis played Go to item 5 5 Installed condition of ignition coil Check for looseness or pinching Improperly installed sensor Reinstall or replace the sens...

Page 343: ...No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector re sistance Replace if out of specifica tion Refer to CHECKING THE FUEL INJECTOR on page 8 6...

Page 344: ...vice is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro...

Page 345: ...bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5...

Page 346: ...in Diagnostic mode Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment push the engine stop switch then push the...

Page 347: ...et it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Wire harness continuity Open or short circuit Re place the...

Page 348: ...tioning Able to drive vehicle Unable when ECU is malfunctioning Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of servi...

Page 349: ...Yamaha diag nostic tool coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Co...

Page 350: ...e wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking co...

Page 351: ...is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Page 352: ...Br W Br W R W R W Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L G...

Page 353: ...PUMP SYSTEM 8 47 1 Joint connector 2 Joint connector 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 20 Fuel pump 24 Joint connector 30 Engine stop switch 36 Frame gr...

Page 354: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG...

Page 355: ...FUEL PUMP SYSTEM 8 49 EASB291348...

Page 356: ...ELECTRICAL COMPONENTS 8 50 ELECTRICAL COMPONENTS EASB291349 8 9 10 1 3 2 4 5 6 7...

Page 357: ...ELECTRICAL COMPONENTS 8 51 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU engine control unit 5 Fuel sender 6 Fuel pump 7 Battery 8 Neutral switch 9 Radiator fan motor For JPN 10 Injector...

Page 358: ...ELECTRICAL COMPONENTS 8 52 11 10 9 2 3 1 6 7 8 4 5...

Page 359: ...ature sensor 2 Intake air pressure sensor 3 Throttle position sensor 4 Starter relay 5 Main fuse 6 Starting circuit cut off relay 7 Lean angle sensor 8 Radiator fan motor fuse 9 Radiator fan motor rel...

Page 360: ...ELECTRICAL COMPONENTS 8 54 EASB291350 CHECKING THE SWITCHES 4 1 3 2 E B S E B E B E E B B...

Page 361: ...ELECTRICAL COMPONENTS 8 55 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 362: ...et tester range to 1 to make a 0 adjustment When checking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal con...

Page 363: ...th the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Seat Side cover left...

Page 364: ...specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Side cover left right Seat Refer to GENERAL CHASSI...

Page 365: ...nect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid...

Page 366: ...harger is recommended d Charge the battery until the battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage af ter leaving the bat...

Page 367: ...n 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 2 1 3 4 R W Br W R L G 1 2 3 4 L R Br R R R W 1 2 3 4 G B L B L G L W Result Continuity...

Page 368: ...tion spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs EASB291356 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spar...

Page 369: ...sensor re sistance EASB291359 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specification Replace Pocket tester 90890 0311...

Page 370: ...sensor to strong shocks If the coolant temperature sensor is dropped replace it b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire ha...

Page 371: ...sure the radiator fan motor movement EASB291363 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor EWA WARNING Handle the coolant temperature sensor with special care Never su...

Page 372: ...tion sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 2 Check Throttle position sensor maximum resis tance Out...

Page 373: ...or out put voltage EASB291367 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case EWA WARNING Handle the intake air temperature sensor with spec...

Page 374: ...from the fuel injector b Connect the pocket tester 10 to the fuel injector coupler c Measure the fuel injector resistance Intake air temperature sensor re sistance 290 390 at 80 C 290 390 176 F Pocke...

Page 375: ...AND HIGH SPEED PERFORMANCE 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 CLUTCH SLIPS 9 2 CLUTCH DRAGS 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE...

Page 376: ...pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or...

Page 377: ...lay Worn shift drum groove 4 Transmission Worn gear dog EASB291377 CLUTCH SLIPS Engine 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engi...

Page 378: ...Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EASB291383 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken f...

Page 379: ...circuit detected 8 33 30 Latch up detected 8 34 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 35 39 Injector open or short circuit detected 8 37 41 Lean a...

Page 380: ...en engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturned Displays...

Page 381: ...o Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals WARNING on the Yamaha diagnostic tool blinks five times when the ignition...

Page 382: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Page 383: ...FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SET...

Page 384: ...eed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies fro...

Page 385: ...the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range EASB291393...

Page 386: ...of damping force Change the rebound damping force Change the compression damping force EASB291396 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor...

Page 387: ...ng load Run with the rebound damping force adjuster one or two clicks turned in and readjust it to suit your preference TIP Adjusting the rebound damping force will be fol lowed more or less by a chan...

Page 388: ...pring preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER ASSEMBLY on page 3 30 Maximum Minimum Position in which the spring is turned in 18 mm 0 71 in from its free length Position in whic...

Page 389: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Page 390: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Page 391: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 392: ...or 27 Throttle position sensor 28 Intake air pressure sensor 29 Lean angle sensor 30 Engine stop switch 31 Neutral switch 32 Diode 33 Starting circuit cut off relay 34 Clutch switch 35 Start switch 36...

Page 393: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Page 394: ...UAL YZ250FXF B29 28199 10 LIT 11626 28 51 YZ250FXF 2015 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014 09 0 8 1 E B29 28199 10_cover_12mm in...

Page 395: ...b Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R R W Br R L R B R R W Br W L G Br W Br L W...

Page 396: ...ON OFF ON OFF B A A A A B B A C Gy Gy B B Gy B B B L L B B B B B YZ250FXF 2015 WIRING DIAGRAM B29 28199 10_W D indd 2 2014 09 04 10 55 01...

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