Yamaha YZ 2019 Series Owner'S Service Manual Download Page 155

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REAR BRAKE

4-27

EAM30046

INSTALLING THE BRAKE CALIPER PISTON

1. Clean:

•

Brake caliper

•

Brake caliper piston seal

•

Brake caliper piston dust seal

•

Brake caliper piston
Use brake fluid for cleaning.

2. Install:

•

Brake caliper piston seal “1”

•

Brake caliper piston dust seal “2”

WARNING

EWA19290

Always use new brake caliper piston seal

and brake caliper piston dust seal.

TIP

•

Apply the silicone grease on the brake caliper
piston seal and brake caliper piston dust seal.

•

Fit the brake caliper piston seals and brake cal-
iper piston dust seals onto the slot on brake
caliper correctly.

3. Install:

•

Brake caliper piston “1”

TIP

Apply the brake fluid on the piston outer surface.

NOTICE

ECA24480

• Install the piston with its side “a” facing the

brake caliper.

• Never force to insert.

EAM30047

INSTALLING THE REAR BRAKE CALIPER

1. Install:

•

Rear brake caliper

•

Rear brake caliper bracket

2. Install:

•

Rear wheel
Refer to “REAR WHEEL” on page 4-7.

•

Copper washer

•

Brake hose

•

Union bolt

WARNING

EWA13531

Proper brake hose routing is essential to in-

sure safe vehicle operation.

NOTICE

ECA24490

Make sure that a bend in its pipe portion “a”

is directed as shown and the brake hose

touches the projection “b” on the brake cali-

per.

3. Install:

•

Brake pad spring

•

Brake pad

•

Brake pad pin

•

Brake pad pin plug

Specified brake fluid

DOT 4

New

Brake hose union bolt

30 N·m (3.0 kgf·m, 22 lb·ft)

New

Summary of Contents for YZ 2019 Series

Page 1: ...17 Read this manual carefully before operating this vehicle YZ250FXK OWNER S SERVICE MANUAL YZ250FX 2019 PRINTED IN JAPAN 2018 04 0 3 1 E PRINTED ON RECYCLED PAPER 2019 YZ250FXK B29 28199 14_13mm ind...

Page 2: ...uals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly thro...

Page 3: ...019 by Yamaha Motor Corporation U S A 1st Edition March 2018 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib...

Page 4: ...equested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MAN...

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

Page 6: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 7: ...p e r u s s e r P 5 1 1 d o r h s u P 6 1 p i l c r i C 7 1 r e h s a W 8 1 g n i r a e B 9 1 l l a B 0 1 1 2 d o r h s u P 1 1 4 1 e t a l p n o i t c i r F 2 1 8 e t a l p h c t u l C 3 1 New New N...

Page 8: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

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

Page 10: ......

Page 11: ...RTS 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 SERVICE INFORMATION 1 7 ELECTRICAL SYSTEM 1 7 SPECIAL TOOLS 1 11 CONTROL...

Page 12: ...BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 22 MAJOR MAINTENANCE 1 22 TORQUE CHECK POINTS 1 23 MOTORCYCLE CARE AND STORAGE 1 25 CARE 1 25 STORAGE 1 26...

Page 13: ...soline 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 purchased 4 2 3 1 9 10 11 8 7 6 5 13 12 19 18 1716 15 14 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Front brake lever 5 Throttle grip 6 Start switch 7 Radiat...

Page 15: ...positive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicl...

Page 16: ...other foreign materials from entering the inside when the fuel hose is discon nected EAM30008 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and s...

Page 17: ...for each 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 t...

Page 18: ...M30013 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 the...

Page 19: ...ead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the...

Page 20: ...n push the starter switch Be sure to wait for five seconds or longer before pushing the start switch after the engine is stopped Checking the electrical system TIP Before checking the electrical syste...

Page 21: ...re to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disco...

Page 22: ...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 quick remedy us...

Page 23: ...number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom...

Page 24: ...403 Exhaust flange nut wrench YU A9472 3 34 4 51 Timing light 90890 03141 Timing light YU 03141 3 37 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 4 39 4 39 4 40 4 43 4 46 4 48 Cap bo...

Page 25: ...M 04108 5 23 5 28 Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 25 Valve guide installer 5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 25 Valve guide reamer 5 90890 0...

Page 26: ...set 90890 01304 Piston pin puller YU 01304 5 30 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 42 5 45 Rotor puller 90890 04142 Rotor puller YM 04142 5 60 Crankcase separating...

Page 27: ...t YU 90060 5 71 Adapter M12 90890 01278 Adapter 3 YU 90063 5 71 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 71 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 4 Fuel pressure ad...

Page 28: ...3212 FI diagnostic tool sub lead YU 03212 8 24 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 61 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P...

Page 29: ...hecked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warning...

Page 30: ...down on the brake pedal to acti vate the rear brake EAM30190 SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it WARNING EWA18980 Never apply additional for...

Page 31: ...over 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 vehicle...

Page 32: ...ery short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine pe...

Page 33: ...DURES A break in is important so that rotating portion sliding surfaces and mounted areas may fit one another and that the rider may become accus tomed to the machine NOTICE ECA25811 Before running do...

Page 34: ...or is not being discon nected 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 an...

Page 35: ...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 36: ...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 37: ...hemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhib...

Page 38: ...aust system are cool before covering the mo torcycle NOTICE ECA24250 Storing the motorcycle in a poorly ventilat ed room or covering it with a tarp while it is still wet will allow water and humidity...

Page 39: ...he battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery refer to CHECKING AND CHARGING THE BAT TERY on page 8 57 TIP Mak...

Page 40: ...MOTORCYCLE CARE AND STORAGE 1 28...

Page 41: ...ICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 19...

Page 42: ...del Model B29M 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 clearance 325 mm 12 80...

Page 43: ...US qt 0 73 Imp qt With oil filter removal 0 85 L 0 90 US qt 0 75 Imp qt Quantity disassembled 1 10 L 1 16 US qt 0 97 Imp qt Oil filter Oil filter type Paper Oil pump Inner rotor to outer rotor tip cl...

Page 44: ...meter intake 5 000 5 012 mm 0 1969 0 1973 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance in take 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080...

Page 45: ...limit 0 10 mm 0 004 in Clutch spring free length 47 80 mm 1 88 in Limit 45 41 mm 1 79 in Push rod bending limit 0 30 mm 0 012 in Drivetrain Primary reduction ratio 3 353 57 17 Transmission type Const...

Page 46: ...ONS 2 5 Engine oil temperature 70 80 C 158 176 F Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Throttle grip free play 3 0 6 0 mm 0 12 0 24 in Front brake lever free play 2 7 11...

Page 47: ...ed on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Disc outside diameter thickness 270 0 3 0 mm 10 63 0 12 in Brake disc thi...

Page 48: ...ing system Mechanical adjustable type Unit for compression damping adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 14 Adjustment value fr...

Page 49: ...stment value from the start position Soft 20 Adjustment value from the start position STD 13 Adjustment value from the start position Hard 0 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in...

Page 50: ...sistance 0 528 0 792 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 23 0 A Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah 10 HR Indicator lig...

Page 51: ...resistance 290 389 at 80 C 290 389 at 176 F Coolant temperature sensor resistance 2513 2777 at 20 C 2513 2777 at 68 F Coolant temperature sensor resistance 210 221 at 100 C 210 221 at 212 F Fuse s Mai...

Page 52: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque speci...

Page 53: ...ain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant...

Page 54: ...2 kgf m 8 9 lb ft Clutch cable holder bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Crankshaft end accessing screw M36 1 10 N m 1 0 kgf m 7 4 lb ft Timing mark accessing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft D...

Page 55: ...1 0 kgf m 7 4 lb ft Starter clutch bolt M6 6 16 N m 1 6 kgf m 12 lb ft Starter motor bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Neutral switch bolt...

Page 56: ...ork and base valve M5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Front fork protector and brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle g...

Page 57: ...nut M8 6 50 N m 5 0 kgf m 37 lb ft Nipple spoke 72 2 5 N m 0 25 kgf m 1 8 lb ft Rear brake disc cover bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb...

Page 58: ...bracket and fuel tank screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Left side cover bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Right side cover bolt M6 2 7 N m 0 7 kgf m 5 2 l...

Page 59: ...oximately 38 N m 3 8 kgf m 28 lb ft by using the steering nut wrench then loosen the lower ring nut one turn 2 Retighten the lower ring nut 7 N m 0 7 kgf m 5 2 lb ft Rear fender and relay bracket scre...

Page 60: ...ston pin outer surface Balancer shaft journal left Balancer nut threads left Decompression system moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump sha...

Page 61: ...Lower bearings and oil seal lip steering head Steering stem threads and nut contacting surface Pivot shaft bearing Swingarm pivot portion collar side surface and thrust bearing Swingarm pivot portion...

Page 62: ...hrottle grip inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper...

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

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAM20151 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30331 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 EAM20152 CABLE ROUTING DIAGRAM...

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

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: ...the cover C Pass the throttle position sensor lead to the outside of the tension arm the outside of the vehicle D After connecting the throttle position sensor coupler attach the cover E Pass the radi...

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

Page 79: ...e 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 the cross member and place...

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

Page 81: ...witch 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 number plate G Pass the start s...

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

Page 83: ...all the two breather hoses so that the yel low paint mark is pointing forwards C Align the white paint mark to the protruding portion of the pipe to install breather hose 3 D Protruding portion of the...

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

Page 85: ...shown and bring it into contact with the projection on the brake cali per B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twis...

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

Page 87: ...INE 3 13 CHECKING THE ENGINE OIL LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 ADJUSTING THE ENGINE IDLING SPEED 3 15 ADJUSTING THE VALVE CLEARANCE 3 16 VALVE CLEARANCE SHIM CHART 3 19 CHASSIS 3 21 BLEEDING...

Page 88: ...ING THE CABLES 3 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 CH...

Page 89: ...valve faces for wear Replace Valve spring Inspect Check the free length and the tilt Replace Valve lifter Inspect Check for scratches and wear Replace Camshaft Inspect Inspect the camshaft surface Ins...

Page 90: ...body Inspect Air filter Clean and lubricate Use Yamaha foam air filter oil or other quality foam air filter oil Replace Breather system Inspect Check ventilation hose for cracks or damage and drain an...

Page 91: ...lace brake fluid Every one year Swingarm Inspect lube and retighten Molybdenum disulfide grease Relay arm con necting rod Inspect lube and retighten Molybdenum disulfide grease Sidestand Lubricate Lit...

Page 92: ...rottle body for dirt and wear Levers Adjust clutch lever free play Brake pedal foot rest Lubricate Outside nuts and bolts Retighten Refer to TORQUE CHECK POINTS on page 1 23 Battery Inspect Check term...

Page 93: ...ive chain is lubricated properly 3 27 4 65 4 65 4 66 4 66 4 66 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 32 3 32 3 33 3 33 Steering Check th...

Page 94: ...INSPECTION AND MAINTENANCE 3 6 TIP Perform usual maintenance enough so that in the race course a confirmation of that and simple setting adjustments may only be left in order to get enough time to us...

Page 95: ...ew minutes until the coolant has settled EAM30211 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...

Page 96: ...lant level Refer to CHECKING THE COOLANT LEV EL on page 3 7 EAM30213 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or repla...

Page 97: ...oolant leaks Correct or replace Radiator hoses Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand EAM30216 ADJUSTING...

Page 98: ...ree play a Out of specification Regulate 2 Adjust Throttle grip free play a Loosen the locknut 1 b Turn the adjuster 2 until the specified free play is obtained c Tighten the locknut WARNING EWA20330...

Page 99: ...e cover 2 TIP Loosen the quick fastener screw 3 and remove the air filter case cover 2 Remove Air filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air filter element 3 Wash Air...

Page 100: ...r hose 1 Crack damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe...

Page 101: ...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 minimu...

Page 102: ...and oil filter element 2 b Replace the O ring 3 c Install the new oil filter element and the oil fil ter element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil str...

Page 103: ...pressure check bolt EAM30336 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 star...

Page 104: ...l damage Make sure that the valve clearance is checked or adjusted while the engine is cold at room temperature While the valve clearance is checked or adjust ed make sure that the piston is positione...

Page 105: ...the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust Refer to CAMSHAFT on page 5 11 b Remove the valve lifter 2 and the adjusting pad 3 with a valve lapper 1 T...

Page 106: ...d number to replace Example Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 NOTICE ECA24310 Do not twist adjusting pads and valve lifters forcibly during in...

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

Page 108: ...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 109: ...astic hose 1 to the bleed screw 2 securely and place a container un der the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the brake pe...

Page 110: ...cknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut WARNING EWA13050 A soft or spongy feeling in the brake lever can indi...

Page 111: ...e brake sys tem Air in the brake system will cause brak ing performance to be reduced NOTICE ECA13510 After adjusting the brake pedal position make sure there is no brake drag EAM30231 CHECKING THE FR...

Page 112: ...their projections 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...

Page 113: ...WHEEL on page 4 7 d Remove 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 pu...

Page 114: ...ake pad Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EAM30234 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a level surface TIP In order to ensure...

Page 115: ...d to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the driv...

Page 116: ...ly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 37 EAM30236 CHECKING THE FRONT FORK PROTECTOR GUIDE 1 Check Protector guide 1 Out of specification Replace TIP The protector guid...

Page 117: ...mping NOTICE ECA24340 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Rebound damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Compression damping N...

Page 118: ...oth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 54 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground...

Page 119: ...or b to make an adjustment Direction b Spring preload is increased suspen sion is harder Direction c Spring preload is decreased suspen sion is softer Spring preload Minimum Position in which the spr...

Page 120: ...off its position Cor rect the tire position EAM30244 CHECKING AND TIGHTENING THE SPOKES 1 Check Spoke Bend damage Replace Loose Tighten Fast compression damping Minimum soft 2 turn s in direction b S...

Page 121: ...ING THE FRONT WHEEL on page 4 4 and CHECKING THE REAR WHEEL on page 4 8 EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1 Use a maintenance stand to raise the front wheel off the ground WARNING EWA1...

Page 122: ...e following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and...

Page 123: ...efore 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 lubrica...

Page 124: ...rk 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 5 Clean Spark plug with a spark...

Page 125: ...firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CH...

Page 126: ...ELECTRICAL SYSTEM 3 38...

Page 127: ...RAKE CALIPER 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 BRAK...

Page 128: ...MBLY 4 54 HANDLING THE REAR SHOCK ABSORBER 4 57 DISPOSING OF A REAR SHOCK ABSORBER 4 57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 REMOVING THE BEARING 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 129: ...Air scoop right 1 4 Side cover left 1 5 Side cover right 1 6 Side cover 2 left 1 7 Number plate 1 8 Rear fender 1 4 2 6 8 5 1 3 7 2 1 3 N m 0 13 kgf m 0 95 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0...

Page 130: ...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 EAM30371 REMOVING THE NUMBER PLATE 1 Remove Bolt number plate N...

Page 131: ...se the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 LT LS LS LS 5...

Page 132: ...32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke 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...

Page 133: ...ing 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 its man...

Page 134: ...ont wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front wheel axle nut push down hard on the handl...

Page 135: ...round 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 6 2 5 7 9 LS LS 6 4 6 1...

Page 136: ...n page 3 33 3 Check Spoke Refer to 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 EAM30024 DISASSEMBLING THE REAR...

Page 137: ...th its manufacture s marks or numbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and...

Page 138: ...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 nut rear wheel axle at thi...

Page 139: ...M on page 3 21 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper...

Page 140: ...embling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 3 4 S S BF BF S 6 N...

Page 141: ...1 2 Union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake maste...

Page 142: ...FRONT BRAKE 4 14 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S...

Page 143: ...tention EAM30029 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 di...

Page 144: ...icating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When the brake caliper is disassembled re place the brake caliper piston seal and the...

Page 145: ...eservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill w...

Page 146: ...YLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder...

Page 147: ...1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper...

Page 148: ...he brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic...

Page 149: ...opper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake cal...

Page 150: ...sassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 1 2 3 4 S BF 6 N m 0...

Page 151: ...21 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder...

Page 152: ...REAR BRAKE 4 24 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S...

Page 153: ...M30041 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 f...

Page 154: ...eal EAM30044 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 caliper assem...

Page 155: ...rake caliper piston 1 TIP Apply the brake fluid on the piston outer surface NOTICE ECA24480 Install the piston with its side a facing the brake caliper Never force to insert EAM30047 INSTALLING THE RE...

Page 156: ...el mark a or below Add Refer to 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 SYSTEM on page 3...

Page 157: ...uses poor braking performance 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 Maste...

Page 158: ...rmance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA24510 Brak...

Page 159: ...e cable cap 1 7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lowe...

Page 160: ...AM30054 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower han...

Page 161: ...Handlebar grip 1 a Slightly coat the handlebar left end with a rub ber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive wi...

Page 162: ...ff 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 cov...

Page 163: ...e master cylinder 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 f...

Page 164: ...er free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 9 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 10 Clutch lever free play 7 0 12 0 mm...

Page 165: ...efer to FRONT WHEEL on page 4 3 Front brake 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 bolt 2 Loosen 3 Damper assem...

Page 166: ...1 5 Stopper ring 1 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 LS 14 2 7 10 9 11 12 5 3 1 6 8 13...

Page 167: ...t fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner t...

Page 168: ...ent inner tube 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...

Page 169: ...LEGS WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure t...

Page 170: ...3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Locknut 1 TIP Fully finger tighten the locknut onto the damper assembly 6 Loosen Compression damping force adjuster 1 TIP...

Page 171: ...valve side NOTICE ECA24540 Take care not 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 10 cm 0 34 US oz 0 3...

Page 172: ...ct the oil seal lip 15 Install Inner tube bushing 1 TIP Install the inner tube bushing onto the slot on in ner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Inner tube bushing 1 Washer 2...

Page 173: ...rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its large...

Page 174: ...ter 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 the damp er assembly 27...

Page 175: ...en the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts...

Page 176: ...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 to...

Page 177: ...FRONT FORK 4 49 1...

Page 178: ...t fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 37 4 Warning light 1 5 Upper bracket 1 6 Steering ring nut 1 7 Lower bracket 1 8 Bearing race cover 1 9 Upper bearing...

Page 179: ...ace 3 Replace Bearing Bearing race 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...

Page 180: ...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 ste...

Page 181: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 182: ...r 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 shock absorber assembly 1 4 Loc...

Page 183: ...15 Stopper ring 1 16 Bearing 1 Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9 9 10 10 11 1 13 LS LS M M M M M 53 N m 5 3 kgf m 3...

Page 184: ...Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2 4 6 6 3 4 4 M M M...

Page 185: ...f run ning EAM30064 DISPOSING OF A REAR SHOCK ABSORBER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent you...

Page 186: ...Damage wear Replace Bearing Damage wear Replace Bolt Bends damage wear Replace EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing S...

Page 187: ...swingarm bolt circumference and threaded portion Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt 6 Install Rear shock absorber assembly TIP When installing the rear sh...

Page 188: ...EAR SHOCK ABSORBER ASSEMBLY 4 60 Rear shock absorber assembly lower bolt Relay arm bolt swingarm side 70 N m 7 0 kgf m 52 lb ft Rear shock absorber assembly lower bolt 53 N m 5 3 kgf m 39 lb ft T R T...

Page 189: ...e the front wheel off the ground Brake 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 Collar 2 2 Oil seal 2 3 Thrust be...

Page 190: ...ving 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 EAM30072 REMOVING THE BEARING 1 Remove Bearing 1 TIP Rem...

Page 191: ...garm 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 Recommended lubric...

Page 192: ...4 64 EAM20104 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 1 75 N m 7 5 kgf m 55 lb ft 7 N m 0 7 kgf...

Page 193: ...h a between pin inner sides length 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 diff...

Page 194: ...CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety...

Page 195: ...this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 NOTICE ECA24590 A drive chain that is too tight will overload th...

Page 196: ...CHAIN DRIVE 4 68...

Page 197: ...OMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE...

Page 198: ...49 INSTALLING THE STOPPER LEVER 5 49 INSTALLING THE SEGMENT 5 50 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 50 INSTALLING THE SHIFT SHAFT 5 51 INSTALLING THE SHIFT PEDAL 5 51 OIL PUMP AND B...

Page 199: ...NG THE CRANKSHAFT ASSEMBLY 5 70 INSTALLING THE CRANKSHAFT ASSEMBLY 5 70 INSTALLING THE BALANCER SHAFT 5 71 TRANSMISSION 5 72 REMOVING THE TRANSMISSION 5 73 CHECKING THE SHIFT FORKS 5 73 CHECKING THE S...

Page 200: ...Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Exhaust pipe 2 protector 1 9 Silencer body 1 10 Si...

Page 201: ...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 switch 1 5 AC magne...

Page 202: ...HROTTLE BODY on page 7 6 Clutch cable Refer to CLUTCH on page 5 39 Shift pedal Refer to SHIFT SHAFT on page 5 48 Starter motor Refer to ELECTRIC STARTER on page 5 34 1 Engine guard 1 2 Brake pedal 1 3...

Page 203: ...Parts to remove Q ty Remarks New New LS M 8 8 7 6 13 4 5 New 1 12 3 2 11 11 10 9 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 55 N m 5 5 kgf m 41 lb ft 45 N m 4 5 kgf m 33 lb ft 45 N m 4 5 kgf...

Page 204: ...2 TIP Put the exhaust pipe 2 into the state as shown by moving this and then remove it EAM30160 REMOVING THE DRIVE SPROCKET 1 Straighten the lock washer tab 2 Remove Nut drive sprocket 1 Lock washer 2...

Page 205: ...e and remove this from its low er part toward the right of the chassis EAM30163 CHECKING THE SILENCER AND EXHAUST PIPE 1 Check Gasket 1 Damage Replace EAM30373 CHANGING THE SILENCER FIBER 1 Remove Bol...

Page 206: ...care not to allow the fiber out of place when installing the silencer body 3 EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from the right side Pivot shaft 2 Engine mounting bolt...

Page 207: ...ET 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 brake...

Page 208: ...2 0 kgf m 15 lb ft 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 209: ...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 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft...

Page 210: ...CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cy...

Page 211: ...1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 5 8 3 4 1 2 7 6 5 4 4 6 M M E New New New E E 10 N m 1 0 kgf m 7 4...

Page 212: ...mshaft sprocket with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts ca...

Page 213: ...to the camshaft journal as shown c Install the dowel pins and the camshaft caps TIP Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when me...

Page 214: ...the camshaft and the timing chain as a set EAM30083 CHECKING THE TIMING CHAIN TENSIONERS 1 Check Timing chain tensioner Crack damage Replace a While pressing the tensioner rod lightly with your finge...

Page 215: ...head TIP Make sure that the alignment mark c on the ex haust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head NOTICE ECA24620...

Page 216: ...Turn Crankshaft Counterclockwise several turns 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 al...

Page 217: ...CAMSHAFT 5 18 Spark plug Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R...

Page 218: ...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 6 Camshaft Refer...

Page 219: ...ent 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 VALVE...

Page 220: ...e 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 221: ...es and valve springs Order Job Parts to remove 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 spri...

Page 222: ...act width Refer to CHECKING THE VALVE SEATS on page 5 25 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene lea...

Page 223: ...n 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 remov er 1 Valve stem to valve guide clearance Valve g...

Page 224: ...KING 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 contact width a Out of specification...

Page 225: ...es with new ones without them When replacing the valves or the 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...

Page 226: ...spring EAM30094 CHECKING THE VALVE LIFTERS 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head EAM30095 INSTALLING THE VALVES 1 Clean Valve stem end 2 Lubricate Valve st...

Page 227: ...CA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly...

Page 228: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 1 2...

Page 229: ...lift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and rep...

Page 230: ...wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replac...

Page 231: ...ston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the F mark a on it point ing to its intake front side Before installing the piston pin clip cover the crankcase openi...

Page 232: ...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 b Up...

Page 233: ...RIC STARTER 5 34 EAM20110 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 1 12 N m 1 2 kgf m 8 9 l...

Page 234: ...5 Disassembling 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 3 5 N m 0...

Page 235: ...specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Bru...

Page 236: ...the part that has a smaller step differ ence a with the magnet of the starter motor yoke facing the starter motor front cover TIP Align the match mark a on the starter motor yoke with the match mark b...

Page 237: ...ELECTRIC STARTER 5 38...

Page 238: ...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 rod 2 1 12 Friction plate 1 4 13 Clutch plate 8 14 Cushion spring 1 15 Fric...

Page 239: ...ring 1 21 Washer 1 22 Push lever shaft 1 Removing the clutch Order Job Parts to remove Q ty Remarks New New New 2 3 4 5 5 6 7 8 9 6 10 11 12 22 1 15 12 13 13 18 19 20 17 16 14 13 LT 21 10 N m 1 0 kgf...

Page 240: ...Drain Refer to CHANGING THE COOLANT on page 3 7 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 39 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiato...

Page 241: ...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 the clutch plates as a set EAM30111...

Page 242: ...KING THE PRESSURE PLATE 1 Check Pressure plate Crack damage Replace EAM30115 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAM30116 CHECKING THE CLUTCH PUSH RODS 1 Check P...

Page 243: ...ll Oil seal 1 Washer 2 Circlip 3 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal in parallel with its manufac ture s marks or numbers facing inward EAM30120 INSTALLING...

Page 244: ...oil on the primary driven gear inner circumference 3 Install Lock washer 1 Clutch boss nut 2 NOTICE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas...

Page 245: ...te 1 2 friction plate 2 identification color purple 5 and friction plate 1 2 Apply the engine oil on the friction plates and clutch plates 6 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 TIP Ap...

Page 246: ...CLUTCH 5 47 10 Install Gasket 1 11 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 New T R 1...

Page 247: ...Collar 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 Sto...

Page 248: ...egment gets an impact the stopper le ver may be damaged Take care not to give an impact to it when removing the bolt EAM30125 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace S...

Page 249: ...NSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 t...

Page 250: ...t shaft 4 TIP Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAM30132 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on...

Page 251: ...ty Remarks Primary driven gear Refer to CLUTCH on page 5 39 Right crankcase cover Refer to CLUTCH on page 5 39 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6...

Page 252: ...TOR AND STARTER CLUTCH on page 5 58 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 Collar 1 9 Bala...

Page 253: ...EAR 1 Check Primary drive gear 1 Balancer drive gear 2 Balancer weight gear 3 Wear damage Replace EAM30135 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1...

Page 254: ...ine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAM30138 INSTALLING THE OIL PUMP AND BALANCER GEAR 1 Install Oil pump assembly 1 Inner rotor to outer rotor tip clearance 0...

Page 255: ...er 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 contact surface and threaded portion of the p...

Page 256: ...OIL PUMP AND BALANCER GEAR 5 57 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 257: ...pedal Refer to SHIFT SHAFT on page 5 48 1 Cover Damper assembly 1 2 Damper assembly 1 3 Breather hose 1 4 Left crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Starter idle gear 1 8 Bearing 1 9 Starter id...

Page 258: ...ing the generator Order Job Parts to remove Q ty Remarks T R T R 6 6 11 9 8 7 2 3 1 14 4 5 12 10 13 T R T R T R LT T R T R 15 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4...

Page 259: ...pitting wear Replace the damper assembly Check the gear of the starter motor armature 5 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the st...

Page 260: ...tor 2 EAM30142 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the crankshaft and generator rotor When installing the woo...

Page 261: ...switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using a crisscross pattern 5 Install Washer 1 Damper assembly 2 Washer 3 TIP Apply the...

Page 262: ...GENERATOR AND STARTER CLUTCH 5 63 1 a 3 3 2 4...

Page 263: ...e 5 48 Stator Refer to GENERATOR AND STARTER CLUTCH on page 5 58 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 7 5 Bolt L 60 mm 2 36...

Page 264: ...arks Transmission Refer to TRANSMISSION on page 5 72 Shift cam and shift fork Refer to TRANSMISSION on page 5 72 1 Circlip 2 2 Oil seal 3 3 Bearing 11 LT LT 2 3 3 3 3 3 3 3 3 3 New 1 1 2 3 New New LT...

Page 265: ...r to 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 c...

Page 266: ...ly 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 posit...

Page 267: ...CRANKCASE 5 68 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 268: ...SEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 64 Transmission Refer to TRANSMISSI...

Page 269: ...2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft 4 Check Crankshaft journal oil passage Obstruction Blow out wi...

Page 270: ...ankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing EAM30381 INSTALLING THE BALANCER SHAFT 1 Install Balancer shaft 1 T...

Page 271: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 64 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring...

Page 272: ...xle lightly with a soft hammer EAM30154 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll...

Page 273: ...pinion gear 27T 1 3rd 4th pinion gear 18T 21T 2 Collar 3 5th pinion gear 23T 4 2nd pinion gear 16T 5 to the main axle 6 TIP Before installation apply molybdenum disulfide oil to the inner and end sur...

Page 274: ...Main axle 1 Drive axle 2 TIP Install to the left crankcase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shif...

Page 275: ...k guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmissio...

Page 276: ...TRANSMISSION 5 77...

Page 277: ...OOLING SYSTEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 5 CHECKING THE WATER PUMP 6 5 CHECKING THE BEARING 6 5 INSTALLING THE OIL SEAL 6 5 ASSEMBL...

Page 278: ...Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 6 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Right radiator 1 4 Radiator hose 2 1 5 Radiator hose 3 1 6 Radiato...

Page 279: ...g the radiator Order Job Parts to remove Q ty Remarks 11 12 LS LS 3 4 5 6 7 8 9 10 2 2 2 2 2 2 2 1 1 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m...

Page 280: ...he radi ator cap EAM30341 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radia tor Damage Repair or replace TIP Correct any flattened fins wit...

Page 281: ...il Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 39 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 Impel...

Page 282: ...Replace EAM30261 INSTALLING THE OIL SEAL 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right...

Page 283: ...3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New 2 1 1 New T...

Page 284: ...WATER PUMP 6 7...

Page 285: ...VING THE FUEL SENDER 7 3 CHECKING THE FUEL SENDER 7 3 INSTALLING THE FUEL SENDER 7 3 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 4 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROT...

Page 286: ...eft right Refer to GENERAL CHASSIS on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump 1 6 Fuel pump gasket 1 7 Fuel sender 1 4 6 2 2...

Page 287: ...uded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnected fuel hose and the fuel pump 3 Remove Side cover left right Seat Air scoop left right Fuel tank TIP Do not set the...

Page 288: ...tall the fuel sender make sure that the projection a faces the rear of the vehicle EAM30267 INSTALLING THE FUEL TANK 1 Install Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose secur...

Page 289: ...he fuel hose is disconnected by hand Do not forcibly disconnect the hose with tools d Connect the pressure gauge 1 and the fuel pressure adapter 2 to the fuel hose e Start the engine f Measure the fue...

Page 290: ...FUEL TANK 7 5 A Left B Right 1 1 A 0 mm 0 in B 1 1 15 mm 0 59 in...

Page 291: ...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 Intake ai...

Page 292: ...e body joint 1 Removing the throttle body Order Job Parts to remove Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 3 5 N m 0...

Page 293: ...Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 2 5 4 3 5 N m 0 5 kgf m 3 7 lb ft 3 4 N m 0 34 kgf...

Page 294: ...foreign 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 cleaning solution Do not directl...

Page 295: ...r to YAMAHA DIAGNOSTIC TOOL on page 8 23 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 S...

Page 296: ...THROTTLE BODY 7 11...

Page 297: ...8 23 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL 8 23 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 8 23 TROUBLESHOOTING DETAILS 8 25 FUEL PUMP SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 47 ELECTRICAL CO...

Page 298: ...KING THE RESISTOR 8 65 CHECKING THE COOLANT TEMPERATURE SENSOR 8 66 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 66 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 67 CHECKING THE FUEL INJECTOR...

Page 299: ......

Page 300: ...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 301: ...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 302: ...spark plug Refer to CHECKING THE SPARK PLUG on page 3 36 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 61 OK The ignition s...

Page 303: ...IGNITION SYSTEM 8 4 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU...

Page 304: ...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 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...

Page 305: ...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 306: ...r is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance th...

Page 307: ...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 308: ...tion 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 step 5 NG 4 Check the starter motor Refer to...

Page 309: ...G Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the engine stop switch OK 12 Check the start switch Refer to CHECKING THE SWITCHES...

Page 310: ...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 311: ...CHARGING SYSTEM 8 12 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 43 Negative battery lead...

Page 312: ...ARGING 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 assembly...

Page 313: ...CHARGING SYSTEM 8 14...

Page 314: ...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 315: ...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 316: ...ls Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 60 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGR...

Page 317: ...SIGNALING SYSTEM 8 18 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 15 NG Properly connect or repair the signaling system s wiring OK Replace the ECU...

Page 318: ...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 319: ...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 320: ...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 321: ...nstatement action for the fuel injection system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS on page 8 25 4 After pushing the engine stop switch pus...

Page 322: ...he diagnostic tool cannot be used to freely change the basic vehicle functions such as ad justing the ignition timing EAM30356 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting...

Page 323: ...w to connect and use the Yamaha diagnostic tool refer to YAMAHA DIAGNO STIC TOOL OPERATION MANUAL FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 1 2 3 2 4 5 6 1 Vehicle 2...

Page 324: ...terminals and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Crank the engine Fault code number is not dis played Service is finis...

Page 325: ...ake air pres sure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Co...

Page 326: ...value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Push the start switch Fault code number is not dis played Service is finished...

Page 327: ...n position Procedure Check with throttle valve fully closed Check with throttle valve fully open Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Con...

Page 328: ...n sensor lead Check the applied voltage black blue blue Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 Location of discon nec...

Page 329: ...ondition of throttle position sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 10 Push the...

Page 330: ...nect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Push the start swit...

Page 331: ...ess Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of th...

Page 332: ...output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 45 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation...

Page 333: ...ngine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Connection of sub wire harness coupler Check the...

Page 334: ...place the wire harness Execute the diagnostic mode Code No 36 No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector resis tance Replace if out of...

Page 335: ...t switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconn...

Page 336: ...or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds...

Page 337: ...2 07 Go to item 3 2 01 is indicated in diagnostic mode Code No 60 EEPROM data error for adjust ment of CO concentration Change the CO concentration and rewrite in EEPROM After this adjustment push th...

Page 338: ...ayed Go to item 2 2 Wire harness continuity Open or short circuit Replace the wire harness Between rectifier regulator cou pler and ECU coupler red red Between battery terminal and ECU coupler red red...

Page 339: ...e wire harness Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking cond...

Page 340: ...ault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the co...

Page 341: ...r is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Page 342: ...code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler...

Page 343: ...FUEL INJECTION SYSTEM 8 44...

Page 344: ...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 345: ...PUMP SYSTEM 8 46 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 346: ...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 53 NG...

Page 347: ...FUEL PUMP SYSTEM 8 48...

Page 348: ...ELECTRICAL COMPONENTS 8 49 EAM20147 ELECTRICAL COMPONENTS 9 10 1 3 2 4 5 6 7 8...

Page 349: ...ELECTRICAL COMPONENTS 8 50 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 Injector...

Page 350: ...ELECTRICAL COMPONENTS 8 51 11 10 9 2 3 1 6 7 8 4 5...

Page 351: ...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 352: ...ELECTRICAL COMPONENTS 8 53 EAM30289 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Page 353: ...ELECTRICAL COMPONENTS 8 54 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 354: ...al circuit tester to the range 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 connection diagr...

Page 355: ...n the bulb section however note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to the respective leads of the bulb socket c Check the bulb socket...

Page 356: ...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 large qu...

Page 357: ...rage current into the battery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overchar...

Page 358: ...current is lower than the standard charging current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage for 3 5 minutes to check the battery d Adjust the v...

Page 359: ...f the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital circuit tester and bat tery 12 V to the relay terminal as shown Check the re...

Page 360: ...ion the ignition system circuit is operating normally a Remove the spark plug cap from the spark plug b Connect the ignition checker 1 as shown 1 Positive battery terminal 2 Negative battery terminal...

Page 361: ...the sub wire harness Spark plug cap from the ignition coil 2 Check Primary coil resistance Out of specification Replace a Connect the digital circuit tester to the ig nition coil b Measure the primary...

Page 362: ...rcuit tester DC to the lean angle sensor coupler as shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Ignition coil terminal 1 1 Negati...

Page 363: ...make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil...

Page 364: ...uel sender EAM30360 CHECKING THE RESISTOR 1 Disconnect Resister coupler from the wire harness 2 Check Resister resistance Out of specification Replace the resister a Connect the digital circuit tester...

Page 365: ...olant d Slowly heat the coolant and then let it cool to the specified temperature indicated in the ta ble e Check the coolant temperature sensor for continuity at the temperatures indicated in the tab...

Page 366: ...r terminal EAM30308 CHECKING THE FUEL INJECTOR 1 Remove Fuel injector Refer to THROTTLE BODY on page 7 6 2 Check Fuel injector resistance Out of specification Replace a Disconnect the fuel injector co...

Page 367: ...S 8 68 c Measure the fuel injector resistance Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Inj...

Page 368: ...ELECTRICAL COMPONENTS 8 69...

Page 369: ...IFT 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 9 3 FRONT FORK OIL LEAKING 9 3 FAULTY FRONT FORK LEGS 9 3 U...

Page 370: ...riorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark...

Page 371: ...Improperly returned stopper lever 2 Shift forks Worn shift fork 3 Shift drum Incorrect axial play Worn shift drum groove 4 Transmission Worn gear dog EAM30316 CLUTCH SLIPS Engine 1 Clutch Improperly a...

Page 372: ...Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EAM30321 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork...

Page 373: ...ected 8 31 22 Intake air temperature sensor open or short circuit detected 8 32 30 Latch up detected 8 33 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 34...

Page 374: ...ant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Displays the output voltage Remove the lean angle sen sor and incline it more than 45 degrees Upright Overturned 0 4...

Page 375: ...rocedure 30 Ignition coil Actuates the ignition coil five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark i...

Page 376: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Page 377: ...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 SETTING PARTS 10 4 SUSPENSION SETTING FRONT FORK 1...

Page 378: ...ed 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 from...

Page 379: ...y too large oil amount will cause the air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork wit...

Page 380: ...he engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rid...

Page 381: ...the rebound damping force will be fol lowed more or less by a change in the compres sion damping force For correction adjust to decrease compression damping force WARNING EWA19200 When using a rear s...

Page 382: ...n page 3 30 Spring preload adjusting position 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 in 10 0 mm 0 39 in f...

Page 383: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Page 384: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Page 385: ...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 386: ...3410 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 Torsion spring 90508 30743...

Page 387: ...ever 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 Crankcase cover gasket 1SM...

Page 388: ...LUTCH on page 5 39 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 origina...

Page 389: ...aft assembly 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 ki...

Page 390: ...kstarter 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 39 5 Kickstarter lever...

Page 391: ...ollow the procedures as described below 1 Fold out the kickstarter lever push it down lightly with your foot until resistance is felt 2 With the throttle fully closed push the kick starter down lightl...

Page 392: ...thium soap based grease to the pivoting point and metal to metal moving parts TIP Check the kickstarter lever movement and lubri cation for every race Installing the kickstarter kit 1 Install Kick gea...

Page 393: ...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 stopper of the torsion spring 4 Install Kick shaft assembly Refer to SET...

Page 394: ...connector 30 Intake air 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 Diod...

Page 395: ...uals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly thro...

Page 396: ...17 Read this manual carefully before operating this vehicle YZ250FXK OWNER S SERVICE MANUAL YZ250FX 2019 PRINTED IN JAPAN 2018 04 0 3 1 E PRINTED ON RECYCLED PAPER 2019 YZ250FXK B29 28199 14_13mm ind...

Page 397: ...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 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...

Page 398: ...ON OFF ON OFF B B B B Gy Gy B B Gy B B B L L B B B B YZ250FXK 2019 WIRING DIAGRAM B29 28199 14_W D indd 2 2018 03 29 17 51 16...

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Yamaha YZ 2019 Series, Owner'S Service Manual

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