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Yamaha YZ 2017 Series, Owner'S Service Manual


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REAR BRAKE

4-29

EASB29B164

ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER

EWA

WARNING

• 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.

1. Wash the brake master cylinder and the 

brake master cylinder kit with brake fluid.

2. Install:

• Primary cylinder cup “1”
• Secondary cylinder cup “2”

Install to the brake master cylinder piston 
“3”.

EWA

WARNING

Apply brake fluid to the cylinder cups and 
install them as 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 brake master cylinder piston.

4. Install:

• Master cylinder kit “1” 
• Push rod “2”
• Circlip “3” 
• Dust boot “4”

TIP

• Before installation, apply brake fluid to the 

brake master cylinder kit.

• Before installation, apply silicone grease to 

the push rod end.

• Use circlip pliers to install the circlip.

EASB29B165

INSTALLING THE REAR BRAKE MASTER 
CYLINDER

1. Install:

• Copper washers
• Brake hose
• Union bolt

Specified brake fluid

DOT 4

2

3

1

2

3

1

Brake hose union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

1

2

New

New

1

3

4

2

New

New

New

T

 

R

.

.

Summary of Contents for YZ 2017 Series

Page 1: ...UAL YZ250FXH B29 28199 12 LIT 11626 30 35 YZ250FXH 2017 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2016 05 0 2 1 E B29 28199 12_cover_13mm 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: ...2016 by Yamaha Motor Corporation U S A 1st Edition May 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib...

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: ...EASB916006 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 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

Page 10: ......

Page 11: ...TION 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 BASIC SERVI...

Page 12: ...1 20 AIR FILTER MAINTENANCE 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 21 BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 23 MAJOR MAINTENANCE 1 23 TORQUE CHECK POINTS 1 24 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: ...e you have pur chased 1 Clutch lever 11 Radiator 2 Engine trouble warning light 12 Coolant drain bolt 3 Fuel level warning light 13 Rear brake pedal 4 Front brake lever 14 Air filter 5 Throttle grip 1...

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 EASB29B011 VEHICLE IDENTIFICATION NUMBER The vehic...

Page 16: ...ed to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EASB29B018 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the...

Page 17: ...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 18: ...ASB29B023 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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...Valve 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...

Page 28: ...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 29: ...s refuel as soon as possible The electrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning l...

Page 30: ...9B036 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on the brake pedal to ac tivate the rear brake EASB29B037 SIDESTAND This sidestand 1 is used to support only the...

Page 31: ...cover 2 Remove the fuel tank cap cover to open the fuel tank cap TIP To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicl...

Page 32: ...ce prob lems EASB29B042 HANDLING NOTE EWA WARNING Never start or run the engine in a closed ar ea The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Al...

Page 33: ...TIP Continue pushing the engine stop switch till the engine comes to a full stop EASB29B045 STARTING A WARM ENGINE Follow the same procedure as for starting a cold engine with the exception that the s...

Page 34: ...g parts are replaced a break in is required Cylinder and Crankshaft A break in is re quired for about an hour Piston Piston ring Valve Camshaft and Gear A break in is required for about 30 minutes at...

Page 35: ...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 36: ...ink to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of w...

Page 37: ...l tank Fuel sender to fuel tank 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...

Page 38: ...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 39: ...ill wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EASB29B052 STORAGE Short term Always store your motorcycle in a cool dry place and if necessary protect it agains...

Page 40: ...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 41: ...FICATIONS 2 10 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 42: ...D EUR B29E AUS NZL ZAF B29F 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 43: ...Oil change 0 83 L 0 88 US qt 0 73 Imp qt With oil filter removal 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 kgf cm2 5 8 11 6...

Page 44: ...clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 17 0 24 mm 0 0067 0 0094 in Valve dimensions Valve head diameter intake 30 90 31 10 mm 1 2165 1 2244 in Valve head diameter exhaust 24 90...

Page 45: ...m 0 06 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Pi...

Page 46: ...1 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 47 80 mm 1 88 in Limit 45 41 mm 1 79 in Spring quantity 5 pcs Push rod bending limit 0 30 mm 0 012 in Transmission Tr...

Page 47: ...utput voltage at idle 0 49 0 51 V Fuel injection sensor Crankshaft position sensor resistance 228 342 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 6...

Page 48: ...t limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 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 mo...

Page 49: ...type Coil spring Hydraulic damper Front fork travel 310 0 mm 12 2 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...

Page 50: ...Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Minimum 30 clicks out Standard 12 clicks out USA CAN EUR AUS NZL ZAF 13 clicks...

Page 51: ...ngle 3 7 4 4 V AC magneto Standard output 14 0 V 160 W at 5000 r min Stator coil resistance 0 528 0 792 W W Rectifier regulator Regulator type Three phase Regulated voltage DC 14 1 14 9V Rectifier cap...

Page 52: ...el sender unit Fuel sender resistance 1350 1900 Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Starting circuit cut off relay Coil resistance 75 6 92 5 Fuses Main fuse 15 0 A Spare fuse 15 0...

Page 53: ...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 54: ...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 lb...

Page 55: ...drain bolt M10 1 20 Nm 2 0 m kgf 14 ft lbf Crankcase bolt 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 kg...

Page 56: ...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 Coolant temperature sensor M10 1 16...

Page 57: ...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 58: ...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 59: ...cap cover bolt M6 2 4 0 Nm 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...

Page 60: ...ing parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear nut threads and contac...

Page 61: ...r surface Swingarm pivot portion oil seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surf...

Page 62: ...eal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake cal...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EASB29B063 LUBRICATION SYSTEM CHART AND DIAGRAMS EASB29B064 LUBRICATION DIAGRAMS...

Page 65: ...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 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Page 72: ...CABLE ROUTING DIAGRAM 2 31 EASB29B065 CABLE ROUTING DIAGRAM...

Page 73: ...under the starter clutch cover N Pass the neutral switch lead to the inside of the front engine bracket the side of the vehicle O Insert the plastic locking tie into the bracket hole and clamp the cl...

Page 74: ...CABLE ROUTING DIAGRAM 2 33...

Page 75: ...heet 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 76: ...CABLE ROUTING DIAGRAM 2 35...

Page 77: ...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 78: ...CABLE ROUTING DIAGRAM 2 37...

Page 79: ...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 Route the diode under th...

Page 80: ...CABLE ROUTING DIAGRAM 2 39...

Page 81: ...itch lead between the head pipe and the cable guide E Pass the warning light lead between the head pipe and cable guide F Pass the front brake hose to the front of the num ber plate G Pass the start s...

Page 82: ...CABLE ROUTING DIAGRAM 2 41...

Page 83: ...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 84: ...CABLE ROUTING DIAGRAM 2 43...

Page 85: ...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 86: ...CABLE ROUTING DIAGRAM 2 45...

Page 87: ...CHECKING 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 22 BLEEDING THE BRAKE SYSTEM 3 22 CHECKING THE BRAKE...

Page 88: ...35 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 36 CHECKING THE CHASSIS FASTENERS 3 36 ELECTRICAL SYSTEM 3 37 CHECKING THE SPARK...

Page 89: ...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 90: ...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 91: ...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 92: ...ls and dust seals Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grease pillow balls and bear ings Retighten Check for tightening t...

Page 93: ...ithium soap based grease STEERING HEAD Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings TIRE WHEELS Inspect air pres sure wheel run out tire...

Page 94: ...les on the throttle body for dirt and wear LEVERS Adjust clutch lever free play BRAKE PEDAL FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to TORQUE CHECK POINTS on page 1 24 BATTERY Inspec...

Page 95: ...heck the play of front brake and effect of front and rear brake 3 22 28 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 28 4 67 68 Wheels Check fo...

Page 96: ...minutes until the coolant has settled EASB29B072 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 97: ...el Refer to CHECKING THE COOLANT LEV EL on page 3 8 EASB29B074 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS...

Page 98: ...a cloth beforehand EASB29B077 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar side a Turn the adjuster 1 i...

Page 99: ...ned 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 does not cause the en gine idling speed to change...

Page 100: ...ir 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 washi...

Page 101: ...properly ECA NOTICE Make sure the cylinder head breather hose is routed correctly EASB29B083 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer...

Page 102: ...gine warm this 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 mi...

Page 103: ...ement and the oil fil 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...

Page 104: ...k bolt EASB29B087 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 id...

Page 105: ...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 106: ...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 107: ...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 108: ...205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195 200 205 210 215 2...

Page 109: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Page 110: ...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 111: ...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 112: ...ir in the brake system will cause braking performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EASB29B094 CHECKING THE FRONT BRAKE PADS 1...

Page 113: ...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 114: ...move the pad pin 6 and the brake 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 pi...

Page 115: ...AR BRAKE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EASB29B097 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on...

Page 116: ...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 117: ...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 EASB29B101 CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1 Re...

Page 118: ...nd its adjusting range 1 Adjust Compression damping 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 is...

Page 119: ...A WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload ECA NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Remove Rear frame Refer to...

Page 120: ...r b to make an adjustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound dampin...

Page 121: ...d to be slipping off its position Cor rect the tire position EASB29B108 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will emit a clear ringing...

Page 122: ...Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 31 Upper bracket Refer to STEERING H...

Page 123: ...points and metal to metal moving parts of the following parts Brake lever Clutch lever EASB29B114 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to metal moving parts of the pedal EAS...

Page 124: ...ivoting point and metal to metal moving parts of the sidestand EASB29B117 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TOR...

Page 125: ...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 126: ...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 EASB29B121 CHECKING AND CHARGING...

Page 127: ...PER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER...

Page 128: ...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 129: ...this manual It may lead to servicing trouble and mechanical damage EASB29B123 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 130: ...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 19 2 Remove Seat 1 EASB29B126 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 131: ...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 132: ...CHECKING THE WHEELS on page 3 34 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 133: ...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 134: ...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 135: ...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 136: ...CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EASB29B136 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing...

Page 137: ...talled first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter...

Page 138: ...nsert the rear wheel axle from the left side Apply the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the...

Page 139: ...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 140: ...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 141: ...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 142: ...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 143: ...ion EASB29B142 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 144: ...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...

Page 145: ...hat 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 WARNIN...

Page 146: ...er cylinder and the end of the brake hose EASB29B150 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master...

Page 147: ...29B152 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 148: ...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 va...

Page 149: ...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 150: ...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 151: ...age 3 22 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 152: ...4 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 153: ...9B155 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 thickness at a fe...

Page 154: ...158 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 Brak...

Page 155: ...with its side a facing the brake caliper Never force to insert EASB29B161 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR...

Page 156: ...to CHECKING THE BRAKE FLUID LEVEL on page 3 27 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 22 EASB29B162 REMOVING THE R...

Page 157: ...as 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 t...

Page 158: ...may 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 po...

Page 159: ...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 160: ...HANDLEBAR 4 32 16 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Page 161: ...SB29B169 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 handleb...

Page 162: ...tall 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...

Page 163: ...f grease or oil on the tube guide surface a with a lac quer thinner 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 cove...

Page 164: ...assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the...

Page 165: ...er to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 10 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Clutch lever free play 7 0 12 0 mm 0 28 0 47 in T...

Page 166: ...rake caliper Refer to FRONT BRAKE on page 4 11 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 167: ...iston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seals 1 13 Base valve 1 14 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 14 2 7 10 9 11 12 5 3 1 6 8 13 New...

Page 168: ...fork leg s EASB29B172 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner...

Page 169: ...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 170: ...G THE FRONT FORK LEGS EWA WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork l...

Page 171: ...essive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Locknut 1...

Page 172: ...nd down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side ECA NOTICE Ta...

Page 173: ...ll the scraper to the inner tube as shown in the illustration When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Inner tube bushing 1 TIP Instal...

Page 174: ...outer tube 20 Install Scraper 1 Dust seal 2 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure...

Page 175: ...juster is fully loosened correct damping characteristic can not be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressi...

Page 176: ...the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly Adjuster locknut 29 Nm 2 9 m k...

Page 177: ...ssembly 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued too much it may cause the fro...

Page 178: ...e TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out...

Page 179: ...page 4 31 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg s 2 Refer to FRONT FORK on page 4 38 4 Warning light 1 5 Upper bracket 1 6 Steering ring nut 1 7 Lower bracket 1 8 Bearing race cover...

Page 180: ...er bracket Order Part name Q ty Remarks 2 5 4 6 8 3 1 7 9 10 11 LS T R LS LS T R 21 Nm 2 1 m lbf kgf 15 ft T R 9 Nm 0 9 m lbf kgf 6 5 ft T R 21 Nm 2 1 m lbf kgf 15 ft T R 10 Nm 1 0 m lbf kgf 7 2 ft T...

Page 181: ...e 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 I...

Page 182: ...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 34 5 Check the steering st...

Page 183: ...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 184: ...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 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Re...

Page 185: ...ring 2 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...

Page 186: ...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 187: ...km of run ning EASB29B182 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 188: ...ng Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EASB29B186 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay ar...

Page 189: ...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 190: ...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 191: ...ake hose holder Refer to REAR BRAKE on page 4 21 Rear brake caliper Refer to REAR BRAKE on page 4 21 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Page 192: ...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 EASB29B191 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 193: ...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 28 Recomm...

Page 194: ...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 195: ...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 196: ...eel sprocket as a set EASB29B196 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EASB29B197 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NO...

Page 197: ...CE 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 2...

Page 198: ...CHAIN DRIVE 4 70...

Page 199: ...NG THE DECOMPRESSION SYSTEM 5 17 INSTALLING THE CAMSHAFTS 5 17 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTA...

Page 200: ...ING THE SEGMENT 5 52 CHECKING THE SHIFT SHAFT 5 52 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 52 CHECKING THE STOPPER LEVER 5 52 INSTALLING THE STOPPER LEVER 5 53 INSTALLING THE SEGMENT 5 53...

Page 201: ...SSEMBLING THE CRANKCASE 5 72 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 74 REMOVING THE CRANKSHAFT ASSEMBLY 5 75 CHECKING THE CRANKSHAFT ASSEMBLY 5 75 INSTALLING THE CRANKSHAFT ASSEMBLY 5 76 INSTALLING...

Page 202: ...ALLING THE EXHAUST PIPE AND MUFFLER on page 5 10 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 Conne...

Page 203: ...g the exhaust 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 Ne...

Page 204: ...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 205: ...n page 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 7 Throttle body Refer to THROTTLE BOD...

Page 206: ...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 207: ...silencer EASB29B201 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 EASB29B202 REMOVING THE DRIVE SPROCKET 1 St...

Page 208: ...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 EASB29B204 CHECKING THE SILENCER AND...

Page 209: ...t 2 TIP Apply heat resistant sealant to the areas a shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 3 E...

Page 210: ...O rings and brake pedal bracket EASB29B208 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1...

Page 211: ...stall Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 13 Nm 1 3 m kgf 9 4 ft lbf Then retighten them to 20 Nm 2 0 m kgf 14 ft lbf 2 Install Clamp Exhaust pipe 2...

Page 212: ...t is positioned as shown with respect to the exhaust pipe 2 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...

Page 213: ...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 214: ...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 R...

Page 215: ...et with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap i...

Page 216: ...the camshaft into the cylinder head b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 31 830 31 930 mm 1 2531 1 2571 in Limit 31 730 m...

Page 217: ...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 the timing chain as a set EASB29B214 CHECKING THE TIMING...

Page 218: ...Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA NOTICE Do not turn the...

Page 219: ...ns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide...

Page 220: ...EL TANK on page 7 1 Exhaust 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...

Page 221: ...uide intake side 1 6 Oil check bolt 1 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...

Page 222: ...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 223: ...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 224: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 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 225: ...e valve seat and the valve seat contact 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...

Page 226: ...inder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 Valve stem to...

Page 227: ...nout Out of specification Replace the valve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the valve stem seal Intake Valve guide re...

Page 228: ...been removed 4 Lap Valve face Valve seat ECA NOTICE This model uses titanium intake and ex haust valves Do not use the valves used for lapping the valve seat Always replace the valves used for lappin...

Page 229: ...to make a clear impres sion j Measure the valve seat contact width c again If the valve seat contact width is out of specification reface and lap the valve seat EASB29B226 CHECKING THE VALVE SPRINGS 1...

Page 230: ...Install Spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 to the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with t...

Page 231: ...e Adjusting 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 pa...

Page 232: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 19 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 233: ...piston crown EASB29B231 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure...

Page 234: ...place the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP L...

Page 235: ...CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 Top ring 4 TIP Be sure to install the piston ring so that the manufacturer s marks or numbers face up 2 Install Pisto...

Page 236: ...lip ends are 3 mm 0 12 in c or more from the cutout in the piston 3 Lubricate Piston Piston rings Cylinder 4 Offset Piston ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressi...

Page 237: ...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 238: ...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 239: ...stances 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 specification re pla...

Page 240: ...arter motor yoke 2 ECA NOTICE Install the 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 s...

Page 241: ...ELECTRIC STARTER 5 40 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring New...

Page 242: ...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 243: ...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 244: ...15 Coolant Drain 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 41 1 Oil filter element cover 1 2 Oil filter element...

Page 245: ...9B241 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 246: ...place EASB29B246 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EASB29B247 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks...

Page 247: ...ll the oil seal in parallel with its manufac ture s marks or numbers facing inward EASB29B251 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithiu...

Page 248: ...the threads and con tact surface of the clutch boss nut Use the clutch holding tool 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction plate 1 1 Clutch plate 2 Cushion spring 3...

Page 249: ...2 1 Ball 2 Push rod 1 3 TIP Apply the engine oil on the push 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...

Page 250: ...CLUTCH 5 49 11 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R 1...

Page 251: ...ar 1 2 Shift pedal 1 3 Shift shaft 1 4 Oil seal 1 5 Collar 1 6 Shift shaft spring 1 7 Roller 1 8 Shift guide 1 9 Shift lever assembly 1 10 Shift lever 1 11 Pawl 2 12 Pawl pin 2 13 Spring 2 14 Stopper...

Page 252: ...proce dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks LS 2 4 14 16 15 LT 7 11 12 13 12 9 13 11 10 5 3 1 6 LT 8 LT E 12 Nm 1 2 m kgf 8 7 ft Ibf T R 30 Nm 3 0 m kgf 22 ft T...

Page 253: ...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 EASB29B256 CHECKING THE SHIFT SHAFT 1 Check Shift...

Page 254: ...ged Take care not to give an impact to it when tightening the bolt EASB29B261 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 255: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EASB29B263 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift s...

Page 256: ...efer to CLUTCH on page 5 41 Right crankcase cover Refer to CLUTCH on page 5 41 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 Oil pum...

Page 257: ...efer to GENERATOR AND STARTER CLUTCH on page 5 62 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 C...

Page 258: ...ND BALANCER GEAR 5 57 For installation reverse the removal proce dure Removing the balancer Order Part name Q ty Remarks T R 75 Nm 7 5 m kgf 54 ft lbf T R 50 Nm 5 0 m kgf 36 ft Ibf T R New 6 12 7 8 11...

Page 259: ...EAR 1 Check Primary drive gear 1 Balancer drive gear 2 Balancer weight gear 3 Wear damage Replace EASB29B267 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EASB29B268 CHECKING THE OIL PUM...

Page 260: ...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 Inner rotor to outer rotor tip clearance 0 000 0 150 mm 0 0000 0 0059 in Limit 0 2...

Page 261: ...ch 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 con...

Page 262: ...OIL PUMP AND BALANCER GEAR 5 61 a 2 10 b 2 9 1 b 5 3 a 4 10 5 9 3 E c d 6 7 8 8 b 6...

Page 263: ...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 50 1 Cover Damper assembly 1 2 Damper assembly 1...

Page 264: ...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 265: ...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 266: ...3 Install Starter clutch 1 To generator rotor 2 EASB29B275 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 267: ...cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using...

Page 268: ...AND STARTER CLUTCH 5 67 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 269: ...T SHAFT on page 5 50 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 62 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in...

Page 270: ...reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 3 1 5 2 6 4 10 5 6 4 4 4 4 6 9 11 7 8 9 LT 12 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R...

Page 271: ...SION on page 5 77 Shift cam and shift fork Refer to TRANSMISSION on page 5 77 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT LT 2 3 3 3 3 3 3 3 3 3 New 1 1 2...

Page 272: ...o tap on the case half 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 chec...

Page 273: ...pply the lithium soap based grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be pos...

Page 274: ...CRANKCASE 5 73 4 45 mm 1 77 in 5 60 mm 2 36 in 6 75 mm 2 95 in a Hexagon socket head bolt without flange b Hexagon socket head bolt with flange 5 4 5 4 4 4 6 6 6 4 a b 2 1 LT 2 3 6...

Page 275: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 68 Transmission Refer to TRANSMISSION on page 5 77 1 Balancer s...

Page 276: ...ion Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measur...

Page 277: ...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 278: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 68 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 279: ...on of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EASB29B290 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift...

Page 280: ...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 281: ...ease on 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...

Page 282: ...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 283: ...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 284: ...vicing trouble and mechanical damage EASB29B295 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 285: ...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 286: ...ra diator cap EASB29B297 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 287: ...e oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Right crankcase cover Refer to CLUTCH on page 5 41 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 Im...

Page 288: ...11 Oil seal 1 For 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...

Page 289: ...spot seizure Replace EASB29B302 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 f...

Page 290: ...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 291: ...EL SENDER 7 4 CHECKING THE FUEL SENDER 7 4 INSTALLING THE FUEL SENDER 7 4 INSTALLING THE FUEL TANK 7 4 CHECKING THE FUEL PRESSURE 7 5 CHECKING THE DAMPER 7 5 CHECKING AND REPLACING THE PROTECTOR 7 6 T...

Page 292: ...cing trouble and mechanical damage EASB29B305 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 293: ...tank Order Part name Q ty Remarks 4 6 2 2 2 2 2 5 6 3 1 New 4 0 Nm 0 40 m kgf 2 9 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 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6...

Page 294: ...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 295: ...damage the installation surfaces of the fuel tank when installing the fuel sender Always use a new fuel sender gasket When install the fuel sender make sure that the projection a faces the rear of the...

Page 296: ...L TANK on page 7 3 EWA WARNING Cover the fuel hose connection with a cloth when disconnecting it This is because re sidual pressure in the fuel hose could cause fuel to spurt out when the hose is remo...

Page 297: ...CKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace TIP Affix the protector as shown A Left B Right 3 31 in 4 53 in 84 mm 115 mm 3 1 1 3 a 2 3 31 in 4 53 in 84 mm 115 mm 1 1 A 0...

Page 298: ...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 299: ...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 300: ...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 301: ...reign 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 302: ...YAMAHA DIAGNOSTIC TOOL on page 8 28 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 303: ...DIAGRAM 8 24 ECU SELF DIAGNOSTIC FUNCTION 8 26 TROUBLESHOOTING METHOD 8 27 YAMAHA DIAGNOSTIC TOOL 8 28 TROUBLESHOOTING DETAILS 8 31 FUEL PUMP SYSTEM 8 52 CIRCUIT DIAGRAM 8 52 TROUBLESHOOTING 8 54 ELEC...

Page 304: ...8 72 CHECKING THE RADIATOR FAN MOTOR For JPN 8 73 CHECKING THE COOLANT TEMPERATURE SENSOR 8 73 CHECKING THE THROTTLE POSITION SENSOR 8 74 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 74 CHECK...

Page 305: ...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 306: ...L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R...

Page 307: ...nt connector 4 AC magneto 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU engine control unit 22 Ignition coil 23 Spark plug 29 Joint connector 34 Lean angle sensor 35 Engine stop switch...

Page 308: ...ery terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 37 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHE...

Page 309: ...Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 70 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 310: ...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 Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Page 311: ...Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 12 Starter motor 13 Starter relay diode 21 ECU engine control unit 29 Joint connector 35 Engine stop switch 36 Neutral switch 37 Diod...

Page 312: ...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 313: ...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 314: ...ce the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 71 OK Starter motor is OK Perform the electric starting system troubleshooting starting w...

Page 315: ...ch Refer to CHECKING THE SWITCHES on page 8 60 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 60 NG Replace the engine stop switch OK 12 Check...

Page 316: ...L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R...

Page 317: ...CHARGING SYSTEM 8 13 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 43 Negative battery lead...

Page 318: ...HARGING THE BATTERY on page 8 64 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 71 NG Replace the stator assembl...

Page 319: ...CHARGING SYSTEM 8 15...

Page 320: ...L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R...

Page 321: ...nector 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 14 Warning light 16 Fuel level warning light 17 Resistor 18 Fuel sender 21 ECU engine control unit 29 Joint...

Page 322: ...TTERY on page 8 64 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 67 NG Replace the main relay OK 4 Check the entire s...

Page 323: ...stor Refer to CHECKING THE RESIST ER on page 8 72 NG Replace the resistor OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 16 NG Properly connect or repair the signal...

Page 324: ...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 Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Page 325: ...ctor 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU engine control unit 26 Radiator fan motor relay 27 Radiator fan motor fuse 28 Radiator fan motor 29 Jo...

Page 326: ...main relay Refer to CHECKING THE RE LAYS on page 8 67 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 73 NG Replace the radiator...

Page 327: ...COOLING SYSTEM For JPN 8 23...

Page 328: ...g 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 Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W...

Page 329: ...4 Warning light 15 Engine trouble warning light 21 ECU engine control unit 24 Injector 29 Joint connector 30 Intake air temperature sensor 31 Coolant temperature sensor 32 Throttle position sensor 33...

Page 330: ...ation and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warnin...

Page 331: ...instatement action for the fuel injection system Refer to Confirmation of service completion in the appropriate table in TROUBLESHOOTING DETAILS on page 8 31 4 After pushing the engine stop switch pus...

Page 332: ...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 333: ...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 334: ...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 335: ...he 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 diagnostic tool di...

Page 336: ...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 337: ...pair 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...

Page 338: ...n page 8 75 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...

Page 339: ...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 340: ...ION SEN SOR on page 7 11 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...

Page 341: ...ensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 11 Push the start switch Fault code number...

Page 342: ...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 343: ...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 344: ...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 345: ...time the ignition 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 servi...

Page 346: ...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 347: ...c mode Code No 36 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 IN...

Page 348: ...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 349: ...erminals 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 seconds Fault code...

Page 350: ...7 Go to item 3 2 01 is indicated 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...

Page 351: ...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 352: ...malfunctioning Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of Yamaha diag nostic...

Page 353: ...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 354: ...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 355: ...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 356: ...R L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R...

Page 357: ...PUMP SYSTEM 8 53 1 Joint connector 2 Joint connector 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU engine control unit 25 Fuel pump 29 Joint connector 35 Engine stop switch 41 Frame gr...

Page 358: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 64 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 60 NG...

Page 359: ...FUEL PUMP SYSTEM 8 55...

Page 360: ...ELECTRICAL COMPONENTS 8 56 EASB29B345 ELECTRICAL COMPONENTS EASB29B346 9 10 11 1 3 2 4 5 6 7 8...

Page 361: ...ICAL COMPONENTS 8 57 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU engine control unit 5 Fuel sender 6 Fuel pump 7 Battery 8 Resistor 9 Neutral switch 10 Radiator fan motor For JPN 11 In...

Page 362: ...ELECTRICAL COMPONENTS 8 58 11 10 9 2 3 1 6 7 8 4 5...

Page 363: ...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 364: ...ELECTRICAL COMPONENTS 8 60 EASB29B347 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Page 365: ...ELECTRICAL COMPONENTS 8 61 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 366: ...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 367: ...in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socke...

Page 368: ...n cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink l...

Page 369: ...battery be sure to re move it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance o...

Page 370: ...charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amper...

Page 371: ...ery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Main relay Starting circuit cut off relay 12 8 V or more Charging is complete 12 7 V or les...

Page 372: ...to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally Result Continuity between 3 to 4 1 Positive battery terminal 2 Ne...

Page 373: ...cap b Measure the spark plug cap resistance EASB29B355 CHECKING THE IGNITION COIL 1 Disconnect Ignition coil terminal from the sub wire harness Spark plug cap from the ignition coil 2 Check Primary co...

Page 374: ...oltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Secondary coil resistance...

Page 375: ...cks 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 harness 2 Check Stator...

Page 376: ...e fuel sender a Connect the pocket tester 1k to the fuel sender as shown b Measure the resistance of the fuel sender EASB29B361 CHECKING THE RESISTER 1 Disconnect Resister coupler from the wire harnes...

Page 377: ...on Replace a Connect the pocket tester 1k 100 to the coolant temperature sensor b Immerse the coolant temperature sensor in a container filled with coolant TIP Make sure the coolant temperature sensor...

Page 378: ...tle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 11 EASB29B365 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sen...

Page 379: ...air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket te...

Page 380: ...Out of specification Replace a Disconnect the fuel injector coupler from the fuel injector b Connect the pocket tester 10 to the fuel injector coupler c Measure the fuel injector resistance Resistance...

Page 381: ...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 382: ...e Deteriorated or contaminated fuel Clogged or damaged fuel hose 2 Fuel pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged bat...

Page 383: ...ized shift fork Bent shift fork guide bar 3 Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EASB29B376 JUMPS OUT OF GEAR Engine 1 Shif...

Page 384: ...evel EASB29B382 FRONT FORK OIL LEAKING Chassis 1 Front fork Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high L...

Page 385: ...NG 9 4 7 Wheel s Incorrect wheel balance Broken or loose spoke Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8 Frame Bent frame Damaged steering head pipe Improperly installed...

Page 386: ...38 22 Intake air temperature sensor open or short circuit detected 8 39 30 Latch up detected 8 40 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 41 39 Injec...

Page 387: ...When 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 Displa...

Page 388: ...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 389: ...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 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETT...

Page 390: ...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 391: ...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 EASB29B393...

Page 392: ...of damping force Change the rebound damping force Change the compression damping force EASB29B396 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor...

Page 393: ...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 394: ...BSORBER ASSEMBLY on page 3 31 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned i...

Page 395: ...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 396: ...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 397: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 398: ...r 90201 20685 1 5 Circlip 93410 20038 1 6 Ratchet wheel 2S2 15671 00 1 7 Spring 90501 160A2 1 8 Washer 90201 167P7 1 Thickness 1 5 mm 0 059 in 9 Circlip 99009 16400 1 10 Spring guide 5NL 15664 00 1 11...

Page 399: ...620 00 1 20 Kickstarter lever boss 1SM 15621 00 1 21 Spring 90501 147A5 1 22 Ball 93507 32009 1 23 Screw 90151 06045 1 M6 24 O ring 93210 17570 1 25 Bolt 90110 08051 1 M8 26 Washer 90201 08048 1 27 Cr...

Page 400: ...UTCH on page 5 41 1 Circlip 1 Remove Do not use the circlip installed originally 2 Washer 1 Remove Do not use the washer installed originally 3 Collar 1 Remove Do not use the collar installed original...

Page 401: ...ssembly 1 TIP Before installation apply molybdenum disul fide grease to the contacting surfaces of the kick shaft ratchet wheel guide 2 and the kick shaft stopper a Apply the engine oil on the kick sh...

Page 402: ...tater lever Order Part name Q ty Remarks 1 Plug 1 Remove Do not use the plug installed originally 2 Oil seal 1 3 Gasket 1 4 Right crankcase cover 1 Refer to CLUTCH on page 5 41 5 Kickstarter lever 1 6...

Page 403: ...ng with the kickstarter When using the kickstarter to start the engine follow the procedures as described below 1 Fold out the kickstarter lever push it down lightly with your foot until resistance is...

Page 404: ...r 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace 3 Check Kickstarter lever 1 smooth movement Unsmooth movement Apply the lithium soap based grease to the pivoting point and metal t...

Page 405: ...opper a of the torsion spring fits into the hole b on the kick shaft 3 Install Spring guide 1 TIP Slide the spring guide into the kick shaft make sure the groove a in the spring guide fits on the stop...

Page 406: ...temperature sensor 31 Coolant temperature sensor 32 Throttle position sensor 33 Intake air pressure sensor 34 Lean angle sensor 35 Engine stop switch 36 Neutral switch 37 Diode 38 Starting circuit cut...

Page 407: ...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 408: ...UAL YZ250FXH B29 28199 12 LIT 11626 30 35 YZ250FXH 2017 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2016 05 0 2 1 E B29 28199 12_cover_13mm in...

Page 409: ...Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br 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 R R L R Lg W B B B Gy Br R W B...

Page 410: ...ON OFF ON OFF B B B B Gy Gy B B Gy B B B L L B B B B B YZ250FXH 2017 WIRING DIAGRAM B29 28199 12_W D indd 2 2016 05 13 16 10 03...

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