Yamaha YZ 2020 Series Owner'S Service Manual Download

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Summary of Contents for YZ 2020 Series

Page 1: ...626 33 34 Read this manual carefully before operating this vehicle YZ250FXL1 OWNER S SERVICE MANUAL YZ250FX 2020 PRINTED IN JAPAN 2019 07 0 8 1 E 2020 YZ250FXL1 BAJ 28199 10_cover_US_10mm_FCC indd 1 3...

Page 2: ...ity you have come to expect Why settle for aftermarket parts that may not provide full confidence and satisfaction Genuine Yamaha Accessories Yamaha only offers accessories that meet our high standard...

Page 3: ...ce could void the user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC ra...

Page 4: ...020 by Yamaha Motor Corporation U S A First edition July 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Page 5: ...uested 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 MANUA...

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

Page 7: ...re 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 the exploded diagram A number indicates a removal or a disas...

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: ...ON 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 BASIC SERV...

Page 12: ...26 BREAK IN PROCEDURES 1 26 ENGINE STARTING PRECAUTION 1 26 MAINTENANCE AFTER BREAK IN 1 27 MAJOR MAINTENANCE 1 27 AIR FILTER MAINTENANCE 1 27 TORQUE CHECK POINTS 1 28 MOTORCYCLE CARE AND STORAGE 1 3...

Page 13: ...lands may be illegal Please check local regulations before riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycle...

Page 14: ...ned tested and approved by Yamaha for use on your vehicle Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not...

Page 15: ...torcycle 2 Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail...

Page 16: ...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 17: ...u have purchased 1 12 13 15 14 16 17 18 19 20 4 2 3 5 7 6 8 9 10 11 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 18: ...r for 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...

Page 19: ...not operate the engine in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard veh...

Page 20: ...equipment such as radios or mobile phones in close proximity of the CCU The CCU is in contact with or covered by a metallic object Other vehicles equipped with a CCU are nearby In such situations move...

Page 21: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Page 22: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Page 23: ...y dangerous TIP If a battery lead 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 ba...

Page 24: ...ti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes...

Page 25: ...th sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All...

Page 26: ...f there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732...

Page 27: ...ting 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 tachometer YU A19...

Page 28: ...3 27 4 55 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501...

Page 29: ...e spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 27 5 32 Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 29 Valve guide installer 5 9...

Page 30: ...eamer 4 5 mm YM 04118 5 29 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 34 Rotor puller 90890 04151 Rotor puller YM 04151 5 39 Sheave holder 90890 01701 Primary clutch holder YS 0188...

Page 31: ...haft installer pot 90890 01274 Installing pot YU 90058 5 72 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 72 Adapter M12 90890 01278 Adapter 3 YU 90063 5 72 Spacer crankshaft installer 90890 0...

Page 32: ...YU 33984 6 4 6 4 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 8 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Lithium battery charger 90890 05376 Lithium battery charge...

Page 33: ...SPECIAL TOOLS 1 21 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 55 Tool name Tool No Illustration Reference pages...

Page 34: ...ectrical 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 light does not come on initially whe...

Page 35: ...g it WARNING EWA18980 Never apply additional force to the sides tand Hold up the sidestand before starting out EAM30189 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press dow...

Page 36: ...er 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 I...

Page 37: ...EAM30196 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not operate the...

Page 38: ...le opening of 3 4 or less 4 Make a pit stop again and thoroughly check mounted areas for looseness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch o...

Page 39: ...s Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket and...

Page 40: ...Link 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...

Page 41: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Page 42: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Page 43: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 44: ...e spark plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lub...

Page 45: ...TIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 6 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSI...

Page 46: ...del Model BAJ1 Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1270 mm 50 0 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60...

Page 47: ...75 L 0 79 US qt 0 66 Imp qt Quantity disassembled 0 95 L 1 00 US qt 0 84 Imp qt Oil filter Oil filter type Cartridge Oil pump Inner rotor to outer rotor tip clearance 0 00 0 15 mm 0 0000 0 0059 in Li...

Page 48: ...de 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 mm 0 0032 in Valve stem to valve guide clearance ex h...

Page 49: ...ngth 44 00 mm 1 73 in Limit 41 80 mm 1 65 in Push rod bending limit 0 30 mm 0 012 in Drivetrain Primary reduction ratio 3 353 57 17 Transmission type Constant mesh 6 speed Gear ratio 1st 2 385 31 13 2...

Page 50: ...ENGINE SPECIFICATIONS 2 5 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in...

Page 51: ...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 Front brake lever free play 2 7 11 1 mm 0 11 0 44 in Disc outside diameter thic...

Page 52: ...Adjustment value from the start position Hard 0 Compression damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment va...

Page 53: ...it for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Swingarm Swingarm end free play...

Page 54: ...14 8 V Battery Model BR98 Voltage capacity 12 V 2 4 Ah 5 HR Indicator light Fuel level warning light 1 7 W Engine trouble warning light 1 7 W Starter motor Brush overall length 7 0 mm 0 28 in Brush ov...

Page 55: ...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 specif...

Page 56: ...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 drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft R...

Page 57: ...ver bolt left side of the drive axle M6 2 12 N m 1 2 kgf m 8 9 lb ft Plate bolt M6 4 12 N m 1 2 kgf m 8 9 lb ft Clutch cover bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m...

Page 58: ...e sure to apply molybdenum disulfide oil to the bolt threads and seats as well as to both sides of the lock washers Stator coil assembly lead holder bolt M5 1 8 N m 0 8 kgf m 5 9 lb ft Coolant tempera...

Page 59: ...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 Brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb f...

Page 60: ...25 kgf m 1 8 lb ft Bolt rear brake disc cover 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 ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33...

Page 61: ...r side M6 2 7 N m 0 7 kgf m 5 2 lb ft Fuel pump bolt M5 5 7 N m 0 7 kgf m 5 2 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft S...

Page 62: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view...

Page 63: ...o the hole in the cylinder head When doing so make sure that the lead is not twisted I Route the starter motor lead through the inside of the engine mounting bracket boss and the front side area than...

Page 64: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view...

Page 65: ...the illustration Then install the lower clip above the radiator stay H Align the red paint mark on the hose with the convex mark on the 3 way joint and then install the cylinder head breather hoses I...

Page 66: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view...

Page 67: ...stop switch lead and mode switch lead to the handlebar using the plastic locking tie Do not cut the end of the plastic locking tie D 30 50 E Vertical direction of vehicle F Pass the engine stop switch...

Page 68: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view...

Page 69: ...arness and start switch lead by the clamp and insert the clamp pro jection into the hole in the sheet metal of the radiator The direction of the clamp lock por tion does not matter It is allowed to ru...

Page 70: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view...

Page 71: ...relay terminal B Install the clamp wire harness to the hole of the battery bracket C After connecting the negative battery coupler position to the right side of the starter relay D The position of the...

Page 72: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view...

Page 73: ...e hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that...

Page 74: ...CABLE ROUTING DIAGRAM 2 29...

Page 75: ...THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3 22 ADJUSTING THE FRONT DISC BRAKE 3 22 ADJUSTING THE REAR DISC BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL 3...

Page 76: ...ND LUBRICATING THE CABLES 3 33 LUBRICATING THE BRAKE LEVER 3 33 LUBRICATING THE CLUTCH LEVER 3 33 LUBRICATING THE PEDAL 3 33 CHECKING THE SIDESTAND 3 34 LUBRICATING THE SIDESTAND 3 34 ELECTRICAL SYSTE...

Page 77: ...e about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve faces for wear Replace 2 Valve spring Check the free length Replace 3 Valve lifter Check for scrat...

Page 78: ...t leaks and tightening torques Clean Replace fiver When the exhaust sound becomes louder or when a perfor mance drop is felt 21 Crankshaft Inspect and clean 22 Throttle body Inspect 23 Air filter Clea...

Page 79: ...k for tightening torques Replace pads Replace brake fluid Every one year 35 Swingarm Inspect lube and retighten 36 Relay arm connect ing rod Inspect lube and retighten 37 Sidestand Lubricate 38 Steeri...

Page 80: ...or dirt and wear 44 Levers Adjust clutch lever free play 45 Brake pedal footrest Lubricate 46 Outside nuts and bolts Retighten 47 Battery Check terminal for looseness and corrosion No Item Routine Aft...

Page 81: ...2 3 22 3 23 3 23 3 23 3 23 3 24 3 24 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 25 4 68 4 68 4 69 4 69 4 69 Wheels Check for excessive wear a...

Page 82: ...ir scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 14 3 Remove Timing mark access...

Page 83: ...or the number on the originally installed ad justing pad convert the last digit of adjusting pad number as per the below table d Select an adjusting pad with a proper valve clearance from the adjustin...

Page 84: ...turn smoothly when rotated with your finger Make sure that valve lifters and adjusting pads are installed in place Make sure that adjusting pads are installed with their numbers facing upward f Insta...

Page 85: ...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 86: ...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 87: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Page 88: ...Remove Holder Spark plug cap Spark plug Refer to CAMSHAFT on page 5 14 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylind...

Page 89: ...l to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1 Start the engine warm this up for several minutes and then stop the engine and wait about 5 min...

Page 90: ...e 3 13 10 Check Engine oil pressure a Slightly loosen the oil pressure check bolt 1 WARNING EWA19120 When the engine is started with the check bolt removed oil will spout therefore al ways loosen it b...

Page 91: ...bar side a Turn the adjuster 1 until the specified clutch lever free play is obtained TIP If the clutch lever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable si...

Page 92: ...ter guide Guide 3 from the air filter element Seal 4 from the air filter element 4 Wash Air filter element WARNING EWA19110 Do not use gasoline or organic acid alka line volatile oil for washing TIP A...

Page 93: ...ion 9 Install Air filter case cover 1 Fuel tank breather hose to the air filter case cover TIP Make sure that the two slots a at the rear side of the vehicle in the air filter case cover are se curely...

Page 94: ...ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage...

Page 95: ...he silencer body by using a flat board 11 h Install the fiber insert 12 to the inner pipe i Install the fiber insert 13 to the inside of the silencer cap 14 j Install the silencer cap 15 and rivet 16...

Page 96: ...If therefore water is used instead of coolant check and if nec essary adjust the antifreeze concentration Use only distilled water However if dis tilled water is not available soft water may be used 4...

Page 97: ...olant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallo...

Page 98: ...position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position a distance from the top of the rider footrest to the top of th...

Page 99: ...g 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 ECA13540 Brake fluid may damage p...

Page 100: ...erating properly EAM30477 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA19140 Bleed the brake system whenever The system is disassembled A brake hose is loosened disconnected or replaced The brake fl...

Page 101: ...hydraulic brake system check the brake operation EAM30481 DRIVE CHAIN SLACK NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can...

Page 102: ...lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAM3...

Page 103: ...er bearing Lower bearing Bearing race EAM30338 CHECKING THE FRONT FORK LEGS 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of i...

Page 104: ...ion of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in productio...

Page 105: ...l pressure from the front fork 3 Tighten Bleed screw EAM30482 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so...

Page 106: ...dirt and mud from around the locknut and adjusting ring before adjust ment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjusting ring e Tighten the locknut 3 Install Rear...

Page 107: ...exactly match the spec ifications listed due to small differences in production Compression damping for slow compres sion damping NOTICE ECA24390 Do not turn the adjuster forcibly beyond its adjusting...

Page 108: ...D RELAY ARM on page 4 62 EAM30243 CHECKING THE TIRES 1 Measure Tire pressure Out of specification Regulate TIP Check the tire while it is cold Loose bead stoppers allow the tire to slip off its positi...

Page 109: ...A13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check C...

Page 110: ...eration Check that the sidestand moves smoothly Rough movement Repair or replace EAM30252 LUBRICATING THE SIDESTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact point o...

Page 111: ...e high tension cord 3 3 Adjust Engine idling speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 11 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is with...

Page 112: ...ELECTRICAL SYSTEM 3 36...

Page 113: ...C 4 17 REPLACING THE FRONT BRAKE PADS 4 18 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 20 ASSEMBLING THE FRONT BRAKE CALIPER 4 2...

Page 114: ...NG THE STEERING HEAD 4 55 REAR SHOCK ABSORBER ASSEMBLY 4 58 HANDLING THE REAR SHOCK ABSORBER 4 61 DISPOSING OF A REAR SHOCK ABSORBER 4 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE RE...

Page 115: ...s 1 Seat 1 2 Side cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 CCU Communication Co...

Page 116: ...to CLEANING THE AIR FILTER ELE MENT on page 3 16 2 Air scoop right 1 3 Air scoop left 1 4 Side cover right 1 5 Number plate 1 6 Rear fender 1 6 4 1 3 5 2 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf m...

Page 117: ...tch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing...

Page 118: ...wn EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover...

Page 119: ...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 120: ...c Remove the bearings with a bearing pull er EAM30018 CHECKING THE FRONT WHEEL 1 Check Front wheel axle Roll the front wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to st...

Page 121: ...the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward NOTICE ECA24420 Install the b...

Page 122: ...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 123: ...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 124: ...e 4 6 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING THE FRONT WHEEL on page 4 6 4 Measure Ra...

Page 125: ...s 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 that...

Page 126: ...le 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...

Page 127: ...SYSTEM on page 3 24 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 cal...

Page 128: ...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 129: ...on 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 master cylind...

Page 130: ...ONT BRAKE 4 16 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 New N...

Page 131: ...attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of s...

Page 132: ...m the front fork d Remove the pad pin and brake pads 4 2 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 3 Install Brake pads a Connect the plastic hose 1 to the bl...

Page 133: ...the brake hose into a container and pump out the brake fluid EAM30031 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper piston 1 Brake caliper piston dust seal 2 Brake caliper piston seal...

Page 134: ...ill cause the piston seals to swell and distort When the brake caliper is disassembled re place the brake caliper piston seal and the brake caliper piston dust seal with new ones EAM30035 INSTALLING T...

Page 135: ...level mark or below Add Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 7 Check Brake lever free play Refer to ADJUSTING THE FRONT DISC BRAKE on page 3 22 Brake lever operation A softy or spongy...

Page 136: ...e brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Brake master cylinder kit 1 Washer 2 Circlip 3 Dust boot 4 Push rod...

Page 137: ...id that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid res...

Page 138: ...3 Copper 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...

Page 139: ...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 140: ...age 3 24 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 cyl...

Page 141: ...REAR BRAKE 4 27 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 New New...

Page 142: ...medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of...

Page 143: ...ll the brake pad 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 a...

Page 144: ...the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston d...

Page 145: ...r 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 with the...

Page 146: ...age wear Replace 3 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Crack damage Replace 4 Check Brak...

Page 147: ...WA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is alr...

Page 148: ...REAR BRAKE 4 34 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 a a a...

Page 149: ...ble 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 Lower handlebar holder 2 16 Dam...

Page 150: ...ver 2 Install Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting...

Page 151: ...ode switch 2 should be installed according to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder a 3 4 4 Lower handlebar holder nut 40 N m 4 0 kgf m 30...

Page 152: ...NG THE CLUTCH LEVER FREE PLAY on page 3 15 9 Install Right grip 1 Collar 2 Apply adhesive to the tube guide 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a...

Page 153: ...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 fo...

Page 154: ...HANDLEBAR 4 40 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in...

Page 155: ...to FRONT WHEEL on page 4 5 Front brake caliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly...

Page 156: ...e 1 6 Outer tube 1 7 Piston metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seal 1 12 Base valve 1 13 Damper assembly 1 14 Upper spring seat 1 LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New N...

Page 157: ...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 tu...

Page 158: ...s 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 159: ...hing Outer tube bushing Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA...

Page 160: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper...

Page 161: ...ge 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 35 Imp oz 13 Check Damper assembly smooth movemen...

Page 162: ...Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube TIP Press the slide metal into t...

Page 163: ...peat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its larger di...

Page 164: ...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 165: ...ighten 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 bo...

Page 166: ...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 167: ...FRONT FORK 4 53 1...

Page 168: ...t fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 41 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 169: ...ace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing 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 170: ...teering ring 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 26 5 Check the steering...

Page 171: ...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 172: ...er 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 Lo...

Page 173: ...sorber assembly Order Job Parts to remove Q ty Remarks 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M M M M LS M LS 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft 10 N m...

Page 174: ...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 175: ...er be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a...

Page 176: ...bearing outer race because it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bushing Stopper ring to rear shock absorber assembly upper si...

Page 177: ...sorber assembly lower bolts connecting arm bolt relay arm side and relay arm bolt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting...

Page 178: ...heel off the ground Brake hose holder Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bus...

Page 179: ...and the collars EAM30073 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to...

Page 180: ...right 4 Install Rear wheel Refer to REAR WHEEL on page 4 9 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 25 Pivot shaft nut 85 N m 8 5 kgf m 63 lb ft Drive chain slack Maintenance s...

Page 181: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1...

Page 182: ...ength 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 different location each time 2 Ch...

Page 183: ...KET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 10 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP In...

Page 184: ...prockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 25 NOTICE ECA24590 A drive chain that is too tight will overload the engi...

Page 185: ...HEAD 5 23 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES...

Page 186: ...53 INSTALLING THE CLUTCH 5 53 SHIFT SHAFT 5 56 REMOVING THE SEGMENT 5 57 CHECKING THE SHIFT SHAFT 5 57 CHECKING THE STOPPER LEVER 5 57 INSTALLING THE SHIFT SHAFT 5 57 OIL PUMP 5 60 REMOVING THE OIL P...

Page 187: ...INSTALLING THE TRANSMISSION 5 75...

Page 188: ...M20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Relief valve 7 Oil pump 8 Oil strai...

Page 189: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 190: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Oil filter element 2 Oil pump...

Page 191: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Intake camshaft 2 Exhaust camshaft...

Page 192: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Camshaft 2 Oil pressure check bolt 3 Oil pump 4 Oil filter element...

Page 193: ...CK ABSORBER ASSEMBLY on page 4 58 1 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 Silencer body 1...

Page 194: ...the boots band installation tool 90890 01526 YM 01526 LT 8 6 New New New LT 1st 2nd 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0...

Page 195: ...efer to FUEL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Refer to THROTTL...

Page 196: ...DY on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 48 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 56 Refer to CHAIN DRIVE on page 4 67 1...

Page 197: ...2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 75 N m 7 5 kgf m 55 lb ft 34 N m 3 4 kgf m 25 lb ft 53 N m...

Page 198: ...rom its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engin...

Page 199: ...pe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2 3 Install Clamp Silencer 1 Bolt silencer 2 TIP Inst...

Page 200: ...he exhaust pipe clamp 1 does not ride on the projection a on the ex haust pipe 2 or silencer 3 Be sure to insert the projection b into the slot in the exhaust pipe or silencer Bolt exhaust pipe 2 20 N...

Page 201: ...left right Refer to GENERAL 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 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1...

Page 202: ...crew 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 LS 5 8 3 4 1 2 7 6 5 4 4 6 M M E E E 6 N m 0 6 kgf m 4 4 lb ft...

Page 203: ...ith 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 camshaft cap in a c...

Page 204: ...l 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 measuring the camshaft j...

Page 205: ...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 fingers use a thin screwdriver 1 to wind th...

Page 206: ...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 Do no...

Page 207: ...p dead center TDC mark on the genera tor 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 to...

Page 208: ...TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4...

Page 209: ...er head Order Job Parts to remove Q ty Remarks 6 Timing chain guide intake side 1 7 Oil passage plug 1 M 1st 3rd 4th 2nd 30 N m 3 0 kgf m 22 lb ft 15 N m 1 5 kgf m 11 lb ft 60 60 10 N m 1 0 kgf m 7 4...

Page 210: ...atch 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 SEATS on page 5 29 Cylinder head...

Page 211: ...ontact surfaces of the bolts and to both contact surfaces of the wash ers 1 c Install the washers and the bolts d Tighten the bolts to the specified torque in two or three steps in the proper tighteni...

Page 212: ...inder head tightening bolts further according to the tightening or der TIP Tighten the bolts in two steps 60 to reach the specified angle in the proper tightening se quence Total tightening angle 60 6...

Page 213: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 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...

Page 214: ...ALVE SEATS on page 5 29 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 leaks from the valve seat 1 3 Remove...

Page 215: ...guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clea...

Page 216: ...Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face Intake Valve guide remover 5...

Page 217: ...coarse lapping compound a to the valve face NOTICE ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve st...

Page 218: ...LLING THE VALVES 1 Clean Valve stem end 2 Lubricate Valve stem 1 Valve stem seal 2 3 Install Spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 to the cylinder head TIP Mak...

Page 219: ...00 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 when...

Page 220: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 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...

Page 221: ...ift 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 repla...

Page 222: ...om of cylinder a where cylinder 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...

Page 223: ...numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installi...

Page 224: ...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 Upper oil ri...

Page 225: ...SSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stator coi...

Page 226: ...G THE GENERATOR 1 Install Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of...

Page 227: ...e keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankc...

Page 228: ...ne oil Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 48 1 Clutch housing 1 2 Starter clutch gear 1 3 Starter clutch assembly 1 4 Side plate 1 5 Absorber 8 6 Primary dr...

Page 229: ...Check Starter clutch operation a Install the starter clutch gear 1 onto the primary driven gear 2 and hold the pri mary driven gear b When turning the starter clutch gear clock wise A the starter clu...

Page 230: ...tarter clutch side 4 Install Starter clutch TIP Install the starter clutch so that the side of the starter clutch assembly with the arrow mark is toward the primary driven gear While holding the side...

Page 231: ...RIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 6 1 Starter motor lead 1 2 Starter motor 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb...

Page 232: ...r assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Washer 1 Starter motor front cover 5 Starter motor yoke 1 6 Gasket 2 7 Armature assembly 1 8 Washer 1 9 Circlip 1 10 Starter motor rear cover 1...

Page 233: ...4 Measure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7...

Page 234: ...on the starter mo tor rear cover 4 Install Circlip 1 Plain washer 2 Gasket 3 Washer starter motor front cover 4 Starter motor front cover 5 TIP For installation align the projections on the washer wit...

Page 235: ...cover 1 3 Gasket 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washers 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 2 Identification color black 13 Clutch plate 7...

Page 236: ...Job Parts to remove Q ty Remarks 16 Thrust washer 1 17 Primary driven gear 1 18 Push lever shaft 1 T R 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 E E E E 95 N m 9...

Page 237: ...OIL on page 3 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 48 1 Oil filter element cover 1 2 Oil f...

Page 238: ...plates as a set TIP Measure it at four points on the friction plate EAM30110 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage w...

Page 239: ...ration EAM30113 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAM30114 CH...

Page 240: ...primary driven gears as a set EAM30121 INSTALLING THE CLUTCH 1 Install Dowel pin 1 Gasket 2 2 Install Right crankcase cover 1 Right crankcase cover bolt 2 TIP Tighten the right crankcase cover bolts i...

Page 241: ...utch plate 2 Friction plate 2 3 TIP Install the clutch plates and friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate From the clutch boss s...

Page 242: ...Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross patt...

Page 243: ...ft shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever sp...

Page 244: ...T 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOP...

Page 245: ...ift lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Instal...

Page 246: ...SHIFT SHAFT 5 59 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b...

Page 247: ...driven gear Refer to CLUTCH on page 5 48 Right crankcase cover Refer to CLUTCH on page 5 48 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 sha...

Page 248: ...Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer weight 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer drive gear 1 10 Conical washer 1 11 Balanc...

Page 249: ...drive gear 2 Balancer weight gear 3 Wear damage Replace 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage...

Page 250: ...oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAM30486 INSTALLING THE OIL PUMP 1 Install Spring 1 Relief valve 2 Pin 3 Inner rotor to outer rotor tip clearance 0 00 0 15 mm...

Page 251: ...sure the oil pump turns smoothly 3 Install Collar 1 Balancer weight gear 2 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with each other 4 Install Balanc...

Page 252: ...10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat portion d Apply LOCTITE to the primary drive gear nut 5 within the area shown in the il...

Page 253: ...il assembly Refer to GENERATOR on page 5 38 1 Timing chain guide stopper plate 1 2 Timing chain guide exhaust side 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in 6 5 Bolt L 60 mm 2 36 in 3 6 Bolt L 75 mm 2...

Page 254: ...ansmission Refer to TRANSMISSION on page 5 73 Shift cam and shift fork Refer to TRANSMISSION on page 5 73 1 Circlip 2 2 Oil seal 3 3 Bearing 13 1 2 3 3 3 3 3 3 3 E E E E LT 3 3 3 3 12 N m 1 2 kgf m 8...

Page 255: ...nly on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt...

Page 256: ...oft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 4 5...

Page 257: ...ND 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 66 Transmission Refer to TRANSMISSION on pa...

Page 258: ...1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3...

Page 259: ...pply 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 the crankshaft installer bo...

Page 260: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 66 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Sprin...

Page 261: ...axle 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 262: ...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 surface of the...

Page 263: ...it a faces to the crankcase side 5 Install 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...

Page 264: ...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 265: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING...

Page 266: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left...

Page 267: ...4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator right 1 4 Radiator hose 2 1 5 Radiator hose...

Page 268: ...marks 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 11 12 10 New LS New New 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 kg...

Page 269: ...TOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 2 Check Cooling system Leaks Repair or replace any faulty part 3 Install Radi...

Page 270: ...level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connections Coolant leaks Correct or replace Radiator hoses Bulges Repla...

Page 271: ...rain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 48 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Circlip 1 6 Washer 2 7 Impeller sha...

Page 272: ...e EAM30262 ASSEMBLING THE WATER PUMP 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 cran...

Page 273: ...Gasket 2 5 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 1 1...

Page 274: ...WATER PUMP 6 9...

Page 275: ...UEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THR...

Page 276: ...left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N...

Page 277: ...emoving the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover...

Page 278: ...ct Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel hose TIP Insert the fuel...

Page 279: ...coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Throttle pos...

Page 280: ...y 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 7 N m 0 7 kgf m 5 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 2 2 2 10 N m 1 0 kgf m 7 4 lb ft 3 0 N...

Page 281: ...the injector 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 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3...

Page 282: ...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 directly push the throttle valves to open them Do not...

Page 283: ...sor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 55 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 21...

Page 284: ...THROTTLE BODY 7 9...

Page 285: ...LS FAULT CODE 8 22 FUEL PUMP SYSTEM 8 41 CIRCUIT DIAGRAM 8 41 TROUBLESHOOTING 8 43 ELECTRICAL COMPONENTS 8 44 CHECKING THE SWITCHES 8 45 CHECKING THE BULBS AND BULB SOCKETS 8 47 CHECKING THE FUSES 8 4...

Page 286: ...CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 55 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 56 CHECKING THE GEAR POSITION SWITCH 8 56 CHECKING THE INJECTOR 8 57...

Page 287: ......

Page 288: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...

Page 289: ...Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 14 CCU Communication Control Unit 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 33 Engine stop s...

Page 290: ...page 8 48 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 12 NG Correct or replace the spark plug OK 5 Check the ign...

Page 291: ...bly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or replace the wire harness OK Replace the ECU 1 Check the mode switch coupler connections NG Reconnect...

Page 292: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Page 293: ...in relay 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 10 Starter relay 11 Starter motor 12 Diode 1 13 Diode 2 21 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 36 Start...

Page 294: ...E RE LAYS on page 8 50 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 53 OK Starter motor is OK Perform the electric starting...

Page 295: ...t switch Refer to CHECKING THE SWITCHES on page 8 45 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the...

Page 296: ...CHARGING SYSTEM 8 9 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Page 297: ...CHARGING SYSTEM 8 10 2 AC magneto 3 Rectifier regulator 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse A Battery sub lead B Wire harness...

Page 298: ...battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 48 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGUL...

Page 299: ...CHARGING SYSTEM 8 12...

Page 300: ...SIGNALING SYSTEM 8 13 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM...

Page 301: ...YSTEM 8 14 4 Joint connector 5 Main relay 7 Battery 8 Frame ground 9 Main fuse 15 Warning light 16 Fuel level warning light 18 Resistor 19 Fuel sender 21 ECU Engine Control Unit A Battery sub lead B W...

Page 302: ...als Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 50 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAG...

Page 303: ...SIGNALING SYSTEM 8 16 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 NG Properly connect or repair the signaling system s wiring OK Replace the ECU...

Page 304: ...FUEL INJECTION SYSTEM 8 17 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM...

Page 305: ...uble warning light 20 Yamaha diagnostic tool coupler 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 24 Fuel injector 25 Fuel pump 26 Radiator fan motor fuse 27 Coupler not used 28 Radiator...

Page 306: ...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 307: ...system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 22 4 After pushing the engine stop switch push the start switch to check w...

Page 308: ...FI diagnostic tool sub lead to the Yamaha diagnostic tool WARNING EWA20450 Never connect the sub lead special tool to the battery Otherwise because of excessive cur rent flow the sub lead can catch f...

Page 309: ...ostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 12 Parts connected to the ECU The following parts are connected to the ECU W...

Page 310: ...ndition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continui...

Page 311: ...lace the wire harness Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and...

Page 312: ...000 m above sea level About 80 kPa about 3 00 V 3000 m above sea level About 70 kPa about 2 70 V Abnormal display Intake air pressure sensor is defective Replace the intake air pressure sensor Start s...

Page 313: ...bove sea level About 90 kPa about 3 30 V 2000 m above sea level About 80 kPa about 3 00 V 3000 m above sea level About 70 kPa about 2 70 V Value does not change during cranking Intake air pressure sen...

Page 314: ...item 8 and finish the service Condition is Detected Go to item 4 4 Mounted condition of throttle position sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly...

Page 315: ...or correctness Improperly mounted sensor Remount or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 8 Start switch to ON main relay ON and open and close the throttle sev...

Page 316: ...d 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 for bent or bro ken terminals and locking condi tion of the...

Page 317: ...e 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 Confirmation of service com...

Page 318: ...Defective intake air tempera ture sensor Execute the diagnostic mode Code No 05 When the machine is cold dis played temperature is close to the ambient temperature Improper display Replace the intake...

Page 319: ...item 3 3 Faulty ECU Execute the diagnostic mode Code No 08 When the vehicle is upright 0 4 1 4 V When the vehicle is overturned 3 7 4 4 V Improper display Replace the ECU Service is finished 4 Delete...

Page 320: ...ct the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely or repair replace the sub wire har ness Start the...

Page 321: ...system Unable to start engine Unable to drive vehicle Diagnostic code No 36 Actuation Actuates injector five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when...

Page 322: ...rt circuit Replace the wire harness Between injector coupler and ECU coupler red black red black Between injector coupler and starter relay red blue red blue red yellow red yellow Start the engine and...

Page 323: ...item 6 and finish the service Condition is Detected 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 b...

Page 324: ...onfirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 44 Item EEPROM fault code number an error is detected while readin...

Page 325: ...m 1 If the same number is indicated go to item 4 4 Faulty ECU Replace the ECU Service is finished 5 Delete the fault code Confirm that the fault code has a condition of Recovered using the Yamaha diag...

Page 326: ...for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detec...

Page 327: ...ool Check that the fault code num ber is not displayed Fault code No 70 Item Engine forcibly stops when the vehicle is left idling for a long period of time Fail safe system Unable to drive vehicle Di...

Page 328: ...FUEL PUMP SYSTEM 8 41 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 329: ...STEM 8 42 2 AC magneto 3 Rectifier regulator 4 Joint connector 6 Engine ground 7 Battery 8 Frame ground 9 Main fuse 21 ECU Engine Control Unit 25 Fuel pump 33 Engine stop switch A Battery sub lead B W...

Page 330: ...on page 8 47 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 48 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Page 331: ...ectifier regulator 5 Mode switch 6 Intake air temperature sensor 7 ECU Engine Control Unit 8 Ignition coil 9 Resistor 10 CCU Communication Control Unit 11 Starter relay 12 Main fuse 13 Battery 14 Radi...

Page 332: ...ELECTRICAL COMPONENTS 8 45 EAM30289 CHECKING THE SWITCHES Y W P Sb 3 1 4 2 P Sb B W R L B R Y W B 1 Engine stop switch 2 Mode switch 3 Gear position switch 4 Engine start switch...

Page 333: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Page 334: ...er 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 for continuity If any of...

Page 335: ...Charge the bat tery again as soon as possible A long state of discharge below 10 V will damage the battery Do not use the specified battery charger to charge a battery other than the lithium ion batte...

Page 336: ...a Yamaha genuine lithium ion battery TIP Do not check the battery at high temperature of 65 C 149 F or more or low temperatures be low 10 C 50 F Otherwise the control feature preventing battery chargi...

Page 337: ...operation Out of specification Replace Starter relay Main relay Radiator fan motor relay EAM30495 CHECKING THE RELAY UNIT DIODE 1 Check Diode Out of specification Replace Digital circuit tester CD732...

Page 338: ...lly increase the spark gap until a misfire occurs EAM30295 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a...

Page 339: ...e wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace a Connect the digital circuit tester to the crankshaft position sensor coupler Digital circuit tester CD732 90...

Page 340: ...t is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or f...

Page 341: ...ess 2 Check Resistor resistance Out of specification Replace the resistor a Connect the digital circuit tester to the resistor as shown b Measure the resistance of the resistor Regulated voltage DC 14...

Page 342: ...the temperatures indicated in the table EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Check Throttle position sensor input voltage Out of specification Replace the ECU a Connect the...

Page 343: ...take air temperature sensor re sistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor re sistance 289 391 at 80 C 289 391 at 176 F Digital circuit tester CD732 90890 03243 Model 88...

Page 344: ...isconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler c Measure the fuel injector resistance Resistance 12 0 Digital circuit test...

Page 345: ...OF COOLING SYSTEM 9 7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF SIGNALING SYS...

Page 346: ...TEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil S...

Page 347: ...ace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Sympt...

Page 348: ...ecified torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from...

Page 349: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Page 350: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Page 351: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Page 352: ...epair the radiator fin or replace the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses...

Page 353: ...brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake pedal p...

Page 354: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Page 355: ...rear shock absorber rod Replace the rear shock absorber Damaged oil seal lip Replace the rear shock absorber Symptom Possible cause Actions Handlebar wobble Loose lower ring nut Tighten the lower rin...

Page 356: ...Rear wheel vibration Incorrect wheel balance Adjust the wheel balance Loose spoke Tighten the spoke and adjust the runout Damaged or worn wheel bearing Replace the wheel bearing Worn deformed or inco...

Page 357: ...ead of the ignition coil 8 32 39 Injector open or short circuit detected 8 34 41 ECU built in lean angle sensor malfunction 8 35 43 Fuel system voltage incorrect voltage supplied to the main relay and...

Page 358: ...perate the shift pedal Gear in 1st or 2nd ON Gear in other than 1st or 2nd OFF 60 EEPROM fault code display No fault 00 CO adjustment valve 01 Power Tuner injection cor rection setting 0 8 or Power Tu...

Page 359: ...he 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 is gener ated five times Connect an i...

Page 360: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 361: ...1 FRONT FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH...

Page 362: ...end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore...

Page 363: ...e air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SET...

Page 364: ...t length of the spring Change the spring 2 Setting of damping force Change the rebound damping force Change the compression damping force EAM30176 CHOOSING SET LENGTH 1 Place a stand or a block under...

Page 365: ...et it 1 Use of soft spring Adjust to decrease rebound damping force to compensate for less spring load Run with the rebound damping force adjuster one or two clicks turned out and readjust it to suit...

Page 366: ...D Mark SOFT 50 B3J 22212 00 Blue Green B3J 22212 10 Black 52 BR9 22212 00 Blue Yellow BR9 22212 50 Black 54 BR9 22212 10 Blue Pink BR9 22212 60 Black 56 BR9 22212 20 Blue White BR9 22212 70 Black 58 B...

Page 367: ...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 368: ...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 369: ...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 370: ...CHASSIS 10 9...

Page 371: ...elay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch 36 Start swit...

Page 372: ......

Page 373: ...ity you have come to expect Why settle for aftermarket parts that may not provide full confidence and satisfaction Genuine Yamaha Accessories Yamaha only offers accessories that meet our high standard...

Page 374: ...626 33 34 Read this manual carefully before operating this vehicle YZ250FXL1 OWNER S SERVICE MANUAL YZ250FX 2020 PRINTED IN JAPAN 2019 07 0 8 1 E 2020 YZ250FXL1 BAJ 28199 10_cover_US_10mm_FCC indd 1 3...

Page 375: ...YZ250FXL1 2020 WIRING DIAGRAM BAJ 28199 10_WD indd 1 2019 07 10 9 35 33...

Page 376: ...YZ250FXL1 2020 WIRING DIAGRAM BAJ 28199 10_WD indd 2 2019 07 10 9 35 33...

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Yamaha YZ 2020 Series, Owner'S Service Manual

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