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Yamaha YZ 2023 Series, Owner'S Service Manual


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CHECKING THE STARTER CLUTCH .....................................................5-41
INSTALLING THE STARTER CLUTCH ...................................................5-41

ELECTRIC STARTER

.....................................................................................5-43

CHECKING THE STARTER MOTOR ......................................................5-45
ASSEMBLING THE STARTER MOTOR ..................................................5-45

CLUTCH

..........................................................................................................5-47

REMOVING THE CLUTCH ......................................................................5-50
CHECKING THE FRICTION PLATES......................................................5-50
CHECKING THE CLUTCH PLATES ........................................................5-50
CHECKING THE CLUTCH SPRINGS......................................................5-50
CHECKING THE CLUTCH HOUSING .....................................................5-50
CHECKING THE CLUTCH BOSS ............................................................5-51
CHECKING THE PRESSURE PLATE .....................................................5-51
CHECKING THE PUSH LEVER SHAFT ..................................................5-51
CHECKING THE PUSH RODS ................................................................5-51
CHECKING THE PRIMARY DRIVE GEAR ..............................................5-51
CHECKING THE PRIMARY DRIVEN GEAR............................................5-51
INSTALLING THE CLUTCH .....................................................................5-51

SHIFT SHAFT

.................................................................................................5-55

REMOVING THE SEGMENT ...................................................................5-56
CHECKING THE SHIFT SHAFT ..............................................................5-56
CHECKING THE STOPPER LEVER........................................................5-56
INSTALLING THE SHIFT SHAFT ............................................................5-56

OIL PUMP

.......................................................................................................5-59

REMOVING THE BALANCER..................................................................5-61
CHECKING THE OIL PUMP ....................................................................5-61
ASSEMBLING THE OIL PUMP ................................................................5-61
INSTALLING THE OIL PUMP ..................................................................5-62

CRANKCASE

.................................................................................................5-65

DISASSEMBLING THE CRANKCASE.....................................................5-67
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE)...................5-67
CHECKING THE CRANKCASE ...............................................................5-67
ASSEMBLING THE CRANKCASE...........................................................5-68

CRANKSHAFT AND BALANCER SHAFT

.....................................................5-69

REMOVING THE CRANKSHAFT.............................................................5-70
CHECKING THE CRANKSHAFT .............................................................5-70
INSTALLING THE CRANKSHAFT ...........................................................5-71

TRANSMISSION

.............................................................................................5-72

REMOVING THE TRANSMISSION..........................................................5-73
CHECKING THE SHIFT FORKS..............................................................5-73
CHECKING THE SHIFT DRUM ASSEMBLY ...........................................5-73
CHECKING THE TRANSMISSION ..........................................................5-73

Summary of Contents for YZ 2023 Series

Page 1: ...BAJ 2819U 13 LIT 11626 36 36 Read this manual carefully before operating this vehicle YZ250FXP OWNER S SERVICE MANUAL YZ250FX 2023...

Page 2: ...and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessar...

Page 3: ...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 radiation exposure l...

Page 4: ...ANUAL 2023 by Yamaha Motor Corporation U S A First edition April 2022 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expre...

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: ...teps 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 disassemb...

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: ...25 BREAK IN PROCEDURES 1 25 ENGINE STARTING PRECAUTION 1 25 MAINTENANCE AFTER BREAK IN 1 26 MAJOR MAINTENANCE 1 26 AIR FILTER MAINTENANCE 1 26 TORQUE CHECK POINTS 1 27 MOTORCYCLE CARE AND STORAGE 1 2...

Page 13: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 14: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 15: ...e 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 to prevent movement 4 S...

Page 16: ...Premium unleaded gasoline only WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open For use on...

Page 17: ...u have purchased 4 2 3 1 10 9 11 12 8 7 6 5 15 13 14 20 19 18 17 16 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: ...n 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 vehicle In case the engine s...

Page 20: ...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 the CCU to another locat...

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: ...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 tachometer YU...

Page 28: ...5 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 4 43 4 43 4 44 4 47 4 50 4 52 Cap bolt wrench 90890 01500 Cap...

Page 29: ...r 5 0 mm YM 04097 5 28 Valve guide installer 5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 28 Valve guide reamer 5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 28 Valve guide remover 4 5 9...

Page 30: ...04151 Rotor puller YM 04151 5 38 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 41 5 42 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 50 5 52 Crankcase separating tool 908...

Page 31: ...0890 01275 Bolt 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 Radiator cap tester 90890 01325 Mityvac cooling system te...

Page 32: ...re adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Lithium battery charger 90890 05376 Lithium battery charger DBY ACC51 70 02 8 51 8 51 Ignition checker 90890 06754 Oppama pet 4000 spark check...

Page 33: ...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 34: ...NG 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 down on the b...

Page 35: ...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 36: ...G 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 throttle grip whe...

Page 37: ...eness oil leaks or other problems Thorough checks and ad justments are required in particular for stretch of cables free play of the brake stretch of the drive chain looseness of the spoke and so on N...

Page 38: ...and nuts 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 brac...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...k 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 Lubricate...

Page 44: ...MOTORCYCLE CARE AND STORAGE 1 32...

Page 45: ...ATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS...

Page 46: ...del Model BAJF Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60...

Page 47: ...Oil change 0 73 L 0 77 US qt 0 64 Imp qt With oil filter removal 0 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 Cooling system...

Page 48: ...0319 in Wear limit 77 060 mm 3 0339 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Diameter 76 955 76 970 mm 3 0297 3 0303 in Measuring point from piston skirt bottom 4 0 mm 0...

Page 49: ...0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 3 923 51 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filt...

Page 50: ...pressure measured 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 Brake disc thickness limit 2 5 mm 0 10 in Brake disc runou...

Page 51: ...from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock a...

Page 52: ...nt Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 11 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Nu...

Page 53: ...l 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 overall length limit...

Page 54: ...o 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 specifi...

Page 55: ...b ft Timing chain 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...

Page 56: ...r plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover 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...

Page 57: ...l to the bolt threads and seats as well as to both sides of the lock washers Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stator coil assembly lead holder bolt M5 1 8 N m 0 8 kgf m...

Page 58: ...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 59: ...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 3...

Page 60: ...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 Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt...

Page 61: ...TIGHTENING TORQUES 2 16...

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: ...int mark on the hose with the convex mark on the 3 way joint and then install the cylinder head breather hoses I Route the radiator breather hose outside the breather hose When doing so cross them at...

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: ...itch 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 run the leads near th...

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 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3...

Page 76: ...S 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICATING THE SIDESTAND 3 34...

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: ...ck 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 Steer...

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: ...3 3 23 3 24 3 24 3 24 3 23 3 25 3 24 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 68 4 68 4 69 4 69 4 69 Wheels Check for excessive wear a...

Page 82: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 13 3 Remove Timing...

Page 83: ...oper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field w...

Page 84: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 13 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

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 13 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: ...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 before the checkup b Start the engine...

Page 91: ...Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return the clutch cable...

Page 92: ...nto a plastic bag and drip the filter oil into the bag b With the element inside the bag rub it thoroughly so that the element is evenly permeated with the oil c Wrap the element in a clean cloth rub...

Page 93: ...cat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and then install the air filter case cover 10 Install Fuel tank cap cover EAM30335 CHECKING THE...

Page 94: ...221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to ENGINE REMOVAL on page 5 6 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage R...

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: ...g sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Stand the vehicle upright on a level surface 2 Remove Radiator cap 1 3 Check Coolant level Maximum level a...

Page 97: ...hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator cap Slowly loose...

Page 98: ...used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several m...

Page 99: ...TING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft...

Page 100: ...f the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 13 EAM30232 CHECKING TH...

Page 101: ...er the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the t...

Page 102: ...ve chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the...

Page 103: ...falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 35...

Page 104: ...ork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times...

Page 105: ...djust Compression damping a Turn the adjuster 1 in the direction 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 th...

Page 106: ...ion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct...

Page 107: ...necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Tur...

Page 108: ...licks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGA...

Page 109: ...ll sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in...

Page 110: ...LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and...

Page 111: ...L SYSTEM 3 35 EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 EAM30505 CHECKING THE FUSES Refer to CHECKING THE FUSES on p...

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

Page 113: ...ACING THE FRONT BRAKE PADS 4 17 REMOVING THE FRONT BRAKE CALIPER 4 19 DISASSEMBLING THE FRONT BRAKE CALIPER 4 19 CHECKING THE FRONT BRAKE CALIPER 4 19 ASSEMBLING THE FRONT BRAKE CALIPER 4 19 INSTALLIN...

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 15 2 Air scoop left 1 3 Air scoop right 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: ...position Make sure that the new seal does not cover the ducts 2 EAM30371 REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 TIP The projection a is inserted into the band of the numb...

Page 118: ...e bolts EAM30459 REMOVING THE SIDE COVER 1 Remove Side cover right 1 TIP Remove the side cover right from the vehicle by removing the bolts and sliding it as shown EAM30460 INSTALLING THE SIDE COVER 1...

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: ...wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on pag...

Page 121: ...2 Install Brake disc Brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip EAM30021 INSTALLING THE...

Page 122: ...l axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 115 N m 11 5 kgf m 85 lb ft Front...

Page 123: ...the ground 1 Rear wheel axle nut 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 2 5 7 9 6 4 6 1 6...

Page 124: ...2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measu...

Page 125: ...bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Brake disc bolt TIP Tighten the bolts...

Page 126: ...Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 26 6...

Page 127: ...ge 3 25 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 bracket...

Page 128: ...BRAKE 4 14 Disassembling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 2 2 Brake caliper piston seal kit 2 3 Bleed screw 1 1 2 3 S S 2 5 N m 0 5 kgf m 3 7 l...

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: ...FRONT BRAKE 4 16 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New...

Page 131: ...inutes and get im mediate medical 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...

Page 132: ...euse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Page 133: ...er 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 dust seal and th...

Page 134: ...its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Othe...

Page 135: ...r 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder r...

Page 136: ...e 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 brake hose routing is essenti...

Page 137: ...ter 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 painted surfaces and plastic parts T...

Page 138: ...1 6 Brake pad pin 1 7 Rear brake pad assembly 1 8 Brake pad shim left 1 9 Brake pad shim right 1 10 Brake pad shim heat insulator 2 11 Brake pad spring 1 12 Rear brake caliper bracket 1 13 Brake pad...

Page 139: ...BRAKE 4 25 Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 1 2 Brake caliper piston seal kit 1 3 Bleed screw 1 2 3 5 N m 0 5 kgf m 3 7 lb ft 1 S...

Page 140: ...age 3 25 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 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1...

Page 142: ...lush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake dis...

Page 143: ...stall the brake pads 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...

Page 144: ...rce out the piston from the brake caliper WARNING EWA13550 Cover 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...

Page 145: ...Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 24 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the de...

Page 146: ...es 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylind...

Page 147: ...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 same ty...

Page 148: ...REAR BRAKE 4 34 system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25...

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: ...Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with the side having the longer distance a from the mounting bolt center fac...

Page 151: ...ould 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 b 1 2 1 2 1 2 1 2 c 1 2 1 2 d Lower handlebar holder nut 40 N...

Page 152: ...ADJUSTING 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...

Page 153: ...ter cylinder assembly 2 Front brake master cylinder holder 3 Front brake master cylinder holder bolt 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order...

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

Page 155: ...aliper Refer to FRONT BRAKE on page 4 13 Number plate Refer to GENERAL CHASSIS on page 4 1 Lower handlebar holder Refer to HANDLEBAR on page 4 35 with the handlebar holder 1 Protector 1 2 Upper bracke...

Page 156: ...1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 15 2 8 1 7 9 14 New New New...

Page 157: ...ork leg from the ve hicle loosen the damper assembly 1 with the cap bolt ring wrench 2 It is allowed to remove the lower handlebar holder with the handlebar installed as shown When doing so make sure...

Page 158: ...THE FRONT FORK LEGS 1 Check Inner tube surface Scratches Repair or replace Use 1000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge...

Page 159: ...and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 5 Check Base valve 1 Wear damage Replace Contamination Clean O ring 2 Wear damage Replace Base valve bushi...

Page 160: ...llow any for eign material to enter the front fork 3 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper as sembly of air TIP Avoid...

Page 161: ...alve 10 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex...

Page 162: ...ttom side TIP Apply the lithium soap based grease on the dust seal lip and oil seal lip Apply the fork oil on the inner tube Install the scraper to the inner tube as shown in the illustration When ins...

Page 163: ...Fit the stopper ring correctly in the groove in the outer tube 20 Install Scraper 1 Dust seal 2 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness bin...

Page 164: ...IP Before loosening the damping force adjuster record the setting position Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 26...

Page 165: ...mmended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install D...

Page 166: ...ing wrench 2 to tighten the damper assembly 3 Adjust Front fork top end a 4 Install Lower handlebar holder with the handlebar 5 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 Damper ass...

Page 167: ...or 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 8 Adjust Compression damping force TIP Turn in the damping adjuster...

Page 168: ...1 3 Front fork leg 2 Refer to FRONT FORK on page 4 41 4 Warning light engine trouble 1 Br Y W 5 Warning light fuel level 1 Br L Y 6 Upper bracket 1 7 Steering ring nut 1 8 Lower bracket 1 9 Bearing ra...

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 27 5 Check the steering...

Page 171: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 172: ...right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear shock absorber assem...

Page 173: ...r shock absorber 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 53 N m 5 3 kgf m 39 lb ft M 56 N m 5 6 kgf m 41 lb ft M M M LS 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 6 6 5 3 2 4 6 6 3 4 4 M M 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: ...asher 2 Oil seal 3 into the relay arm 4 Collar 5 3 Install Bearing 1 Oil seal 2 into the connecting arm 3 Collar 4 EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Bearing lower side D...

Page 177: ...IP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly upper bolt and connecting arm bolt frame side from the right Install the rear shock a...

Page 178: ...er Refer to REAR BRAKE on page 4 24 Rear brake caliper Refer to REAR BRAKE on page 4 24 Bolt brake pedal Refer to ENGINE REMOVAL on page 5 6 Drive chain Refer to CHAIN DRIVE on page 4 67 1 Collar 2 2...

Page 179: ...nds cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bus...

Page 180: ...SWINGARM 4 66 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 26 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in...

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: ...OCKET 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...

Page 184: ...rockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engin...

Page 185: ...HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES...

Page 186: ...51 INSTALLING THE CLUTCH 5 51 SHIFT SHAFT 5 55 REMOVING THE SEGMENT 5 56 CHECKING THE SHIFT SHAFT 5 56 CHECKING THE STOPPER LEVER 5 56 INSTALLING THE SHIFT SHAFT 5 56 OIL PUMP 5 59 REMOVING THE BALAN...

Page 187: ...INSTALLING THE TRANSMISSION 5 74...

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: ...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 9 Silencer cap 1 LT 9 5 8 2 6 1 6 6 3 4 7 8 6 New New New LT 1st 2nd 7...

Page 194: ...EL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 15 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Engine Control Unit Refer...

Page 195: ...on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 47 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 55 Refer to CHAIN DRIVE on page 4 67 1 En...

Page 196: ...2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 8 9 11 12 13 10 10 11 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...

Page 197: ...ve this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engine bracket...

Page 198: ...kgf m 7 4 lb ft 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust...

Page 199: ...nd rear joints are inserted in position Make sure that the 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...

Page 200: ...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 201: ...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 202: ...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 203: ...p bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the wid...

Page 204: ...your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the tensioner rod will come...

Page 205: ...rankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips the camshaft caps and the bolts camshaft cap TIP Before installing the clips cover the cylin...

Page 206: ...amshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cylinder head cover 4 T...

Page 207: ...EL TANK on page 7 1 Exhaust pipe 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 Ca...

Page 208: ...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 209: ...ECKING THE VALVE SEATS on page 5 28 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straighted...

Page 210: ...en the bolts to the specified torque in two or three steps in the proper tightening sequence as shown e Remove the one bolt according to the tightening order of the bolts f Again apply molybdenum disu...

Page 211: ...r ther according to the tightening order TIP Tighten the bolts in two steps 60 to reach the specified angle in the proper tightening se quence Total tightening angle 60 60 120 l Tighten the nuts to th...

Page 212: ...s Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem s...

Page 213: ...G THE VALVE SEATS on page 5 28 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...

Page 214: ...ve 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 c...

Page 215: ...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 b Install the valve into the cylinder head Intake...

Page 216: ...ng compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve fa...

Page 217: ...e is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve s...

Page 218: ...ECA13800 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 smooth...

Page 219: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 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 220: ...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 221: ...here 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 rail s gap is exce...

Page 222: ...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 installing the piston pin...

Page 223: ...r 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 U...

Page 224: ...L CHASSIS 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 Stato...

Page 225: ...stall 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 the stator coil asse...

Page 226: ...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 crankca...

Page 227: ...ngine oil Refer to CHANGING THE ENGINE OIL on page 3 13 Clutch Refer to CLUTCH on page 5 47 1 Clutch housing 1 2 Starter clutch gear 1 3 Starter clutch assembly 1 4 Side plate 1 5 Absorber 8 6 Primary...

Page 228: ...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 229: ...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 230: ...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 231: ...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 232: ...easure 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 Chec...

Page 233: ...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 with the slots in the front cover A...

Page 234: ...over 1 3 Gasket 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Bearing 1 9 Ball 1 10 Push rod 2 1 11 Friction plate 1 2 Identification color black 12 Clutch plate 7 13 Friction pl...

Page 235: ...utch Order Job Parts to remove Q ty Remarks 16 Primary driven gear 1 17 Push lever shaft 1 T R 17 16 E E E E LT E E E E 95 N m 9 5 kgf m 70 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft...

Page 236: ...NE 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 47 1 Oil filter element cover 1 2 Oi...

Page 237: ...pecification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specifi...

Page 238: ...cation Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the...

Page 239: ...ICE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away fr...

Page 240: ...tification color orange 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TI...

Page 241: ...ts in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7...

Page 242: ...l 1 2 Shift 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...

Page 243: ...SHAFT 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...

Page 244: ...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 Install Ro...

Page 245: ...SHIFT SHAFT 5 58 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 246: ...driven gear Refer to CLUTCH on page 5 47 Right crankcase cover Refer to CLUTCH on page 5 47 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 shaf...

Page 247: ...r 1 2 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 B...

Page 248: ...ce 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 wear Replace the oil pump assembly 2 Check Oil pump o...

Page 249: ...f valve before installing the pri mary drive gear and collar 2 Install Collar 1 Balancer weight gear 2 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with...

Page 250: ...inum plate a between the teeth of the balancer drive gear 9 and balancer weight gear 10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat po...

Page 251: ...OIL PUMP 5 64 A Primary drive gear side B Crankcase cover side 5 7 mm 0 02 0 28 in 5 c d 6 8 b 8 6 7 E...

Page 252: ...fer to GENERATOR on page 5 37 1 Timing chain guide stopper plate 1 2 Timing chain guide exhaust side 1 3 Timing chain 1 4 Bolt 7 L 45 mm 1 77 in 5 Bolt 3 L 60 mm 2 36 in 6 Bolt 3 L 75 mm 2 95 in 7 Rig...

Page 253: ...s Transmission Refer to TRANSMISSION on page 5 72 Shift cam Shift fork Refer to TRANSMISSION on page 5 72 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 LT E LT E 3 E 1 2 2...

Page 254: ...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 255: ...mmer 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 5 0 m...

Page 256: ...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 65 Transmission Refer to TRANSMISSION on p...

Page 257: ...SHAFT 1 Measure Crankshaft runout a Out of specification Replace the crank shaft TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Cr...

Page 258: ...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 259: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 65 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 260: ...1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to stra...

Page 261: ...oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 22T 2 3rd wheel gear 26T 3 4th wheel gear 24...

Page 262: ...ase 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 Shift cam 4 to the main axle and the drive axle TIP Apply e...

Page 263: ...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 264: ...TRANSMISSION 5 77...

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: ...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: ...rks 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 New 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 15 N m 1...

Page 269: ...e 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for...

Page 270: ...s of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection...

Page 271: ...l Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Right crankcase cover Refer to CLUTCH on page 5 47 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Circlip 1 6 Washer 2 7 Impeller...

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 3 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: ...or cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the...

Page 278: ...nstall Fuel tank 2 Connect 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...

Page 279: ...2 Ignition 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 Th...

Page 280: ...y 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 2 2 2 11 11 11 11 13 15 14 12 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0...

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: ...f 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 57 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: ...SYSTEM 8 43 CIRCUIT DIAGRAM 8 43 TROUBLESHOOTING 8 45 ELECTRICAL COMPONENTS 8 46 CHECKING THE SWITCHES 8 47 CHECKING THE BULBS AND BULB SOCKETS 8 49 CHECKING THE FUSES 8 49 CHECKING AND CHARGING THE B...

Page 286: ...CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 58 CHECKING THE GEAR POSITION SWITCH 8 58 CHECKING THE INJECTOR 8 59...

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 50 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 51 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 55 OK Starter motor is OK Perform the electric starting...

Page 295: ...t switch Refer to CHECKING THE SWITCHES on page 8 47 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 50 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 51 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 23 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: ...it 2 Lead battery 12 V 3 Vehicle battery 4 Vehicle 5 Coupler for connecting optional part 6 FI diagnostic tool sub lead 7 Sub harness included with the Yamaha diag nostic tool 8 Vehicle communication...

Page 310: ...Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool d...

Page 311: ...of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor...

Page 312: ...e 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 4 4 Mounted condition of intake air pressure sens...

Page 313: ...twisted or bent Repair or replace the sensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunctio...

Page 314: ...r 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 pins Improperly connected Con nect the coupler secure...

Page 315: ...ned 86 92 displays Incorrect display range Replace the throttle position sensor Start switch to ON main relay ON and then check the condi tion of the fault code using the malfunction mode of the Yamah...

Page 316: ...stic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the fault...

Page 317: ...condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Start switch to ON main rela...

Page 318: ...tected 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 o...

Page 319: ...nable to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or...

Page 320: ...ion 1 Connection of ignition coil cou pler 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 pins Imprope...

Page 321: ...on of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for app...

Page 322: ...jector Refer to CHECKING THE INJECTOR on page 8 59 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnosti...

Page 323: ...and CCU Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push...

Page 324: ...e engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recove...

Page 325: ...ion Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Start switch to ON main relay ON and then check the condi tion of...

Page 326: ...nd 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 Check the condition...

Page 327: ...de No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Start switch to ON main relay ON...

Page 328: ...he fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is l...

Page 329: ...FUEL INJECTION SYSTEM 8 42...

Page 330: ...FUEL PUMP SYSTEM 8 43 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Page 331: ...STEM 8 44 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 332: ...on page 8 49 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 50 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Page 333: ...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 334: ...ELECTRICAL COMPONENTS 8 47 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 Start switch...

Page 335: ...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 336: ...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 337: ...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 battery Otherwise the battery or charger c...

Page 338: ...n the battery terminals 13 25 V or more The battery is normal Checking is finished Less than 13 25 V Go to step c c Connect the battery charger special tool to the battery and charge it TIP For instru...

Page 339: ...e battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester pr...

Page 340: ...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 Connect the digital circuit tester to the spark plug cap...

Page 341: ...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 342: ...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 343: ...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 344: ...t 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 345: ...take air temperature sensor re sistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor re sistance 290 390 at 80 C 290 390 at 176 F Digital circuit tester CD732 90890 03243 Model 88...

Page 346: ...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 347: ...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 348: ...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 349: ...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 350: ...orque 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 around cy...

Page 351: ...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 352: ...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 353: ...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 354: ...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 355: ...Damaged 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...

Page 356: ...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 357: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 358: ...e nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swingarm bearing Damaged or worn swingarm bear in...

Page 359: ...ead of the ignition coil 8 33 39 Injector open or short circuit detected 8 35 41 ECU built in lean angle sensor malfunction 8 36 43 Fuel system voltage incorrect voltage supplied to the main relay and...

Page 360: ...r 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 Tuner ignition timing correc...

Page 361: ...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 362: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Page 363: ...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 364: ...e 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 Therefor...

Page 365: ...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 366: ...the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bo...

Page 367: ...ing force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never...

Page 368: ...BER AS SEMBLY on page 3 30 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 6...

Page 369: ...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 370: ...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 371: ...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 372: ...CHASSIS 10 9...

Page 373: ...lay 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 switc...

Page 374: ......

Page 375: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Page 376: ......

Page 377: ...YZ250FXP 2023 WIRING DIAGRAM BAJ 2819U 13_WD indd 1 2022 04 01 9 58 37...

Page 378: ...YZ250FXP 2023 WIRING DIAGRAM BAJ 2819U 13_WD indd 2 2022 04 01 9 58 37...

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