Yamaha YZ250FX 2021 Owner'S Manual Download

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TROUBLESHOOTING

8-5

Clutch drags

Faulty clutch spring

Replace the clutch springs as a

set.

Warped pressure plate

Replace the pressure plate.

Swollen friction plate

Replace the friction plates as a

set.

Warped clutch plate

Replace the clutch plates as a set.

Bent pull rod (outer pull type)

Replace the pull rod.

Worn pull rod tooth (outer pull

type)

Replace the pull rod and pull lever

shaft as a set.

Bent push rod (inner push type)

Replace the push rod.

Damaged or worn clutch boss

Replace the clutch boss.

Seized clutch housing 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.

Incorrect oil viscosity (high)

Change to recommended engine

oil.

Deteriorated oil

Change to recommended engine

oil.

Clutch noise

Damaged or worn primary driven

gear

Replace the primary drive gear or

crankshaft, and the clutch housing

as a set.

Loose clutch boss nut

Tighten the clutch boss nut to the

specified torque.

Fatigued clutch damper

Replace the clutch housing.

Worn clutch housing bearing

Replace the clutch housing bear-

ing.

Worn pressure plate bearing

Replace the pressure plate bear-

ing.

Symptom

Possible cause

Actions

Summary of Contents for YZ250FX 2021

Page 1: ... 28199 11 LIT 11626 34 55 Read this manual carefully before operating this vehicle YZ250FXM OWNER S MANUAL YZ250FX 2021 PRINTED IN JAPAN 2020 08 0 5 1 E BAJ 28199 11_cover_4mm indd 1 3 2020 08 03 17 22 12 ...

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

Page 3: ... the user s authority to operate the equipment This transmitter must not be co located or operated in conjunction with any other antenna or transmitter This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency RF Exposure Guidelines This equipment has very low levels of RF energy that is deemed to comply without maximum p...

Page 4: ...by Yamaha Motor Corporation U S A First edition August 2020 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 34 55 Printed in Japan ...

Page 5: ...quested 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 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 UNTIL YOU H...

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

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

Page 8: ......

Page 9: ...N 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 INSTRUMENT AND CONTROL FUNCTIONS 1 10 WARNING LIGHTS 1 10 ENGINE STOP SWITCH 1 10 START SWITCH 1 10 MODE SWITCH 1 10 SHIFT PEDAL 1 11 FRONT BRAKE LEVER 1 11 SIDESTAND 1 11 REAR BRAKE PEDAL 1 11 STARTER KNOB 1 11 FUEL TANK CAP 1 12 STARTING AND BREAK IN 1 13 FUEL 1 13 STARTING A COLD ENGINE 1 13 STARTING A WARM ENGINE 1 14 BREA...

Page 10: ...MOTORCYCLE CARE AND STORAGE 1 18 CARE 1 18 STORAGE 1 19 ...

Page 11: ...re 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 motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspic uous appears to be very effective in reducing the chance of this type...

Page 12: ... 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 companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a ...

Page 13: ...he 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 Shift the transmission in gear for models with a manual transmission 5 Secure the motorcycle with tie downs or suit able straps that are attached to solid parts of the motorcycle such as the frame or ...

Page 14: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding ...

Page 15: ...ou have purchased 1 12 13 15 14 16 17 18 19 20 4 2 3 5 7 6 8 9 10 11 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Front brake lever 5 Throttle grip 6 Start switch 7 Radiator cap 8 Fuel tank cap 9 Mode switch 10 Engine stop switch 11 Fuel tank 12 Radiator 13 Coolant drain bolt 14 Oil level check window 15 Rear brake pedal 16 Air filter 17 Drive chain 18 Shift pedal 19 ...

Page 16: ...er 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 vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the lower left side of the engine 1 1 1 1 ...

Page 17: ...in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case the engine specifications muffler com pression ratio etc have been changed the performance may not match to the actu al settings Do not run the engine with the smartphone carried with you Otherwise the smart pho...

Page 18: ... 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 location and perform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ber into ...

Page 19: ...ot to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 6 If coolant is left adhered 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 your eyes wash it away with wa ter enough and then get medical attention If it spla...

Page 20: ...lectrical 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 when the start switch is pushed or if the warning light remains on have a Yamaha dealer check the electrical circuit EAM30182 ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar...

Page 21: ...ING 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 brake pedal to acti vate the rear brake EAM30444 STARTER KNOB Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob 1 Pushing the knob toward a turns ON t...

Page 22: ...ver 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 Install the fuel tank cap cover after placing the bands 3 all the way in under the seat a a b b 1 1 1 2 3 a a a 2 2 ...

Page 23: ...s EAM30196 STARTING A COLD ENGINE 1 Press the shift pedal to neutral 2 Push the starter knob 1 completely TIP When the ambient temperature is 15 C 59 F or below use the starter knob Do not operate the throttle grip when operating the starter knob 3 Start the engine by pushing the start switch If the engine fails to start when using the start switch release it wait a few seconds and then try again ...

Page 24: ...seness 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 NOTICE ECA25821 After a break in or after each race always check the points shown in TORQUE CHECK POINTS for tightening torques and retighten them Also when the following parts are replaced a break in...

Page 25: ...s 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 bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke for looseness Brake s Check the brake disc mounting bolt for loose ness Check that the reservoir contains the...

Page 26: ...e 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 wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake ...

Page 27: ...ft 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 rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 28: ...ly 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 lenses etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thor oughly cleaned with water diluted mild de tergent with water m...

Page 29: ...and 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 completely before storing or covering it WARNING EWA19050 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean ...

Page 30: ...rk 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 all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so tha...

Page 31: ...ENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 4 ELECTRICAL SPECIFICATIONS 2 7 TIGHTENING TORQUES 2 8 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 8 ENGINE TIGHTENING TORQUES 2 9 CHASSIS TIGHTENING TORQUES 2 12 ...

Page 32: ...CIFICATIONS Model Model BAJ5 Dimensions Overall length 2175 mm 85 6 in Overall width 825 mm 32 5 in Overall height 1270 mm 50 0 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 111 kg 245 lb ...

Page 33: ...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 Cooling system Coolant quantity Radiator including all routes 0 93 L 0 98 US qt 0 82 Imp qt Spark plug s Manufacturer model NGK LMAR8E J Spark plug gap 0 6 0 7 mm 0 024 0 028 in Valve Valve clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 17 0 24 mm 0 0067 0 0094 in Clutch Clutch ...

Page 34: ...8 4th 1 143 24 21 5th 0 957 22 23 6th 0 815 22 27 Secondary reduction ratio 3 923 51 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Idling condition Engine idling speed 1900 2100 r min Coolant temperature 70 80 C 158 176 F Throttle grip free play 3 0 6 0 mm 0 12 0 24 in ...

Page 35: ...ickness limit 1 0 mm 0 04 in Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brake Brake pedal position 5 0 mm 0 20 in Brake pad lining thickness limit 1 0 mm 0 04 in Specified brake fluid DOT 4 Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 310 mm 12 2 in Fork spring free length limit 492 0 mm 19 37 in Inner tube bending lim...

Page 36: ...n Adjustment value Hard 18 0 mm 0 71 in Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 30 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Compression damping Adjusting system Mechanical adjustable type Fast compression damping Unit for adjustment Turn Adjustment valu...

Page 37: ...CHASSIS SPECIFICATIONS 2 6 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in 15 link length limit 239 3 mm 9 42 in ...

Page 38: ...130 ELECTRICAL SPECIFICATIONS Battery Model BR98 Voltage capacity 12 V 2 4 Ah 5 HR Indicator light Fuel level warning light 1 7 W Engine trouble warning light 1 7 W Fuse s Main fuse 15 0 A Radiator fan motor fuse 5 0 A Spare fuse 15 0 A ...

Page 39: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6...

Page 40: ...28 lb 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 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Radiator pipe joint bolt M6 1 10 ...

Page 41: ... cover 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 m 1 0 kgf m 7 4 lb ft Crankcase cover bolt left M6 7 10 N m 1 0 kgf m 7 4 lb ft Crankcase cover bolt right M6 9 10 N m 1 0 kgf m 7 4 lb ft Oil filter element cover bolt M6 2 10 N m 1 0 kgf m 7 4...

Page 42: ...il 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 5 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Gear position switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Rectifier regulator bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft ECU bolt M5 2 ...

Page 43: ...5 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 ft Clutch lever holder bolt M6 2 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever position locknut M5 1 4 8 N m 0 48 kgf m 3 5 lb ft Front brake master cylinde...

Page 44: ... brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting bolt front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting bolt lower side M10 1 53 N m 5 3 kgf m 39 lb ft Engine bracket bolt upper side M8 4 34 N m 3 4 kgf m 25 lb ft Engine bracket bolt front side ...

Page 45: ...m 0 7 kgf m 5 2 lb ft Screw fuel inlet pipe M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Bolt fuel tank cap cover M6 2 4 0 N m 0 40 kgf m 3 0 lb ft Seat set bracket screw M6 1 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop b...

Page 46: ...TIGHTENING TORQUES 2 15 ...

Page 47: ...CHECKING THE COOLING SYSTEM 3 17 CHANGING THE COOLANT 3 17 CHASSIS 3 19 ADJUSTING THE FRONT DISC BRAKE 3 19 ADJUSTING THE REAR DISC BRAKE 3 19 CHECKING THE BRAKE FLUID LEVEL 3 20 CHECKING THE FRONT BRAKE PADS 3 20 CHECKING THE REAR BRAKE PADS 3 20 CHECKING THE FRONT BRAKE HOSE 3 20 CHECKING THE REAR BRAKE HOSE 3 21 CHECKING THE BRAKE OPERATION 3 21 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 21 DRIVE CH...

Page 48: ...9 LUBRICATING THE BRAKE LEVER 3 30 LUBRICATING THE CLUTCH LEVER 3 30 LUBRICATING THE PEDAL 3 30 CHECKING THE SIDESTAND 3 30 LUBRICATING THE SIDESTAND 3 30 ELECTRICAL SYSTEM 3 31 CHECKING AND CHARGING THE BATTERY 3 31 CHECKING THE FUSES 3 31 ...

Page 49: ...ce 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 scratches and wear Replace 4 Camshaft Inspect the camshaft surface Inspect the decompression sys tem Replace 5 Timing chain Check for damage and sticking Replace the timing chain and tim ing chain tension...

Page 50: ...st 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 Clean and lubricate Replace 24 Breather system Check ventilation hose for cracks or damage and drain any depos its Replace Every two years 25 Spark plug Check the electrodes and the ter minals for wear R...

Page 51: ...eck 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 Steering head Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings 39 Tire wheels Inspect air pressure wheel run out tire wear and spoke loose ness ...

Page 52: ...for 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 After break in Every race about 2 5 hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required ...

Page 53: ... rear brake 3 19 3 19 3 20 3 20 3 20 3 20 3 21 3 21 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 22 4 31 4 31 4 32 4 32 4 32 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 28 3 29 3 29 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 23 Front forks an...

Page 54: ... Remove Seat Side cover left right Air scoop left right Fuel tank Refer to FUEL TANK on page 6 1 ECU 2 Remove Spark plug Cylinder head cover 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Regulate a Turn the crankshaft counterclockwise with a wrench b Align the top dead center TDC mark a on the generator rotor with the al...

Page 55: ... 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 Adjust Engine idling speed a Turn the idle screw 1 to make an adjust ment EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 C...

Page 56: ...e to pull the hose TIP Remove the fuel tank turn this 180 clockwise and put it in the frame 2 as shown 2 Remove Holder Spark plug cap Spark plug NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder clean it before re moving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode 1 Damage wear Replace...

Page 57: ...the clutch the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign material 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 minutes TIP This model is equipped with an engine auto stop...

Page 58: ... ring 2 d Install the oil strainer 6 Install Gasket Drain bolt 7 Pour the specified amount of engine oil into the oil filler cap hole 8 Install Oil filler cap 9 Check Oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 9 10 Check Engine oil pressure a Slightly loosen the oil pressure check bolt 1 Oil filter element cover bolt 10 N m 1 0 kgf m 7 4 lb ft 2 1 3 1 1 3 3 2 2 T R Oil strainer bol...

Page 59: ...essure again e Tighten the oil pressure check bolt EAM30216 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar side a Turn the adjuster 1 until the specified clutch lever free play is obtained TIP If the clutch lever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable side...

Page 60: ...nt 2 from the air filter guide Guide 3 from the air filter element Seal 4 from the air filter element 4 Wash Air filter element a After washing the element with air filter cleaner or kerosene squeeze and dry it completely WARNING EWA19110 Do not use gasoline or organic acid alka line volatile oil for washing NOTICE ECA24280 Do not twist the element when squeezing the element 5 Check Air filter ele...

Page 61: ...case Check that the air filter element is turned up be tween the air filter guide and air filter case and that there is no gap Gap Reinstall 8 Turn the plates 1 to the original position 9 Install Air filter case cover 1 Fuel tank breather hose to the air filter case cover TIP Make sure that the two slots a at the rear side of the vehicle in the air filter case cover are se curely fitted into the t...

Page 62: ... 1 Crack damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to EXHAUST SYSTEM on page 5 1 2 Remove Exhaust pipe protector 3 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace 4 Check Silencer fiber Damage Replace 5 Replace Sile...

Page 63: ... 9 TIP Apply heat resistant sealant to the areas d shown making sure that there are no gaps in the beads of sealant g Install the fiber 10 TIP Stuff the fiber into the 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 Silencer body bolt 8 N m 0 8 kgf m 5 9 lb ft LOCTITE 2 4 3 5 5 5 7 6 c b T R 9...

Page 64: ...hich could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing 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...

Page 65: ...1 EAM30212 CHANGING THE COOLANT WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the ...

Page 66: ...ect the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be 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 minutes stop it and then wait for it to cool down 9 Check Coolan...

Page 67: ... will consid erably reduce braking performance NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position a distance from the top of the rider footrest to the top of the brake pedal Out of specification Regulate 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn t...

Page 68: ...When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAM30231 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pa...

Page 69: ...y brake fluid or allow the reservoir to overflow Make sure that there is enough brake fluid be fore applying the brake Ignoring this precau tion could allow air to enter 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 tiny bubbles in the hose have disa...

Page 70: ...nger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive 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 bottom of the chain as shown Adjusting the drive chain slack WARNING EWA13120 Secure...

Page 71: ... Adjust the steering head 3 Remove Handlebar Upper bracket 4 Adjust Steering head a Remove the washer 1 b After loosening the ring nut 2 with a steering nut wrench 3 tighten it to the specified torque TIP Set the torque wrench at a right angle to the steering nut wrench Move the steering to the left and right a couple of times to check that it moves smoothly c Turn the front fork to the right and ...

Page 72: ...the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 15 TIP If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it 5 Check Protector guide 1 Out of specification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same hei...

Page 73: ...ge 1 Adjust 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 the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to ch...

Page 74: ...sorber assembly smooth ac tion 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 or replace EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle ...

Page 75: ... 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 Turn the adjuster 1 in the direction of a or b to make an adjustment Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Pos...

Page 76: ...uld be advisable to check the number of clicks 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 SWINGARM on page 4 30 EAM30500 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seal Collar EAM30243 CHECKING THE TIRES 1 Measure Tire pressure Out of specification Re...

Page 77: ...break in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel EAM30253 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES...

Page 78: ...oting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHECKING THE SIDESTAND 1 Check Sidestand operation Check that the sidestand moves smoothly Rough movement Repair or replace EAM30252 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to m...

Page 79: ...CAL SYSTEM 3 31 EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 7 3 EAM30505 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 7 3 ...

Page 80: ...ELECTRICAL SYSTEM 3 32 ...

Page 81: ... 4 6 REAR BRAKE 4 8 REPLACING THE REAR BRAKE PADS 4 8 HANDLEBAR 4 10 REMOVING THE HANDLEBAR 4 10 CHECKING THE HANDLEBAR 4 10 INSTALLING THE HANDLEBAR 4 10 FRONT FORK 4 15 REMOVING THE FRONT FORK LEGS 4 15 DISASSEMBLING THE FRONT FORK LEGS 4 15 CHECKING THE FRONT FORK LEGS 4 16 ASSEMBLING THE FRONT FORK LEGS 4 17 INSTALLING THE FRONT FORK LEGS 4 23 STEERING HEAD 4 26 REMOVING THE LOWER BRACKET 4 26...

Page 82: ...CHAIN DRIVE 4 31 REMOVING THE DRIVE CHAIN 4 31 CHECKING THE DRIVE CHAIN 4 31 CHECKING THE DRIVE SPROCKET 4 32 CHECKING THE REAR WHEEL SPROCKET 4 32 INSTALLING THE DRIVE CHAIN 4 32 ...

Page 83: ...Remove the clutch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30458 INSTALLING THE AIR SCOOP 1 Install Air scoop left 1 right TIP After inser...

Page 84: ...own EAM30460 INSTALLING THE SIDE COVER 1 Install Side cover right 1 TIP Install the side cover right by sliding it as shown and secure it with the bolts to fit it to the vehicle Install the side cover right so that the rib is lo cated under the rib of the rear fender a Projection b Slot a Projection b Slot c Rib side cover d Rib rear fender 1 1 b b a a a a b b 1 1 c c d d ...

Page 85: ... TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle...

Page 86: ...n 1 4 tooth wear a Replace the rear wheel sprocket and the drive sprocket as a set Bent tooth Replace the rear wheel sprock et and the drive sprocket as a set 2 Replace Rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket TIP Tighten ...

Page 87: ...r wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel axle at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 22 6 Tighten Rear wheel axle nut 1 Locknut 2 1 2 LS 1 2 3 Drive chain slack Maintenance stand 50 0 60 0 mm 1 97 2 36 in Wheel axle nut 125 N m 12 5 kgf m 92 lb ft Locknut 21 N m 2 1 kgf m 15 ...

Page 88: ... specification Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw and push the brake caliper piston in WARNING EWA19160 Do not reuse 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 proj...

Page 89: ...efer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 5 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 Bolt brake caliper 28 N m 2 8 kgf m 21 lb ft Pad pin 17 N m 1 7 kgf m 13 lb ft Pad pin plug 2 5 N m 0 25 kgf m 1 8 lb ft 3 a b T R 4 5 T R 6 ...

Page 90: ...wear limit a Out of specification Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw and push the brake caliper piston in WARNING EWA19170 Do not reuse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin 4 TIP Install the brake...

Page 91: ...fluid level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 Pad pin 17 N m 1 7 kgf m 13 lb ft Pad pin plug 2 5 N m 0 25 kgf m 1 8 lb ft Bolt protector 7 N m 0 7 kgf m 5 2 lb ft 3 4 a b T R 7 5 6 7 5 6 T R 8 9 8 9 ...

Page 92: ... falling over 2 Install Damper 1 Lower handlebar holder 2 temporarily Handlebar 3 Upper handlebar holder 4 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Installing the lower handlebar holders in the re verse direction allow the front to rear offset amount of the handlebar position to be changed The upper handlebar ...

Page 93: ...mode switch 2 should be installed according to the dimensions shown Pass the engine stop switch lead through the middle of the clutch lever holder a 3 4 4 Lower handlebar holder nut 40 N m 4 0 kgf m 30 lb ft Clutch lever holder bolt 5 N m 0 5 kgf m 3 7 lb ft Clutch lever nut 4 0 N m 0 40 kgf m 3 0 lb ft Engine stop switch screw 0 5 N m 0 05 kgf m 0 37 lb ft Screw mode switch 1 3 N m 0 13 kgf m 0 9...

Page 94: ... ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 11 9 Install Right grip 1 Collar 2 Apply adhesive to the tube guide 3 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 10 Install Rubber cover 1 Throttle grip 2 TIP Apply the lithium...

Page 95: ...e master cylinder assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the front brake master cylinder assembly to be level First tighten the upper bolt then the lower bolt 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 7 Sc...

Page 96: ...HANDLEBAR 4 14 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in ...

Page 97: ...Remove Front fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster NOTICE ECA24520 Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out 3 Remove Dust sea...

Page 98: ...gerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling ...

Page 99: ... tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA24530 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg take care not to allow any for eign mate...

Page 100: ...tion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten Base valve 1 Standard oil...

Page 101: ...he damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Scraper 2 Stopper ring 3 Oil seal 4 Washer 5 Slide metal 6 to the inner tube 7 NOTICE ECA24550 Make sure that the numbered s...

Page 102: ...the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube TIP Press the slide metal into the outer tube with fork seal driver 3 18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears LS 1 2 3 4 5 6 ...

Page 103: ...s Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring seat with its larger dia end a facing the fork spring 24 Install Damper assembly 1 to the inner tube 2 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 New Distance a 16 mm 0 63 in or more Between th...

Page 104: ...r 2 Adjuster 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure Gap a between the adjuster 1 and the locknut 2 Out of specification Retighten and readjust the locknut TIP If it is installed with a gap out of specification correct damping force ca...

Page 105: ...tighten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly Adjuster 55 N m 5 5 kgf m 41 lb ft LOCTITE Recommended oil Yamaha Suspension Oil S1...

Page 106: ... TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm 0 20 in Upper bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Lower bracket...

Page 107: ...FRONT FORK 4 25 1 ...

Page 108: ...e Damage pitting Replace 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 Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing ra...

Page 109: ...steering 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 23 5 Check the steering stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten th...

Page 110: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 20 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 l...

Page 111: ... 1 TIP While removing the rear shock absorber assem bly lower bolt hold the swingarm so that it does not drop down 3 Remove Rear shock absorber assembly upper bolt Rear shock absorber assembly EAM30067 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Gas leaks oil leaks Replace the rear shock absorbe...

Page 112: ...l movement a Measure the tightening torque of the pivot shaft nut b Check the swingarm side play a by mov ing the swingarm from side to side If the swingarm has side to side play check the bushings the bearings and the collars c Check the swingarm vertical movement b by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the bushings the bearing...

Page 113: ...nner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and re move any remaining dirt c Remove...

Page 114: ...ROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 4 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the master link with the drive chain cut rivet tool Use goods on the market a When press fitting the master link plate 1 make sure the space a between the end of the connecting pin 2 and the m...

Page 115: ... dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 22 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubricant Chain lubricant suitable...

Page 116: ...CHAIN DRIVE 4 34 ...

Page 117: ...HE FRICTION PLATES 5 3 CHECKING THE CLUTCH PLATES 5 3 CHECKING THE CLUTCH SPRINGS 5 3 CHECKING THE CLUTCH HOUSING 5 3 CHECKING THE CLUTCH BOSS 5 4 CHECKING THE PRESSURE PLATE 5 4 CHECKING THE PUSH LEVER SHAFT 5 4 CHECKING THE PUSH RODS 5 4 CHECKING THE PRIMARY DRIVE GEAR 5 4 CHECKING THE PRIMARY DRIVEN GEAR 5 4 INSTALLING THE CLUTCH 5 5 ...

Page 118: ...silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2 3 Install Clamp Silencer 1 Bolt silencer 2 TIP Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp 1 TIP Tighten while checking that their front and rear Nut exhaust pipe 1 10 N m 1 0 kgf m 7 4 lb ft New T R 2 2 ...

Page 119: ...at 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 in the exhaust pipe or silencer A Exhaust pipe 1 and exhaust pipe 2 B Exhaust pipe 2 and silencer 2 1 a b a b A 3 1 B ...

Page 120: ...warpage with a surface plate and thickness gauge Out of specification 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 specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the cl...

Page 121: ...M30484 CHECKING THE PUSH RODS 1 Check Push rod 1 1 Bearing Washer 2 Push rod 2 3 Ball 4 Cracks damage wear Replace 2 Measure Push rod 2 bending limit Out of specification 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 primary drive and primary driven gea...

Page 122: ...1 Thrust washer 2 Clutch boss 3 Washer 4 TIP Apply the engine oil on the primary driven gear inner circumference 5 Install Conical washer 1 Clutch boss nut 2 NOTICE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away from the vehi cle Apply engine oil to the...

Page 123: ...tion plate 2 identification 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 TIP Apply the engine oil on the bearing washer and push rod 1 8 Install Push rod 2 1 Ball 2 Push rod 1 3 TIP Apply the engine oil on the push rod 1 2 and ball 9 Install Pressure plate 1...

Page 124: ...t TIP Tighten the bolts 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 4 lb ft Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft 1 a a b b T R New 1 T R ...

Page 125: ...1 2 3 4 5 6 7 8 9 10 FUEL SYSTEM FUEL TANK 6 1 REMOVING THE FUEL TANK 6 1 INSTALLING THE FUEL TANK 6 1 ...

Page 126: ... 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 area under where it will be removed To prevent sand dust and other foreign mate rials from entering the fuel pump install the in cluded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnected fuel hose and the fuel pump 3 Remove Side cover left righ...

Page 127: ...FUEL TANK 6 2 3 Connect Fuel pump coupler 4 Install Air scoop left right Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 1 a ...

Page 128: ...FUEL TANK 6 3 ...

Page 129: ...1 2 3 4 5 6 7 8 9 10 ELECTRICAL SYSTEM FUEL INJECTION SYSTEM 7 1 ECU SELF DIAGNOSTIC FUNCTION 7 1 ELECTRICAL COMPONENTS 7 3 CHECKING THE FUSES 7 3 CHECKING AND CHARGING THE BATTERY 7 3 ...

Page 130: ...ning light indication 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 warning light The engine trouble warning light comes on for around 2 seconds when pushing the start switch to turn on the engine trouble warning light comes on while the start switch is bein...

Page 131: ...ng light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the condit...

Page 132: ... BATTERY WARNING EWA20430 To avoid sparking burns fire and explo sion Charge battery only with specified charger Use battery only for specified product no other use Do not place near fire or immerse in water Do not use battery if it has been dropped subject to impact or visibly damaged Do not disassemble or modify the battery or short across its terminals NOTICE ECA26041 To prevent damage to the b...

Page 133: ...sconnect the negative battery lead and then the positive battery lead 3 Remove Battery 4 Connect the battery charger special tool to the battery TIP For instructions on charging and handling the battery charger refer to the battery charger s instruction manual Once battery charging starts the sleep mode is canceled 5 Charge the battery until it is fully charged 6 Install Battery terminal 7 Connect...

Page 134: ... tempera ture e Measure the voltage between the termi nals of the battery 13 25 V or more The battery is normal Checking is finished 10 V or more and less than 13 25 V Perform from step c again Less than 10 V Replace the battery TIP Before replacing the battery make sure that the battery temperature is proper temperature not more than 65 C 149 F or less than 0 C 32 F Otherwise wait until the batte...

Page 135: ...LESHOOTING OF TRANSMISSION 8 6 TROUBLESHOOTING OF COOLING SYSTEM 8 7 TROUBLESHOOTING OF BRAKE 8 8 TROUBLESHOOTING OF SUSPENSION 8 8 TROUBLESHOOTING OF STEERING HANDLING 8 10 TROUBLESHOOTING OF CHARGING SYSTEM 8 11 TROUBLESHOOTING OF SIGNALING SYSTEM 8 11 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8 12 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 8 12 ...

Page 136: ...Engine will not start or is difficult to start but it cranks Symptom Possible cause Actions Starter motor does not operate Have a Yamaha dealer check the electrical system 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 Stuck piston or seized crankshaft Disassemble...

Page 137: ...ng Replace 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 Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plug Defective spark plug cap Repla...

Page 138: ...torque Clogged air filter element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from around cylinder head Incorrect valve clearance too wide Adjust the valve clearance Fatigued or broken valve spring Replace the valve spring Worn or damaged camshaft lobe Replace the camshaft Worn or damaged v...

Page 139: ...ive 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 journal bearing Worn or damaged balancer shaft journal bearing Replace the balancer shaft journal bearing Symptom Possible cause Actions Clutch slippage Improperly assembled clutch Reassemble the clutch I...

Page 140: ... 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 Incorrect oil viscosity high Change to recommended engine oil Deteriorated oil Change to recommended engine oil Clutch noise Damaged or worn primary driven gear Replace the primary drive gear or cranksh...

Page 141: ...transmis 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 axle assembly Jumps out of gear Incorrect shift pedal position Adjust the shift pedal position Improperly returned stopper lever Replace the stopper lever spring Bent or worn shift fork Replace the s...

Page 142: ...Repair 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 and pipes properly Damaged throttle body joint Replace the throttle body joint Loose throttle body joint Tighten the throttle body joint bolts to the specified torque Clogged air filter element Clea...

Page 143: ... 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 pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 144: ...per 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 cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft D...

Page 145: ...ied 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 tire pressure Adjust to the specified tire pres sure Worn deformed or incorrect tire Replace the tire Heavy steering Lower ring nut is tightened too tight Tighten the lower ring nut to the specified tor...

Page 146: ...he wheel axle 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 ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Have a Yamaha dealer check the electrical system Symptom Possible cause Actions I...

Page 147: ...sor stuck throttle position sensor is detected 21 Coolant temperature sensor open or short circuit detected 22 Intake air temperature sensor open or short circuit detected 30 The vehicle has overturned 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 39 Injector open or short circuit detected 41 ECU built in lean angle sensor malfunction 43 Fuel system volta...

Page 148: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8 13 ...

Page 149: ...RE 9 1 FRONT FORK SETTING 9 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 9 2 SETTING OF SPRING AFTER REPLACEMENT 9 2 FRONT FORK SETTING PARTS 9 3 REAR SUSPENSION SETTING 9 3 CHOOSING SET LENGTH 9 3 SETTING OF SPRING AFTER REPLACEMENT 9 4 REAR SHOCK ABSORBER SETTING PARTS 9 5 SUSPENSION SETTING FRONT FORK 9 6 SUSPENSION SETTING REAR SHOCK ABSORBER 9 7 ...

Page 150: ...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 Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30170 TI...

Page 151: ...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 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front fo...

Page 152: ...et length of the spring Change the spring 2 Setting of damping force Change the rebound damping force Change the compression damping force EAM30176 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a r...

Page 153: ...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 two clicks turned out and readjust it to suit your preference 2 Use of stiff spring Adjust to increase rebound damping force to compensate for greater spring load Run with the rebound damping force adjuster one or two clicks turned in and readju...

Page 154: ... D mark SOFT 50 B3J 22212 00 Blue Green B3J 22212 10 Black 52 BR9 22212 00 Blue Yellow BR9 22212 50 Black 54 BR9 22212 10 Blue Pink BR9 22212 60 Black 56 BR9 22212 20 Blue White BR9 22212 70 Black 58 BR9 22212 30 Blue Silver BR9 22212 80 Black 60 BR9 22212 40 Blue Brown STIFF BR9 22212 90 Black 1 a Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in ...

Page 155: ...oticeable 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 specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomin...

Page 156: ...ount 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 Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0 ...

Page 157: ...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 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft ...

Page 158: ...CHASSIS 9 9 ...

Page 159: ...elay 29 Intake air temperature sensor 30 Coolant temperature sensor 31 Throttle position sensor 32 Intake air pressure sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch 36 Start switch 37 Diode 3 A Battery sub lead B Wire harness C Ignition coil sub lead D CCU sub lead EAM30323 COLOR CODE B Black Br Brown Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Y...

Page 160: ......

Page 161: ...erformance and durability you have come to expect Why settle for aftermarket parts that may not provide full confidence and satisfaction Genuine Yamaha Accessories Yamaha only offers accessories that meet our high standards for quality and performance 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 ...

Page 162: ... 28199 11 LIT 11626 34 55 Read this manual carefully before operating this vehicle YZ250FXM OWNER S MANUAL YZ250FX 2021 PRINTED IN JAPAN 2020 08 0 5 1 E BAJ 28199 11_cover_4mm indd 1 3 2020 08 03 17 22 12 ...

Page 163: ...YZ250FXM 2021 WIRING DIAGRAM BAJ 2819U 11_WD indd 1 2020 06 29 15 46 05 ...

Page 164: ...YZ250FXM 2021 WIRING DIAGRAM BAJ 2819U 11_WD indd 2 2020 06 29 15 46 06 ...

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Yamaha YZ250FX 2021, Owner'S Manual

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