Yamaha YZ250F(E) Owner'S Service Manual Download

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REAR BRAKE

4-29

ASSEMBLING THE REAR BRAKE MASTER
CYLINDER

EWA13520

WARNING

• Before installation, clean and lubricate the

internal parts. Use new brake fluid for
cleaning and lubricating.

• Never use solvents on internal brake com-

ponents.

1. Wash the brake master cylinder and the

brake master cylinder kit with brake fluid.

2. Install:

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

Install to the brake master cylinder piston
“3”.

EWA13520

WARNING

Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.

3. Install:

• Spring “1”

Install to the brake master cylinder piston
“2”.

TIP

Install the spring with a smaller inside diameter
to the brake master cylinder piston.

4. Install:

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

TIP

• Before installation, apply brake fluid to the

brake master cylinder kit.

• Before installation, apply silicone grease to

the push rod end.

• Use circlip pliers to install the circlip.

EAS1SM1160

INSTALLING THE REAR BRAKE MASTER
CYLINDER

1. Install:

• Copper washers
• Brake hose
• Union bolt

EWA13530

WARNING

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CA-
BLE ROUTING DIAGRAM” on page 2-31.

ECA1DX1008

NOTICE

Make sure that the pipe portion of the brake
hose touches the projection “a” on the
brake caliper.

Recommended brake fluid

DOT 4

New

Brake hose union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

New

Summary of Contents for YZ250F(E)

Page 1: ...CLED PAPER 2014 YZ250F E 2014 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule q Bitte lesen Sie diese...

Page 2: ...remis avec le v hicule en cas de vente de ce dernier Q Leggere attentamente questo manuale prima di utilizzare il veicolo Questo manuale dovrebbe accompagnare il veicolo se viene venduto Q Bitte lesen...

Page 3: ...Z250F E 2014 2014 1SM 28199 30 E0 1SM 28199 30 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating thi...

Page 4: ......

Page 5: ...NER S SERVICE MANUAL 2013 by Yamaha Motor Co Ltd First edition August 2013 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly p...

Page 6: ...IS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTI...

Page 7: ...HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or ex haust system Never refuel in the vicinity of an open flame or while smoking GASOLIN...

Page 8: ...he section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in t...

Page 9: ...FINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit...

Page 10: ......

Page 11: ...1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST MENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING TUNING...

Page 12: ......

Page 13: ...COUPLER FOR CONNECTING OPTIONAL PART 1 8 IMPORTANT INFORMATION 1 10 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 10 REPLACEMENT PARTS 1 10 GASKETS OIL SEALS AND O RINGS 1 11 LOCK WASHERS PLATES AND COTTE...

Page 14: ...2 FUEL 1 22 STARTING A COLD ENGINE 1 22 STARTING A WARM ENGINE 1 23 BREAK IN PROCEDURES 1 23 MAINTENANCE AFTER BREAK IN 1 24 MAJOR MAINTENANCE 1 24 TORQUE CHECK POINTS 1 25 CLEANING AND STORAGE 1 27 C...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 1 EAS1SM1008 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CAN 9 10 11 7 8 13 12 1 2 3 4 5 6...

Page 16: ...LOCATION OF IMPORTANT LABELS 1 2 EUR...

Page 17: ...LOCATION OF IMPORTANT LABELS 1 3 AUS NZL ZAF...

Page 18: ...erent from those for the vehicle you have pur chased 1 Clutch lever 10 Coolant drain bolt 2 Front brake lever 11 Rear brake pedal 3 Throttle grip 12 Air filter 4 Radiator cap 13 Drive chain 5 Fuel tan...

Page 19: ...is stolen the authorities will need the number to search for and identify your vehicle EAS1SM1011 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of th...

Page 20: ...eration under a heavy load The carburetor that mea sures fuel through the use of jets are provided with various auxiliary devices so that the optimum air fuel ratio can be obtained to accommodate freq...

Page 21: ...esser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals input from the throt tle position sensor the coolant temperature sensor the...

Page 22: ...e spoke EAS1SM1020 HANDLEBAR PROTECTOR Install the handlebar protector 1 with the mark a facing forward EAS1SM1021 FUEL HOSE JOINT COVER The fuel hose joint covers 1 are used to pre vent mud dust and...

Page 23: ...INCLUDED PARTS 1 9 The Power Tuner is an optional part Part name Part number GYTR Power Tuner For USA 33D H59C0 V0 00 YZ Power Tuner Except for USA 33D 859C0 10...

Page 24: ...ection 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 7...

Page 25: ...027 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces the oi...

Page 26: ...sert the probes from the opposite end a of the coupler taking care not to loosen or damage the leads ECA16640 NOTICE For waterproof couplers never insert the tester probes directly into the coupler Wh...

Page 27: ...stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling or assembling a cou...

Page 28: ...ontinuity TIP If 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 Pocket tester...

Page 29: ...se tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This t...

Page 30: ...01403 Exhaust flange nut wrench YU A9472 This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 YM 01500 This tool is used to remove or tighten the base valve Cap bolt rin...

Page 31: ...3215 This tool is used to check er ror codes or carry out self di agnosis Fuel pressure adapter 90890 03186 YM 03186 This tool is used to mount the pressure gauge Test harness S pressure sensor 3P 908...

Page 32: ...lve and the valve spring Valve spring compressor adapter 22 mm 90890 04108 YM 04108 This tool is used to discon nect or connect the valve and the valve spring Valve guide remover 5 90890 04097 Valve g...

Page 33: ...eplace the valve guide Rotor puller 90890 04151 YM 04151 This tool is used to remove the rotor Crankcase separating tool 90890 04152 YU A9642 This tool is used to remove the crankshaft Ignition checke...

Page 34: ...shift pedal 1 has adopted a method of 1 down 4 ups press down kick ups Press it down for N neutral to 1st and kick it up for 2nd to 5th EAS1SM1036 KICKSTARTER LEVER The kickstarter lever 1 is in the r...

Page 35: ...larger amount of intake air Pushing the knob toward b turns OFF the starter EWA WARNING While handling the starter knob idle screw take care not to burn yourself on exhaust pipes EAS1SM1040 FUEL TANK...

Page 36: ...ing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAS1SM1043 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Pull the...

Page 37: ...e a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check m...

Page 38: ...g dis connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brack...

Page 39: ...absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tighten...

Page 40: ...2 Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fend...

Page 41: ...pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid using such wax as contains abrasives because it may scratch surfaces 9 After completing the above start the...

Page 42: ...CLEANING AND STORAGE 1 28...

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

Page 44: ...2 in USA CAN AUS NZL ZAF 2170 mm 85 4 in EUR JPN Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in USA CAN EUR JPN 1275 mm 50 2 in AUS NZL ZAF Seat height 965 mm 38 0 in USA CAN EUR JPN 960...

Page 45: ...0 77 US qt 0 64 Imp qt Without oil filter element replacement 0 71 L 0 75 US qt 0 62 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance L...

Page 46: ...B 22 450 22 550 mm 0 8839 0 8878 in Limit 22 350 mm 0 8799 in Exhaust A 33 370 33 470 mm 1 3138 1 3177 in Limit 33 270 mm 1 3098 in Exhaust B 25 211 25 311 mm 0 9926 0 9965 in Limit 25 111 mm 0 9886...

Page 47: ...e 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 010 mm 0 0004 in Val...

Page 48: ...76 955 76 970 mm 3 0297 3 0303 in Height H 6 0 mm 0 24 in Offset 0 00 mm 0 0000 in Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in Limit 16 043 mm 0 6316 in Piston pin outside diamet...

Page 49: ...quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring free length 45 00 mm 1 77 in Limit 44 00 mm 1 73 in Spring quantity 5 pcs Push rod bending limit 0 10 mm 0 0039 in Transmission Transmissio...

Page 50: ...on sensor Resistance 6 30 k Output voltage at idle 0 5 V Fuel injection sensor Crankshaft position sensor resistance 228 342 Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa Intake a...

Page 51: ...aterial Aluminum Wheel travel 315 0 mm 12 40 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 0 02 in Front tire Type With tube Si...

Page 52: ...in 1 Recommended fluid DOT 4 Steering Steering bearing type Taper roller bearing Center to lock angle left 43 0 Center to lock angle right 43 0 Front suspension Type Telescopic fork Spring shock abso...

Page 53: ...ich the spring is turned in 10 mm 0 39 in from its free length Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Position in whic...

Page 54: ...anufacturer 1SM0 YAMAHA USA CAN 1SM1 YAMAHA EUR AUS NZL ZAF 1SM2 YAMAHA JPN Ignition coil Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 2 16 2 64 Secondary coil resistance 8 64 12...

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

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

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

Page 58: ...3 8 Nm 0 8 m kgf 5 8 ft lbf Crankshaft position sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf AC magneto lead holder bolt M5 1 8 Nm 0 8 m kgf 5 8 ft lbf Coolant temperature sensor M10 1 16 Nm 1 6 m kgf...

Page 59: ...protector bolt M6 6 5 Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Clutch lever hol...

Page 60: ...kgf 1 8 ft lbf Rear brake disc cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft...

Page 61: ...6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel inlet pipe screw M5 2 3 4 Nm 0 34 m kgf 2 5 ft lbf F...

Page 62: ...rotors inner and outer Oil passage gasket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear...

Page 63: ...OINTS AND LUBRICANT TYPES 2 20 EAS1SM1061 Cylinder head cover gasket Three bond No 1215 Crankcase mating surface Three bond No 1215 Stator assembly lead grommet Three bond No 1215 Lubrication point Lu...

Page 64: ...outer surface and dust seal lip upper side Rear shock absorber assembly bearing and dust seal lip lower side Brake pedal pivot portion O ring and bolt outer surface Front wheel oil seal lip Front whe...

Page 65: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22 Rear brake caliper pin bolt and boot Rear brake master cylinder push rod end Rear brake master cylinder kit Lubrication point Lubricant types S S...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS1SM1062 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS1SM1063 LUBRICATION DIAGRAMS...

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

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

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

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

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

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

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

Page 74: ...CABLE ROUTING DIAGRAM 2 31 EAS1SM1064 CABLE ROUTING DIAGRAM...

Page 75: ...lamp the clutch cable and the AC magneto lead by the plastic locking tie Regardless of the orien tation of the lock on the plastic locking tie cut the end L Pass the clutch cable with no downward sag...

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

Page 77: ...e to the outside of the tension arm and the throttle position sensor lead the outside of the vehicle and to the inside of the radiator hose the side of the vehicle H Pass the protector of the cylinder...

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

Page 79: ...of the number plate band C Clamp the engine stop switch lead to the handle bar by the plastic band Do not cut the end of the plastic band D Pass the engine stop switch lead between the head pipe and...

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

Page 81: ...sert the projection of the plastic clamp into the hole in the sheet metal of the radiator B Insert the projection of the main harness into the hole in the frame C To the sub wire harness D Pass the hi...

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

Page 83: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

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

Page 85: ...3 13 CHECKING THE FUEL LINE 3 14 CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 21 BLEEDING THE BR...

Page 86: ...HE WHEEL BEARINGS 3 33 CHECKING AND ADJUSTING THE STEERING HEAD 3 33 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDAL 3 34 ELECTRICAL SYSTEM 3 35 CHECKING THE SPARK PLUG 3 35 CHECKING THE IGNITION TI...

Page 87: ...to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold...

Page 88: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Page 89: ...R Clean and lubri cate Use foam air filter oil or equiv alent oil Replace SPARK PLUG Inspect and clean Check the electrodes and the terminals for wear Replace COOLING SYSTEM Check coolant lev el and l...

Page 90: ...Inspect and adjust Lubricate After rain ride Grease pillow balls and bear ings Retighten Check for tightening torques BRAKE S Adjust lever posi tion and pedal height Lubricate pivot point Check brake...

Page 91: ...sure wheel run out tire wear and spoke looseness Retightensprocket bolt Check the bearing Replace bearings Lubricate Lithium soap base grease DRIVE CHAIN Use chain oil Clean lubricate slack alignment...

Page 92: ...play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to TORQUE CHECK POINTS on page 1 25 ITEM After break in Every race about 2 5 hours Every third about 7 5...

Page 93: ...es Check the play of front brake and effect of front and rear brake 3 21 27 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 27 4 64 65 Wheels Chec...

Page 94: ...a few minutes until the coolant has settled EAS1SM1071 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover...

Page 95: ...level Refer to CHECKING THE COOLANT LEV EL on page 3 8 EAS1SM1073 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace...

Page 96: ...spout therefore cover it with a cloth beforehand EAS1SM1076 ADJUSTING THE CLUTCH LEVER POSI TION 1 Adjust Clutch lever position a Loosen the locknut 1 and use the adjuster 2 to adjust the clutch lever...

Page 97: ...be adjusted 1 Check Throttle grip free play a Out of specification Regulate 2 Adjust Throttle grip free play a Loosen the locknut 1 b Turn the adjuster 2 until the specified free play is obtained c T...

Page 98: ...AIR FILTER ELEMENT 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 21 Air filter case cover 2 2 Remove Air filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air...

Page 99: ...Breather hose 1 Crack damage Replace Loose connection Connect properly ECA14920 NOTICE Make sure that the breather hoses are rout ed correctly EAS1SM1083 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust p...

Page 100: ...r 2 3 min utes and then stop the engine and wait about 5 minute 3 Check Oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark...

Page 101: ...the oil filter element cover 1 and oil filter element 2 b Replace the O rings 3 c Install the new oil filter element and the oil fil ter element cover 5 To check the oil strainer perform the follow in...

Page 102: ...d Tighten the oil pressure check bolt EAS1SM1087 ADJUSTING THE ENGINE IDLING SPEED TIP Because the air pressure is lower at high alti tudes the air fuel mixture will become richer If the idling speed...

Page 103: ...ual It may lead to servicing trouble and mechanical damage Make sure that the valve clearance is checked or adjusted while the engine is cold at room temperature While the valve clearance is checked o...

Page 104: ...using a thickness gauge 1 TIP Record the measured reading if the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust Refer to CAMSHAFT on page 5 11 b Remove the v...

Page 105: ...pad number to replace Example Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 ECA NOTICE Do not twist adjusting pads and valve lifters forcibly during insta...

Page 106: ...40 1 25 1 29 230 235 240 1 30 1 34 235 240 1 35 1 39 240 0 19 0 12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145...

Page 107: ...b Install the reservoir diaphragm c Connect the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pul...

Page 108: ...en the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA13050 WARNING A soft or spongy feeling in the brake lever...

Page 109: ...in the brake system will cause braking performance to be reduced ECA13510 NOTICE After adjusting the brake pedal position make sure that there is no brake drag EAS1SM1094 CHECKING THE FRONT BRAKE PAD...

Page 110: ...nstall the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad...

Page 111: ...pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper piston in EWA WARNING Do not reuse...

Page 112: ...KE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EAS1SM1097 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a leve...

Page 113: ...itable stand to raise the rear wheel off the ground EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pu...

Page 114: ...pecification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EAS1SM1101 CLEANING THE FRONT FORK OIL SEAL AND D...

Page 115: ...Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 Nm 0 13 m kgf 0 94 ft lbf Direction a Rebound damping force is increased suspension is harder Direction b Rebo...

Page 116: ...EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Remove Rear fr...

Page 117: ...djustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping force is increased suspension is harder Direction b Rebound damping force is decreased suspension is softer c b d T R Rebound da...

Page 118: ...tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position EAS1SM1108 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose...

Page 119: ...S1SM1111 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Use a suitable stand to raise the front wheel off the ground EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling...

Page 120: ...lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 49 f Install the washer 1 5 Install Upper bracket Refer to STEERING HEAD on page 4 49 Handlebar Refer to HANDLEBA...

Page 121: ...re removing the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to lig...

Page 122: ...6 4 Check Ignition timing Check whether the alignment mark a on the left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 I...

Page 123: ...PER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER...

Page 124: ...MBLY 4 53 HANDLING THE REAR SHOCK ABSORBER 4 56 DISPOSING OF A REAR SHOCK ABSORBER 4 56 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 REMOVING THE BEARING 4 56 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 125: ...this manual It may lead to servicing trouble and mechanical damage EAS1SM1118 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop rig...

Page 126: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 21 2 Remove Seat 1 EAS1SM1121 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 127: ...wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm...

Page 128: ...age 3 32 and CHECKING THE WHEELS on page 3 33 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sou...

Page 129: ...earing right side 3 Oil seals 4 TIP Apply the lithium soap base grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with its m...

Page 130: ...ront wheel axle 1 TIP Apply the lithium soap base grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA14140 NOTICE Before tightening the front wheel axle nut push down hard on the handl...

Page 131: ...el axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m...

Page 132: ...o CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EAS1SM1131 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Beari...

Page 133: ...led first Install the oil seal with its manufacture s marks or numbers facing outward ECA1DX1006 NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diam...

Page 134: ...el axle from the left side Apply the lithium soap base 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...

Page 135: ...washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Page 136: ...ake caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Page 137: ...Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake mas...

Page 138: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Page 139: ...137 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness...

Page 140: ...ubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When the brake ca...

Page 141: ...olt 1 TIP Make sure that the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the speci...

Page 142: ...der and the end of the brake hose EAS1SM1145 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinde...

Page 143: ...ont brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washers Brake hose Union bolt EWA13530 WARNING Proper brake hose routing i...

Page 144: ...l that water does not enter the reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE Immediately wipe off the spilled brake fluid to...

Page 145: ...pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse...

Page 146: ...brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2...

Page 147: ...3 21 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Split pin 1 5 Plain washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master...

Page 148: ...4 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Page 149: ...ention EAS1SM1150 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thick...

Page 150: ...EAS1SM1153 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assem...

Page 151: ...e a facing the brake caliper Never force to insert EAS1SM1156 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WHEEL on page...

Page 152: ...to CHECKING THE BRAKE FLUID LEVEL on page 3 26 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 21 EAS1SM1157 REMOVING THE R...

Page 153: ...piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Master cylinder kit 1 Push rod 2 Circlip 3 Dust boot 4 TIP Before installation apply brake...

Page 154: ...e fluid be careful that water does not enter the reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE Brake fluid may damage painted...

Page 155: ...he band only 1 Clutch cable 1 Disconnect 2 Clutch lever holder 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Throttle cable cap 1 6 Throttle cable pull 1 Disconnect 7 Throttle cable return 1 Di...

Page 156: ...HANDLEBAR 4 32 14 Handlebar lower holder 2 15 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Page 157: ...dlebar 3 Upper handlebar holders 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Installing the lower handlebar hold...

Page 158: ...TIP Install the handlebar grip to the handlebar so that the line a between the two arrow marks faces straight upward 5 Install Engine stop switch 1 Clutch lever 2 Clutch lever holder 3 Clamp 4 TIP Th...

Page 159: ...pply the lithium soap base grease on the throttle grip sliding surface 8 Install Throttle cables 1 TIP Slightly coat the end of throttle cable and inside of throttle grip with lithium soap based greas...

Page 160: ...embly to be level First tighten the upper bolt then the lower bolt 12 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 13 Adjust Clutch lever...

Page 161: ...rake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bol...

Page 162: ...al 1 8 Protector guide 1 9 Slide metal 1 10 Oil seal washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New N...

Page 163: ...nch 2 3 Remove Front fork leg s EAS1SM1167 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 wrenc...

Page 164: ...bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend dama...

Page 165: ...Outer tube bushing Oil seals Copper washers 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 ECA14210 NOT...

Page 166: ...ristic can not be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releas ing the dam...

Page 167: ...8 cm3 0 27 US oz 0 28 lmp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Oil seal clip 2 Oil seals 3 Washer 4 Outer tube bus...

Page 168: ...to the outer tube TIP Press the inner tube bushing into the outer tube with fork seal driver 3 18 Install Oil seals 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groov...

Page 169: ...all Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its larger dia end a fac ing the fork spring 24 Install Damper assembly 1 to the inner tube 2 ECA32D1010 NOTICE Allow th...

Page 170: ...r tube and locknut 6 Fully finger tighten the adjuster onto the damper assembly 27 Measure Gap a between the adjuster 1 and the locknut 2 Out of specification Retighten and read just the locknut TIP I...

Page 171: ...ide 1 EAS1SM1170 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly...

Page 172: ...2 6 Adjust Rebound damping force 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...

Page 173: ...3 Front fork leg s 2 Refer to FRONT FORK on page 4 37 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing lower side 1 10 Bearing races 2 For...

Page 174: ...aring races a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c Install a new bearing r...

Page 175: ...steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 33 5 Check the steering ste...

Page 176: ...ering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA33DD049 WARNING Tighten the lower bracket to specified torque If torq...

Page 177: ...r 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 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber as...

Page 178: ...der Part name Q ty Remarks 8 Spring 1 9 Dust seal 2 10 Collars 2 11 Bushing 1 12 Collars 2 13 O ring 2 14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure 2 1...

Page 179: ...e relay arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6...

Page 180: ...run ning EAS1SM1177 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA33DD052 WARNING Wear protective glasses to prevent...

Page 181: ...e wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EAS1SM1181 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing Spa...

Page 182: ...ng arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circumference and threaded portion Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt 6...

Page 183: ...de Relay arm bolt swingarm side Rear shock absorber assembly lower bolt Connecting arm bolt relay arm side 80 Nm 8 0 m kgf 58 ft lbf Relay arm bolt swingarm side 70 Nm 7 0 m kgf 51 ft lbf Rear shock a...

Page 184: ...ake hose holder Refer to REAR BRAKE on page 4 21 Rear brake caliper Refer to REAR BRAKE on page 4 21 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Page 185: ...wingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EAS1SM1186 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remove the...

Page 186: ...tall Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Recommend...

Page 187: ...ving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m...

Page 188: ...nk sec tion of the drive chain as shown in the illus tration b Calculate the length c of the 15 link section of the drive chain using the following formu la Drive chain 15 link section length c length...

Page 189: ...WA WARNING When installing the joint clip always keep the direction as shown in the figure 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on pa...

Page 190: ...CHAIN DRIVE 4 66...

Page 191: ...KING THE TIMING CHAIN TENSIONERS 5 15 CHECKING THE DECOMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 18 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SID...

Page 192: ...5 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 5 47 INSTALLING THE KICK SHAFT ASSEMBLY 5 45 INSTALLING THE KICK IDLE GEAR 5 46 SHIFT SHAFT 5 47 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSE...

Page 193: ...INER 5 66 CHECKING THE CRANKCASE 5 64 INSTALLING THE OIL SEAL 5 65 ASSEMBLING THE CRANKCASE 5 65 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 66 REMOVING THE CRANKSHAFT ASSEMBLY 5 67 CHECKING THE CRANKSHA...

Page 194: ...ide cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 53 Connecting arm bolt frame side Refer to REAR SHOCK ABSO...

Page 195: ...Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New 10 Nm 1 0 m k...

Page 196: ...age 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Condenser 1 5 Neutr...

Page 197: ...page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTLE BODY on page 7 5 Throttle body Refer to THROTTLE BODY...

Page 198: ...1 Thickness 2 3 mm 0 09 in 10 Washer 1 Thickness 1 0 mm 0 04 in 11 Lower engine bracket 2 12 Pivot shaft 1 13 Engine 1 For installation reverse the removal proce dure Removing the engine Order Part na...

Page 199: ...er EAS1SM1198 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EAS1SM1199 REMOVING THE DRIVE SPROCKET 1 Straight...

Page 200: ...uplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EAS1SM1201 CHECKING THE SILENCER AND EXHAUST PIPE 1 Check Gasket...

Page 201: ...ll the engine from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Front engine bracket 4 Engine bracket bolt front side 5 Engine mounting bolt front side 6 Upper engine bracket 7 Engin...

Page 202: ...n 2 Install Lock washer 1 Nut drive sprocket 2 TIP Tighten the nut while applying the rear brake ECA33DD040 NOTICE Make sure to tighten to specification other wise it may damage the other part that is...

Page 203: ...positioned as shown with respect to the exhaust pipe 1 3 Install Clamp Silencer 1 Bolt silencer 2 TIP Install and temporarily tighten the silencer so that its joint is positioned as shown with respect...

Page 204: ...eft right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 3 4 Cylinder head cover 1 5 Cylinder h...

Page 205: ...ioner 1 5 Gasket 1 6 Camshaft cap bolt 8 7 Camshaft cap 2 8 Clip 2 9 Exhaust camshaft 1 10 Intake camshaft 1 For installation reverse the removal proce dure 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kg...

Page 206: ...with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a...

Page 207: ...ft journal diameter a Install the camshaft into the cylinder head b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Intake A 31 730 31 830 mm 1 2492 1 253...

Page 208: ...ess Replace the timing chain and camshaft and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set EAS1SM1211 CHE...

Page 209: ...the cylinder head TIP Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA33...

Page 210: ...ckwise several turns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install T...

Page 211: ...L TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5...

Page 212: ...uide intake side 1 6 Oil check bolt 1 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf...

Page 213: ...p instrument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve CHECKING THE VALVE...

Page 214: ...the cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 3 Tighten Cylinder head bolt 1 4 Cylinder head nut 5 6 TIP Apply molybdenum disulfide grease to the threads and contact...

Page 215: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 18 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 216: ...d the valve seat width CHECKING THE VALVE SEATS on page 5 25 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene...

Page 217: ...valve guide installer 2 and the valve guide re mover 1 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guid...

Page 218: ...SEATS 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder...

Page 219: ...a coarse lapping compound a to the valve face ECA13790 NOTICE 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...

Page 220: ...lifter Damage scratches Replace the valve lift ers and cylinder head EAS1SM1225 Free length intake 36 69 mm 1 44 in Limit 35 69 mm 1 41 in Free length exhaust 34 86 mm 1 37 in Limit 33 86 mm 1 33 in b...

Page 221: ...tch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor adapter 3 5 To fasten the valv...

Page 222: ...sting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjust ing pad are...

Page 223: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 18 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the remov...

Page 224: ...r fingers and lift the opposite end gap of the piston ring over the piston crown EAS1SM1228 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the c...

Page 225: ...clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP Level the piston ring into the cylinder with the piston 3 Measure Piston ring end gap...

Page 226: ...nstall the piston ring so that the manufacturer s marks or numbers face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the F ma...

Page 227: ...er 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 en...

Page 228: ...on page 3 15 Brake pedal Refer to ENGINE REMOVAL on page 5 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Beari...

Page 229: ...rust washer 1 17 Primary driven gear 1 18 Spacer 1 19 Bearing 1 20 Washer 1 21 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks LS Ne...

Page 230: ...in Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 35 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pi...

Page 231: ...plate EAS1SM1235 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specificatio...

Page 232: ...M1240 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAS1SM1241 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks damage wear...

Page 233: ...in parallel with its manufac ture s marks or numbers facing inward EAS1SM1245 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O rings 2 Collar 3 Gasket 4 TIP Apply the lithium soap based gr...

Page 234: ...tighten to specification other wise it may damage the other part that is fastened together TIP Use the clutch holding tool 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction pla...

Page 235: ...ush rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install Gasket 1 11 Install Clutch cover 1 Clu...

Page 236: ...shers Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever does not contact the right cra...

Page 237: ...aft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 35 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick...

Page 238: ...Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EAS1SM1252 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Page 239: ...kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Ins...

Page 240: ...t pedal 1 2 Shift shaft 1 3 Oil seals 1 4 Collars 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 LS...

Page 241: ...reverse the removal proce dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks LS 1 3 10 Nm 1 0 m kgf 7 2 ft lbf 13 15 14 10 Nm 1 0 m kgf 7 2 ft lbf 30 Nm 3 0 m kgf 22 ft lbf L...

Page 242: ...loosen the bolt ECA1DX1021 NOTICE If the segment gets an impact it may be damaged Take care not to give an impact to it when removing the bolt EAS1SM1257 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1...

Page 243: ...care not to give an impact to it when tightening the bolt EAS1SM1262 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply the engine...

Page 244: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAS1SM1264 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift s...

Page 245: ...Refer to CLUTCH on page 5 35 Right crankcase cover Refer to CLUTCH on page 5 35 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Rotor...

Page 246: ...age 5 58 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer shaft drive gear...

Page 247: ...E BALANCER 1 Check Balancer Crack damage Replace EAS1SM1269 CHECKING THE OIL PUMP 1 Check Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump housing cover Cracks damage wear Replace th...

Page 248: ...r Fit the dowel pin into the groove in the inner rotor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAS1SM1271 INSTALLING THE O...

Page 249: ...each other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the c...

Page 250: ...OIL PUMP AND BALANCER GEAR 5 57 c d 6 6 7 8 8 b...

Page 251: ...to lead Disconnect 2 Crankshaft position sensor lead 1 Disconnect 3 Shift pedal 1 4 Left crankcase cover 1 5 Gaskets 1 6 Dowel pin 2 7 Holder 1 8 Stator assembly 1 9 Rotor 1 10 Woodruff key 1 For inst...

Page 252: ...EAS1SM1276 INSTALLING THE AC MAGNETO 1 Install Stator 1 Screw stator 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder 5 Bolt holder 6 TIP Apply the sealant to the grommet of the...

Page 253: ...tor align the keyway c of the rotor with the woodruff key 3 Install Washers Nut rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Left crankcase cover 3 Lead holder 4 Bolt left crankcase cov...

Page 254: ...er to KICKSTATER on page 5 44 Segment Refer to SHIFT SHAFT on page 5 47 Stator Refer to AC MAGNETO on page 5 58 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain...

Page 255: ...eeze nozzle 1 For assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft...

Page 256: ...Transmission Refer to TRANSMISSION on page 5 69 Shift cam and shift fork Refer to TRANSMISSION on page 5 69 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT L...

Page 257: ...rtions 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 or fitting Do not fo...

Page 258: ...p lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two 2 stages with 1 4 t...

Page 259: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 61 Transmission Refer to TRANSMISSION on page 5 69 1 Balancer s...

Page 260: ...he crankshaft slowly 2 Measure Big end side clearance D a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crankshaft width A a Out of specification Replace...

Page 261: ...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 bolt until the crankshaft as sembly bottoms...

Page 262: ...E REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 61 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift fork...

Page 263: ...ift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EAS1SM1291 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fork paw...

Page 264: ...eck Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement R...

Page 265: ...ing 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on the spline cre...

Page 266: ...rk 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shi...

Page 267: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WA...

Page 268: ...by reference to this manual It may lead to servicing trouble and mechanical damage EAS1SM1296 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on...

Page 269: ...iator hose 4 1 7 Radiator pipe 2 1 8 Radiator breather hose 1 9 Left radiator 1 10 Radiator hose 1 1 11 Radiator pipe 1 1 12 Coolant temperature sensor 1 For installation reverse the removal proce dur...

Page 270: ...the ra diator cap EAS1SM1298 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins...

Page 271: ...ine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Right crankcase cover Refer to CLUTCH on page 5 35 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Washer 2 5 Collar 1 6 Gear 1 7 Pin 1 8...

Page 272: ...1 11 Oil seal 1 For installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 273: ...1SM1303 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right crankcase...

Page 274: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2...

Page 275: ...2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8...

Page 276: ...icing trouble and mechanical damage EAS1SM1306 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fuel...

Page 277: ...foreign ma terials from entering the fuel pump install the included fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover...

Page 278: ...Refer to GENERAL CHASSIS on page 4 1 EAS1SM1312 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the side cover left right the seat and the air scoop left right Refer to GENERAL CHASSIS on pa...

Page 279: ...nd 3 with the arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EAS1SM1314 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear da...

Page 280: ...ge 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Air filter case 1 3 Fuel injector coupler 1 Disconnect 4 Intake air pressure sensor coup...

Page 281: ...ion reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 2 1 6 10 11 9 8 3 7 5 4 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1...

Page 282: ...ks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5...

Page 283: ...gn material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly pu...

Page 284: ...ic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 12 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire...

Page 285: ...SWITCHES 8 38 CHECKING THE IGNITION SPARK GAP 8 41 CHECKING THE SPARK PLUG CAP 8 41 CHECKING THE IGNITION COIL 8 41 CHECKING THE CRANKSHAFT POSITION SENSOR 8 42 CHECKING THE ECU 8 43 CHECKING THE STA...

Page 286: ......

Page 287: ...servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas semb...

Page 288: ...W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B...

Page 289: ...IGNITION SYSTEM 8 3 EAS1SM1323 1 Crankshaft position sensor 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU 10 Ignition coil 11 Spark plug...

Page 290: ...e spark plug OK 3 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 41 OK The ignition system circuit is OK NG 4 Check the ignition coil Refer to CHECKING THE IGNI TION...

Page 291: ...IGNITION SYSTEM 8 5 8 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 2 NG Repair or replace the wire harness OK Replace the ECU...

Page 292: ...W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B B...

Page 293: ...CHARGING SYSTEM 8 7 EAS1SM1325 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser...

Page 294: ...ring NG Reconnect OK 2 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 43 NG Replace the rectifier regulator OK 3 Check the stator coil Refer to CHECKING THE STA TOR...

Page 295: ...CHARGING SYSTEM 8 9 EAS1SM1326...

Page 296: ...r W B L B L B L B L B R B R R B R B O O R O R O R R R Sb B Gy R B W P L B L B L Gy B LB LB LB LB L L L P P B B B B P P Sb R B B R R R B B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B...

Page 297: ...on sensor 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 8 Neutral switch 9 ECU 12 Fuel injector 14 Intake air temperature sensor 15 Coolant temperature sensor 1...

Page 298: ...OOL However the diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connect...

Page 299: ...the malfunction following the order given in the troubleshooting chart After the check and service of the malfunctioning part have been completed reset the Yamaha diag nostic tool display according to...

Page 300: ...ion of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Crank the engine Fault code No is not dis played Repair is finished Fault code No is displayed Go...

Page 301: ...pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fau...

Page 302: ...7 Faulty ECU Replace the ECU Fault code 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic co...

Page 303: ...Reinstatement method 1 Connection of throttle posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking con...

Page 304: ...e sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displaye...

Page 305: ...heck for looseness or pinching Check the mounted condition for correctness Improperly mounted sensor Remount or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Turn ON...

Page 306: ...and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis p...

Page 307: ...and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis...

Page 308: ...d Raise the vehicle upright Turn ON the switch on the FI diagnostic tool sub lead Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Mounted condition of...

Page 309: ...the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the e...

Page 310: ...pins Improperly connected Connect the coupler secure ly or repair replace the wire harness After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repair is finis...

Page 311: ...and ECU coupler red black red black Between injector coupler and rectifier regulator coupler red red After starting the engine idle this and wait about 5 sec onds Fault code No is not dis played Repai...

Page 312: ...e Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment turn OFF the switch on the FI di agnostic tool sub lead and...

Page 313: ...diagnostic tool sub lead and wait about 5 sec onds or more Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Wire harness continuity Open or short circu...

Page 314: ...dition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repair replace the...

Page 315: ...d Fault code No is not dis played Repair is finished Fault code No is displayed Go to next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coup...

Page 316: ...r 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pins Improperl...

Page 317: ...o next order 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or broken terminals and locking condition of the pin...

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

Page 319: ...FUEL PUMP SYSTEM 8 33 EAS1SM1332 2 AC magneto 3 Rectifier regulator 4 Joint connector 5 Condenser 7 Engine stop switch 9 ECU 13 Fuel pump...

Page 320: ...Check the fuel pump system wire harness connections NG Reconnect OK 2 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 38 NG Replace the engine stop switch OK 3 Check fuel pressu...

Page 321: ...FUEL PUMP SYSTEM 8 35 EAS1SM1333...

Page 322: ...ELECTRICAL COMPONENTS 8 36 ELECTRICAL COMPONENTS EAS1SM1334 9 10 1 2 3 4 5 6 7 8...

Page 323: ...S 8 37 EAS1SM1335 1 Rectifier regulator 2 Intake air pressure sensor 3 Throttle position sensor 4 Injector 5 Intake air temperature sensor 6 ECU 7 Ignition coil 8 Condenser 9 Neutral switch 10 Coolant...

Page 324: ...ELECTRICAL COMPONENTS 8 38 CHECKING THE SWITCHES B Y P Sb 2 1...

Page 325: ...ELECTRICAL COMPONENTS 8 39 1 Engine stop switch 2 Neutral switch...

Page 326: ...cket tester range to 1 to make a 0 adjustment When checking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal c...

Page 327: ...heck Spark plug cap resistance Out of specification Replace a Connect the pocket tester 1k to the spark plug cap b Measure the spark plug cap resistance EAS1SM1338 CHECKING THE IGNITION COIL 1 Disconn...

Page 328: ...aft position sensor resistance Out of specification Replace a Connect the pocket tester 100 to the crankshaft position sensor coupler b Measure the crankshaft position sensor re sistance EAS1SM1340 Se...

Page 329: ...asure the stator coil resistance EAS1SM1342 CHECKING THE RECTIFIER REGULATOR 1 Check Rectifier regulator output voltage Out of specification Replace a Set the digital tachometer to the ignition coil b...

Page 330: ...not get wet c Place a thermometer in the coolant d Slowly heat the coolant and then let it cool to the specified temperature indicated in the table e Check the coolant temperature sensor for continuit...

Page 331: ...r input voltage Out of specification Replace the ECU a Connect the test harness S pressure sensor 3P to the throttle position sensor coupler and the wire harness b Connect the pocket tester 20 VDC to...

Page 332: ...intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester 1k 100 to the intake air temperature senso...

Page 333: ...r coupler c Measure the fuel injector resistance Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a Continuity Positive tester probe Black Yellow 2 Negative tester pro...

Page 334: ...ELECTRICAL COMPONENTS 8 48...

Page 335: ...SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFOR...

Page 336: ...taminated fuel Clogged or damaged fuel hose 2 Fuel pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorre...

Page 337: ...ift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS1SM1358 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Loose or fatigued...

Page 338: ...amaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorre...

Page 339: ...ort circuit detected 8 20 22 Intake air temperature sensor open or short circuit detected 8 21 30 The vehicle has overturned 8 22 33 Ignition coil open or short circuit detected in the primary lead of...

Page 340: ...emper ature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturn Displays the output voltage 1 0 V 4 0 V Remove the EC...

Page 341: ...ting map erasure There is no setting There is some setting Displays the presence or ab sence of the setting history by Power Tuner 00 01 Erase all setting maps by the operation start process ing 70 Pr...

Page 342: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Page 343: ...FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 3 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SET...

Page 344: ...aking notes of lap times to find the best balance then determine the second ary reduction ratio If a course has a long straight portion where a machine can run at maximum speed the ma chine is general...

Page 345: ...ARACTERIS TICS OF FORK OIL Damping characteristic near the final stroke can be changed by changing the fork oil amount EWA1DX4001 WARNING Adjust the oil amount in 5 cm3 0 2 US oz 0 2 Imp oz increments...

Page 346: ...ct with the road surface or in a vibrating handlebar EAS1SM1373 FRONT FORK SETTING PARTS Front fork spring 1 Except for USA and CAN TIP The I D mark slits a is proved on the end of the spring EAS1SM13...

Page 347: ...length sunken length 90 100 mm 3 5 3 9 in and set 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...

Page 348: ...THE REAR SHOCK ABSORBER ASSEMBLY on page 3 30 Type Spring rate N mm Part number I D Mark SOFT 52 1SL 22212 40 Blue Yellow 1SL 22212 50 Red STD 54 1SL 22212 60 Blue Pink 1SL 22212 70 Red STD 56 1SL 22...

Page 349: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Page 350: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Page 351: ...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 352: ...9 ECU 10 Ignition coil 11 Spark plug 12 Injector 13 Fuel pump 14 Intake air temperature sensor 15 Coolant temperature sensor 16 Throttle position sensor 17 Intake air pressure sensor EAS1SM1382 COLOR...

Page 353: ......

Page 354: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER...

Page 355: ...8 10 9 12 11 13 14 15 16 17 P P Sb R B B R R R B B L Gy B R B Y P Sb B B R R B L Y B L B W R Lg B L Br W B L P B L B L G W B B Y B B L B L B L B L B L B L B B B B R R P P P L L L R R R R R B O P Gy R...

Page 356: ...ACK BLACK 4 1 3 2 5 6 7 8 10 9 12 11 13 14 15 16 17 WIRING DIAGRAM YZ250F E 2014 SCH MA DE C BLAGE YZ250F E 2014 SCHALTPLAN YZ250F E 2014 SCHEMA ELETTRICO YZ250F E 2014 1SM 28199 30_W D indd 2 2013 09...

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Yamaha YZ250F(E), Owner'S Service Manual

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