Yamaha YZ250FX 2021, Owner'S Service Manual

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CABLE ROUTING DIAGRAM
2-18
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Cable holder
5. Warning light lead
6. Intake air temperature sensor coupler (black)
7. Rectifier/regulator coupler
8. Stator coil assembly lead
9. Battery band
10.CCU (Communication Control Unit)
11.Starter relay diode
12.Radiator fan motor fuse
13.Engine mounting bracket boss
14.Starter motor lead
15.Gear position switch lead
16.Lower engine bracket
17.Protector (clutch cable)
18.Radiator hose
19.Gear position switch coupler
20.Stator coil assembly coupler
21.Tension arm
22.Rectifier/regulator lead
23.Wire harness
24.Yamaha diagnostic tool coupler
25.Tank rail
26.Mode switch lead
27.Radiator
28.Radiator breather hose
29.Rectifier/regulator
30.Crankcase cover
31.Crankcase
32.Clamp
33.Frame
34.Plate
35.Warning light coupler
36.Cylinder head breather hose
37.Clamp
A. Pass the engine stop switch lead and the
mode switch lead between the frame and the
cable holder. Pass the mode switch lead
above the engine stop switch lead.
B. Insert the Yamaha diagnostic tool coupler into
the connector, and fix it to the bracket.
C. Fasten the engine stop switch coupler to the
bracket of the inside. Fasten the mode switch
coupler to the bracket of the outside. Route
the mode switch lead under the bracket.
D. Pass the warning light lead over the wire har-
ness and radiator hose.
E. Fasten the warning light coupler to the
bracket.
F. Fasten the rectifier/regulator coupler to the
bracket. Attach the coupler cover.
G. Pass the stator coil assembly lead through
back side of the radiator. No pinch is allowed
between the radiator and tension arm.
H. Insert the clip portion of the clamp of the
starter motor lead into the hole in the cylinder
head. When doing so, make sure that the
lead is not twisted.
I. Route the starter motor lead through the
inside of the engine mounting bracket boss
and the front side area than the back end of
the engine mounting bracket boss.
J. Route the gear position switch lead along the
crankcase without slack.
K. Pass the gear position switch lead to the
inside of the lower engine bracket (the side of
the vehicle).
L. Pass the clutch cable with no downward sag
allowed.
M. Bring the protector of the clutch cable into
contact with the radiator hose, and pass it to
the outside of the neutral switch lead and the
stator coil assembly lead (the outside of the
vehicle).
N. No pinch is allowed the leads between the
radiator hose and the tension arm.
O. After connecting the gear position switch cou-
pler, attach the coupler cover.
P. After connecting the stator coil assembly cou-
pler, attach the coupler cover.
Q. Pass the rectifier/regulator lead (wire harness
side) to the inside of the tension arm (the side
of the vehicle).
R. Pass the main harness to the front of the radi-
ator hose (the front of the vehicle), and to the
inside of the throttle cable (the side of the
vehicle).
S. Pass the engine stop switch lead between the
Yamaha diagnostic tool coupler and the tank
rail.
T. Pass the warning light lead under the mode
switch lead.
U. Clamp the clutch cable at the front of the lead
(the front of the vehicle).
V. Insert the clamp into the hole in the frame.
Cut off the excess end of the locking portion,
and the locking portion should face toward
the front of the vehicle.
W. Diagram for routing the radiator hose and
radiator breather hose.
X. Route the radiator breather hose between the
radiator hose and the cylinder head breather
hose. Then route it between the down tubes.
Y. Route the cylinder head breather hose
between the radiator and the frame, and in
front of the lower boss of the radiator.