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SPECIAL TOOLS

1-14

EAM20121

SPECIAL TOOLS

The following special tools are required for accurate and complete adjustment and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and tool number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.

TIP

•

For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.

•

For others, use tool number starting with “90890-”.

Tool name/Tool No.

Illustration

Reference

pages

Digital circuit tester (CD732)

90890-03243

Model 88 Multimeter with tachometer

YU-A1927

1-13, 5-45, 8-58,

8-59, 8-59, 8-59,

8-62, 8-64, 8-65,

8-66, 8-66, 8-66,

8-67, 8-67, 8-68,

8-69, 8-69, 8-70,

8-70, 8-71, 8-71

Thickness gauge

90890-03268

Feeler gauge set

YU-26900-9

3-7, 4-11, 5-50

Valve lapper (ø14)

90890-04101

Valve lapper (ø14)

YM-A8998

Yamaha diagnostic tool USB (US)

90890-03269

3-12, 7-8, 8-31

Yamaha diagnostic tool (A/I)

90890-03264

3-12, 7-8, 8-31

FI diagnostic tool sub–lead

90890-03212

FI diagnostic tool sub–lead

YU-03212

3-12, 7-8, 8-32

90890-04101

YM-A8998

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Содержание WR250F 2022

Страница 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL WR250F WR250FN1 LIT 11626 35 42 BAK 2819U 12...

Страница 2: ...cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wea...

Страница 3: ...ANUAL 2022 by Yamaha Motor Corporation U S A First edition July 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Страница 4: ...manual is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill conce...

Страница 5: ...EAM20093 YAMAHA MOTOR CORPORATION U S A WR MOTORCYCLE LIMITED WARRANTY...

Страница 6: ...teps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassemb...

Страница 7: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Страница 8: ......

Страница 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS...

Страница 10: ......

Страница 11: ...ECTING OPTIONAL PART 1 7 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS...

Страница 12: ...HANDLING NOTE 1 32 STARTING A COLD ENGINE 1 32 STARTING A WARM ENGINE 1 33 BREAK IN PROCEDURES 1 33 SHIFTING 1 33 MAINTENANCE AFTER BREAK IN 1 35 MAJOR MAINTENANCE 1 35 AIR FILTER MAINTENANCE 1 35 TOR...

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

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

Страница 15: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Страница 16: ...BELS Please read the following important labels carefully before operating this vehicle 3 2 1 4 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read...

Страница 17: ...20 19 16 15 14 13 17 2 3 4 1 5 10 12 11 9 8 7 6 18 1 Clutch lever 2 Multi function display 3 Engine trouble warning light 4 Fuel level warning light 5 Front brake lever 6 Throttle grip 7 Start switch...

Страница 18: ...dentify 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...

Страница 19: ...other foreign materials from entering the inside when the fuel hose is discon nected EAM30008 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the op tional Power Tuner and so...

Страница 20: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Страница 21: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Страница 22: ...y dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct ba...

Страница 23: ...ti function display goes off Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes...

Страница 24: ...th sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with compressed air Rust stains Connect and disconnect sev eral times 3 Check All...

Страница 25: ...f there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732...

Страница 26: ...ing with YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A192...

Страница 27: ...3 27 4 57 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 33 Timing light 90890 03141 Timing light YU 03141 3 35 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501...

Страница 28: ...M 04108 5 26 5 30 Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 28 Valve guide installer 5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 28 Valve guide reamer 5 90890 0...

Страница 29: ...ler YU 01304 5 33 Rotor puller 90890 04151 Rotor puller YM 04151 5 38 Sheave holder 90890 01903 Primary clutch holder YS 01880 A 5 41 5 42 Clutch holder 90890 04199 Universal clutch holder YM 91042 5...

Страница 30: ...0890 01275 Bolt YU 90060 5 71 Adapter M12 90890 01278 Adapter 3 YU 90063 5 71 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 71 Radiator cap tester 90890 01325 Mityvac cooling system te...

Страница 31: ...adapter 90890 03186 Fuel pressure adapter YM 03186 7 8 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 65 Test harness speed sensor 5TJ 3P 90890 03228 Test harness speed sensor 5...

Страница 32: ...The electrical 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 initial...

Страница 33: ...is supplied by the starter knob 1 Pushing the knob toward a turns ON the start er resulting in a larger angle of throttle valve TIP When operating the throttle grip in the closing di rection the star...

Страница 34: ...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 w...

Страница 35: ...button to change the meter dis play The display will change in the following order ODO TRIP A TRIP B Clock Timer Accumulated fuel consumption ODO TIP To reset the digits select the meter involved and...

Страница 36: ...o perform a new mea surement long push the A button for 1 second or more to reset the timer Manual start 1 Push the A button and B button simultane ously to start the timer measurement 2 Push the A bu...

Страница 37: ...sumption correction Setting the tire di ameter correction Setting the backlight brightness TIP If one of the following situations occurs while performing the setting mode the setting value that is dis...

Страница 38: ...IP The digits capable of setting go on flashing 2 Push the A button to set the minute The set ting of the time will then be kept and the dis play of the multifunction meter will shift to the unit disp...

Страница 39: ...If the outer diameter of a tire varies with tire wear or tire pressure it can be corrected in the follow ing manner TIP The initial value is preset with approximately 700 mm 27 56 in as 100 If the out...

Страница 40: ...MULTI FUNCTION DISPLAY 1 28 TIP When terminating the setting mode long push the engine stop switch to turn off the display and terminate the setting mode...

Страница 41: ...MULTI FUNCTION DISPLAY 1 29...

Страница 42: ...Measurement starts as the machine moves A button B button Timer in operation Timer not in operation Reset timer A button B button A short push on the button changes the operation in the arrowed direct...

Страница 43: ...er 7 Accumulated fuel consumption 8 Speedometer 9 Speed 10 SETTING MODE 11 Setting the backlight brightness 12 Setting the clock time hour 13 Setting the clock time minute 14 Setting the unit 15 Setti...

Страница 44: ...The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throttle is open the a...

Страница 45: ...left idling for 7 minutes If the engine stops push the start switch to restart the engine 2 Make a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about...

Страница 46: ...ansmission into second gear Make sure not to shift the transmission into the neutral position 6 Open the throttle part way and gradually re lease the clutch lever 7 Follow the same procedure when shif...

Страница 47: ...and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the brac...

Страница 48: ...frame 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 Tighten...

Страница 49: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Страница 50: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Страница 51: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Страница 52: ...k plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate...

Страница 53: ...TIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSI...

Страница 54: ...lbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 115 kg 254 lb Riding capacity 1 person Shift up points 1st 2nd 20 km h 12 mph 2nd 3rd 30 km h 19 mph 3rd 4th 40 km h 25 mph 4t...

Страница 55: ...Oil change 0 73 L 0 77 US qt 0 64 Imp qt With oil filter removal 0 75 L 0 79 US qt 0 66 Imp qt Quantity disassembled 0 95 L 1 00 US qt 0 84 Imp qt Oil filter Oil filter type Cartridge Cooling system...

Страница 56: ...0319 in Wear limit 77 060 mm 3 0339 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Diameter 76 955 76 970 mm 3 0297 3 0303 in Measuring point from piston skirt bottom 4 0 mm 0...

Страница 57: ...in Secondary reduction ratio 3 923 51 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Fuel pump Pum...

Страница 58: ...pressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runou...

Страница 59: ...from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock a...

Страница 60: ...nt Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 11 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Nu...

Страница 61: ...HR Headlight Bulb type Halogen bulb Bulb wattage Headlight HS1 35 0 W 35 0 W Brake tail light LED Meter lighting EL Electroluminescent Indicator light Fuel level warning light LED Engine trouble warn...

Страница 62: ...ELECTRICAL SPECIFICATIONS 2 9 Radiator fan motor fuse 5 0 A Spare fuse 15 0 A...

Страница 63: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Страница 64: ...3 8 kgf m 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...

Страница 65: ...sing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left sid...

Страница 66: ...oth sides of the lock washers Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stat...

Страница 67: ...rk protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Speed sensor bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Plate bolt M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Throttle grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft...

Страница 68: ...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 nut front side M10 1 55 N m 5 5 kgf m...

Страница 69: ...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...

Страница 70: ...CABLE ROUTING DIAGRAM 2 17 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view...

Страница 71: ...ack end of the engine mounting bracket boss I Route the gear position switch lead along the crankcase without slack J Pass the gear position switch lead to the inside of the lower engine bracket the s...

Страница 72: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view...

Страница 73: ...the radiator G When installing the engine ground lead termi nal it can face either way Make sure that the terminal does not contact the cylinder head bolt and that it faces to the rear beyond the cyli...

Страница 74: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view...

Страница 75: ...the end of the plastic locking tie to the right side of the vehi cle The excess should be cut D Connect the headlight lead to the headlight E After fastening the speed sensor lead route it as U lette...

Страница 76: ...CABLE ROUTING DIAGRAM 2 23 Frame and engine top view...

Страница 77: ...bolts is accepted E Right side of the vehicle F 10 G Install the plug cap so that it faces to the right side of the vehicle H Install the collar with its flange facing to the head of the bolt I Insert...

Страница 78: ...CABLE ROUTING DIAGRAM 2 25 Frame and battery top view...

Страница 79: ...gative battery lead with their battery sides downward C No slack in this section D No slack to the rear side of the vehicle E Absorb the slack in this section F Connect the positive battery lead and s...

Страница 80: ...CABLE ROUTING DIAGRAM 2 27 Rear brake right side view...

Страница 81: ...e hose holders C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that...

Страница 82: ...CABLE ROUTING DIAGRAM 2 29 Front brake front view and right side view...

Страница 83: ...speed sensor lead B Clamp securely the speed sensor lead to the hook of the protector C Install the front brake hose with its paint aligning with the upper end of the clamp The circumference direction...

Страница 84: ...CABLE ROUTING DIAGRAM 2 31 Taillight top view and right side view...

Страница 85: ...CABLE ROUTING DIAGRAM 2 32 1 Taillight lead 2 Clamp 3 Taillight A Pass the taillight lead to the groove of the rear fender B There should be no slack of the taillight lead...

Страница 86: ...CABLE ROUTING DIAGRAM 2 33...

Страница 87: ...G THE FUEL LINE 3 18 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 18 CHECKING THE EXHAUST SYSTEM 3 19 CHECKING THE COOLANT LEVEL 3 20 CHECKING THE COOLING SYSTEM 3 21 CHANGING THE COOLANT 3 21 CHASSIS 3...

Страница 88: ...G THE CHASSIS FASTENERS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE BRAKE LEVER 3 34 LUBRICATING THE CLUTCH LEVER 3 34 LUBRICATING THE PEDAL 3 34 CHECKING THE SIDESTAND 3 34 LUBRICAT...

Страница 89: ...l Odometer readings 600 mi 1000 km or 1 month 1800 mi 3000 km or 3 months 3000 mi 5000 km or 6 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check conditio...

Страница 90: ...Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every ride 12 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease ever...

Страница 91: ...runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data a...

Страница 92: ...vel and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses 22 Outside nuts and bolts Retighten 23 Air filter Clean and lubricate Replace 24 Oil filter Replace 25 Engine...

Страница 93: ...Swingarm Inspect lube and retighten 37 Relay arm connect ing rod Inspect lube and retighten 38 Sidestand Lubricate 39 Steering head Inspect free play and retighten Clean and lubricate Replace bearing...

Страница 94: ...23 3 23 3 24 3 24 3 24 3 24 3 25 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 26 4 70 4 70 4 71 4 71 4 71 Wheels Check for excessive wear and...

Страница 95: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFT on page 5 13 3 Remove Timing...

Страница 96: ...roper valve clearance from the adjusting pad se lection table TIP There are 25 types of adjusting pads ranging from 1 20 mm 0 0472 in to 2 40 mm 0 0945 in in increments of 0 05 mm 0 0020 in The field...

Страница 97: ...ir numbers facing upward f Install the camshafts exhaust and intake Refer to CAMSHAFT on page 5 13 g Measure the valve clearance again h If the valve clearance is out of specifica tion repeat adjustin...

Страница 98: ...80 185 190 195 200 205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195...

Страница 99: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Страница 100: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Страница 101: ...Remove Holder Spark plug cap Spark plug Refer to CAMSHAFT on page 5 13 NOTICE ECA24410 In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylind...

Страница 102: ...l to enter the crankcase EAM30225 CHANGING THE ENGINE OIL Stand the vehicle upright on a level surface 1 Start the engine warm this up for several minutes and then stop the engine and wait about 5 min...

Страница 103: ...a Slightly loosen the oil pressure check bolt 1 WARNING EWA19120 When the engine is started with the check bolt removed oil will spout therefore al ways loosen it before the checkup b Start the engine...

Страница 104: ...clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return...

Страница 105: ...hat the element is evenly permeated with the oil c Wrap the element in a clean cloth rub the element gently and wipe off any excess oil TIP The element should be permeated with oil so that it is wet b...

Страница 106: ...tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1 Check Throttle body joint 1 Crack damage Replace EAM30222 CHECKING THE FUEL LINE 1 Remove Seat Side cover left right Air scoop left right Ref...

Страница 107: ...bolts 2 c Remove the tail pipe 3 tail pipe gasket 4 and spark arrester 5 TIP Pull the spark arrester out of the muffler d Remove the spark arrester gasket 6 e Clean the spark arrester TIP Tap the spar...

Страница 108: ...wly 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...

Страница 109: ...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 s...

Страница 110: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is...

Страница 111: ...STING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting nut 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft...

Страница 112: ...f the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 16 EAM30232 CHECKING TH...

Страница 113: ...er the brake system considerably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the t...

Страница 114: ...ve chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive chain slack a Out of specification Regulate TIP Measure drive chain slack between the drive chain guide and the...

Страница 115: ...falling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 37...

Страница 116: ...ork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times...

Страница 117: ...just 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...

Страница 118: ...ion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct...

Страница 119: ...necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Tur...

Страница 120: ...licks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGA...

Страница 121: ...ll sound flat 2 Tighten Spoke with a spoke nipple wrench 1 TIP Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in...

Страница 122: ...LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and...

Страница 123: ...eft crankcase cover is within the firing range b on the generator rotor Incorrect firing range Check generator ro tor and crankshaft position sensor 5 Install Timing mark accessing screw EAM30339 REPL...

Страница 124: ...he head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly c...

Страница 125: ...ISC 4 20 REPLACING THE FRONT BRAKE PADS 4 20 REMOVING THE FRONT BRAKE CALIPER 4 22 DISASSEMBLING THE FRONT BRAKE CALIPER 4 22 CHECKING THE FRONT BRAKE CALIPER 4 22 ASSEMBLING THE FRONT BRAKE CALIPER 4...

Страница 126: ...NG THE STEERING HEAD 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE RE...

Страница 127: ...arks 1 Seat 1 2 Side cover left 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery band 1 6 Battery 1 7 Cover 1 8 Starter relay 1 9 Main relay 1 10 Radiator fan moto...

Страница 128: ...er case cover 1 Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 2 Air scoop left 1 3 Air scoop right 1 4 Side cover right 1 5 Rear fender 1 5 4 1 3 2 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m...

Страница 129: ...ht coupler 1 Disconnect 3 Headlight unit 1 4 Speed sensor coupler 1 Disconnect 5 Multi function meter coupler 1 Disconnect 6 Multi function meter 1 7 Meter bracket 1 4 2 6 7 5 1 3 2 3 8 N m 0 38 kgf m...

Страница 130: ...n serting the grooves c into the ribs d of the air filter case and inserting the projection e into the slot f in the air filter case install the air scoop and secure it with the bolts EAM30459 REMOVIN...

Страница 131: ...GENERAL CHASSIS 4 5 a Projection b Slot c Rib side cover d Rib rear fender a a a 1 1 c c b b d d...

Страница 132: ...ge 4 45 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Speed sensor bracket 1 5 Speed sensor 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 10 Brake disc...

Страница 133: ...attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the speed sensor Do not drop or shock the speed sensor or t...

Страница 134: ...P After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout a Lateral wheel runout b Out of specification Repair replace 6 Check Collar Damage wear Replace 7 Check Bearing Fro...

Страница 135: ...or numbers facing outward NOTICE ECA24420 Install the bearing by pressing its outer race parallel TIP Use a socket 5 that matches the diameter of the bearing outer race and that of the oil seal 4 Inst...

Страница 136: ...eel sensor lead for twists 3 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 4 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front whe...

Страница 137: ...If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front...

Страница 138: ...round 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 9 LS LS 6 4 6 1 6...

Страница 139: ...2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 33 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 33 4 Measu...

Страница 140: ...umbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 6 that matches the diameter of the bearing outer race and that of the oil seal 2 Install...

Страница 141: ...the lithium soap based grease to the rear wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive ch...

Страница 142: ...ge 3 25 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket...

Страница 143: ...BRAKE 4 17 Disassembling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 2 2 Brake caliper piston seal kit 2 3 Bleed screw 1 1 2 3 S S 2 5 N m 0 5 kgf m 3 7 l...

Страница 144: ...on bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylind...

Страница 145: ...FRONT BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New...

Страница 146: ...inutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a...

Страница 147: ...euse the drained brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tigh...

Страница 148: ...er piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and th...

Страница 149: ...aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids...

Страница 150: ...r 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder r...

Страница 151: ...e master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer Brake hose Union bolt WARNING EWA13531 Proper brake hose routing is essenti...

Страница 152: ...ter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts T...

Страница 153: ...6 Brake pad pin 1 7 Rear brake pad assembly 1 8 Brake pad shim left 1 9 Brake pad shim right 1 10 Brake pad shim heat insulator 2 11 Brake pad shim bracket 1 12 Rear brake caliper bracket 1 13 Brake p...

Страница 154: ...AR BRAKE 4 28 Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 1 2 Brake caliper piston seal kit 1 3 Bleed screw 1 3 5 N m 0 5 kgf m 3 7 lb ft 1 2...

Страница 155: ...age 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cyl...

Страница 156: ...REAR BRAKE 4 30 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1...

Страница 157: ...ush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc...

Страница 158: ...l the brake pads 3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 a...

Страница 159: ...iper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and...

Страница 160: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brak...

Страница 161: ...eplace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use s...

Страница 162: ...r seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction l...

Страница 163: ...7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect 9 Right grip 1 10 Tube guide 1 11 Start switch 1 12 Left grip 1 13 Upper handlebar holder 2 14 Handlebar 1 15 Lower handlebar ho...

Страница 164: ...M30054 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower hand...

Страница 165: ...3 Tighten Lower handlebar holder nut 4 Install Clutch lever holder 1 Clutch lever 2 Clutch switch 3 TIP The clutch lever holder 1 should be installed according to the dimensions shown 5 Install Engine...

Страница 166: ...es straight upward 7 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 8 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE...

Страница 167: ...le grip 3 moves smoothly If it does not retighten the screws for adjustment 13 Install Rubber cover 1 Cover throttle cable housing 2 14 Install Start switch 1 Front brake master cylinder assembly 2 Fr...

Страница 168: ...HANDLEBAR 4 42 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 12 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 2 5 1 4 3 4...

Страница 169: ...Front brake caliper Refer to FRONT BRAKE on page 4 16 Headlight Refer to GENERAL CHASSIS on page 4 1 1 Protector 2 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch...

Страница 170: ...1 7 Inner tube 1 8 Outer tube 1 9 Piston metal 1 10 Protector guide 1 11 Slide metal 1 12 Washer 1 13 Oil seal 1 14 Base valve 1 15 Damper assembly 1 16 Upper spring seat 1 LS 15 2 8 10 12 13 5 4 1 7...

Страница 171: ...t 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 t...

Страница 172: ...erously 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 R...

Страница 173: ...er 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...

Страница 174: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper...

Страница 175: ...e 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 Tig...

Страница 176: ...ct 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 T...

Страница 177: ...t the steps 14 to 20 22 Measure Distance a Out of specification Turn the locknut to specification 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring sea...

Страница 178: ...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...

Страница 179: ...ghten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the lower bracket pinch bolts Do not tighten the upper bra...

Страница 180: ...fork protector 6 Install Protector 1 Bolt protector 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Cap bolt ring wre...

Страница 181: ...FRONT FORK 4 55 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1 1...

Страница 182: ...4 1 Handlebar Refer to HANDLEBAR on page 4 37 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 43 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Be...

Страница 183: ...ace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c...

Страница 184: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 27 5 Check the steering...

Страница 185: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Страница 186: ...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 assembly upper bolt 1 3 Rear shoc...

Страница 187: ...assembly Order Job Parts to remove Q ty Remarks 11 Bushing 1 12 Bearing 1 13 Collar 2 14 O ring 2 15 Dust seal 2 16 Bushing 1 17 Stopper ring 1 M 56 N m 5 6 kgf m 41 lb ft 53 N m 5 3 kgf m 39 lb ft M...

Страница 188: ...Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 6 6 5 3 2 4 6 6 3 4 4 M M M M M...

Страница 189: ...er be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a...

Страница 190: ...asher 2 Oil seal 3 into the relay arm 4 Collar 5 3 Install Bearing 1 Oil seal 2 into the connecting arm 3 Collar 4 EAM30070 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Bearing lower side D...

Страница 191: ...IP When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly upper bolt and connecting arm bolt frame side from the right Install the rear shock a...

Страница 192: ...heel off the ground Brake hose holder Refer to REAR BRAKE on page 4 27 Rear brake caliper Refer to REAR BRAKE on page 4 27 Brake pedal bolt Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bus...

Страница 193: ...Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft B...

Страница 194: ...SWINGARM 4 68 4 Install Rear wheel Refer to REAR WHEEL on page 4 12 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 Drive chain slack Maintenance Stand 50 0 60 0 mm 1 97 2 36 in...

Страница 195: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 6 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1...

Страница 196: ...ength b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Ch...

Страница 197: ...OCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 13 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP...

Страница 198: ...rockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 26 NOTICE ECA24590 A drive chain that is too tight will overload the engin...

Страница 199: ...5 20 REMOVING THE CYLINDER HEAD 5 22 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVE...

Страница 200: ...HE PRIMARY DRIVE GEAR 5 51 CHECKING THE PRIMARY DRIVEN GEAR 5 51 INSTALLING THE CLUTCH 5 51 SHIFT SHAFT 5 55 REMOVING THE SEGMENT 5 56 CHECKING THE SHIFT SHAFT 5 56 CHECKING THE STOPPER LEVER 5 56 INS...

Страница 201: ...CHECKING THE SHIFT DRUM ASSEMBLY 5 73 CHECKING THE TRANSMISSION 5 73 INSTALLING THE TRANSMISSION 5 74...

Страница 202: ...M20185 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30526 ENGINE OIL LUBRICATION CHART 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil filter element 5 Oil nozzle 6 Relief valve 7 Oil pump 8 Oil strai...

Страница 203: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAM30507 LUBRICATION DIAGRAMS 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Страница 204: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 1 Oil filter element 2 Oil pump...

Страница 205: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 Intake camshaft 2 Exhaust camshaft...

Страница 206: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 5 1 Camshaft 2 Oil pressure check bolt 3 Oil pump 4 Oil filter element...

Страница 207: ...R SHOCK ABSORBER ASSEMBLY on page 4 60 1 Silencer clamp 1 Loosen 2 Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gasket 3 7 Exhaust pipe 1 protector 1 8 Silencer c...

Страница 208: ...EL TANK on page 7 1 Air filter case cover Refer to CLEANING THE AIR FILTER ELE MENT on page 3 16 Intake air temperature sensor coupler Refer to THROTTLE BODY on page 7 4 ECU Engine Control Unit Refer...

Страница 209: ...on page 7 4 Throttle body Refer to THROTTLE BODY on page 7 4 Clutch cable Refer to CLUTCH on page 5 47 Shift pedal Drive chain Refer to SHIFT SHAFT on page 5 55 Refer to CHAIN DRIVE on page 4 69 1 En...

Страница 210: ...2 11 Lower engine bracket inside 2 12 Pivot shaft 1 13 Engine 1 8 9 11 12 13 10 10 11 7 N m 0 7 kgf m 5 2 lb ft 34 N m 3 4 kgf m 25 lb ft 85 N m 8 5 kgf m 63 lb ft 75 N m 7 5 kgf m 55 lb ft 34 N m 3 4...

Страница 211: ...ve this from its low er part toward the right of the chassis EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 from the right side Pivot shaft 2 Engine mounting bolt lower side 3 Lower engine bracket...

Страница 212: ...kgf m 7 4 lb ft 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust...

Страница 213: ...and rear joints are inserted in position Make sure that the exhaust pipe clamp 1 does not ride on the projection a on the ex haust pipe 2 or silencer 3 Be sure to insert the projection b into the slot...

Страница 214: ...left right Refer to GENERAL CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Ignition coil Refer to ENGINE REMOVAL on page 5 6 1...

Страница 215: ...crew 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 LS 5 8 3 4 1 2 7 6 5 4 4 6 M M E E E 6 N m 0 6 kgf m 4 4 lb ft...

Страница 216: ...ith the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap in a c...

Страница 217: ...p bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance d Remove the camshaft caps and then mea sure the wid...

Страница 218: ...oner rod lightly with your fingers use a thin screwdriver 1 to wind the tensioner rod up fully clock wise b When releasing the screwdriver by press ing lightly with your fingers make sure that the ten...

Страница 219: ...rankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips the camshaft caps and the bolts camshaft cap TIP Before installing the clips cover the cylin...

Страница 220: ...mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cylinder head co...

Страница 221: ...EL TANK on page 7 1 Exhaust pipe Silencer Refer to ENGINE REMOVAL on page 5 6 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 4 Ca...

Страница 222: ...er head Order Job Parts to remove Q ty Remarks 6 Timing chain guide intake side 1 7 Oil passage plug 1 M 1st 3rd 4th 2nd 30 N m 3 0 kgf m 22 lb ft 15 N m 1 5 kgf m 11 lb ft 60 60 10 N m 1 0 kgf m 7 4...

Страница 223: ...ECKING THE VALVE SEATS on page 5 28 Cylinder head coolant passages Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straighted...

Страница 224: ...n the bolts to the specified torque in two or three steps in the proper tightening sequence as shown e Remove the one bolt according to the tightening order of the bolts f Again apply molybdenum disul...

Страница 225: ...r ther according to the tightening order TIP Tighten the bolts in two steps 60 to reach the specified angle in the proper tightening se quence Total tightening angle 60 60 120 l Tighten the nuts to th...

Страница 226: ...s Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem s...

Страница 227: ...THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene leaks from the valve seat 1 3 R...

Страница 228: ...ve guide installer 1 and the valve guide re mover 2 c After installing the valve guide expand the hole in the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide c...

Страница 229: ...the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head Intake...

Страница 230: ...ng compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve fa...

Страница 231: ...e is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve s...

Страница 232: ...ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smooth...

Страница 233: ...ston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Cylinder body 1 2 Gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set...

Страница 234: ...ift the opposite end gap of the piston ring over the piston crown EAM30097 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and repla...

Страница 235: ...here cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exce...

Страница 236: ...s face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the mark a on it pointing to its exhaust rear side Before installing the...

Страница 237: ...e compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b Upper oil r...

Страница 238: ...L CHASSIS on page 4 1 1 Stator coil assembly coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Shift pedal 1 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Holder 1 8 Stato...

Страница 239: ...stall Stator coil assembly 1 Screw stator coil assembly 2 Crankshaft position sensor 3 Bolt crankshaft position sensor 4 Holder Bolt holder TIP Apply the sealant to the grommet of the stator coil asse...

Страница 240: ...keyway c of the generator rotor with the woodruff key 3 Install Washer Nut generator rotor 1 4 Install Dowel pin 1 Gasket left crankcase cover 2 Crankcase cover left 3 Lead holder 4 Bolt left crankca...

Страница 241: ...ngine oil Refer to CHANGING THE ENGINE OIL on page 3 14 Clutch Refer to CLUTCH on page 5 47 1 Clutch housing 1 2 Starter clutch gear 1 3 Starter clutch assembly 1 4 Side plate 1 5 Absorber 8 6 Primary...

Страница 242: ...Check Starter clutch operation a Install the starter clutch gear 1 onto the primary driven gear 2 and hold the pri mary driven gear b When turning the starter clutch gear clock wise A the starter clu...

Страница 243: ...tarter clutch side 4 Install Starter clutch TIP Install the starter clutch so that the side of the starter clutch assembly with the arrow mark is toward the primary driven gear While holding the side...

Страница 244: ...RIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 6 1 Starter motor lead 1 2 Starter motor 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb...

Страница 245: ...r assembly 1 2 O ring 1 3 Starter motor front cover 1 4 Washer 1 Starter motor front cover 5 Starter motor yoke 1 6 Gasket 2 7 Armature assembly 1 8 Washer 1 9 Circlip 1 10 Starter motor rear cover 1...

Страница 246: ...easure Brush length a Out of specification Replace the brush set 5 Measure Brush spring force Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the starter motor 7 Chec...

Страница 247: ...4 Install Circlip 1 Plain washer 2 Gasket 3 Washer starter motor front cover 4 Starter motor front cover 5 TIP For installation align the projections on the washer with the slots in the front cover A...

Страница 248: ...over 1 3 Gasket 1 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Bearing 1 9 Ball 1 10 Push rod 2 1 11 Friction plate 1 2 Identification color black 12 Clutch plate 7 13 Friction pl...

Страница 249: ...utch Order Job Parts to remove Q ty Remarks 16 Primary driven gear 1 17 Push lever shaft 1 T R 17 16 E E E E LT E E E E 95 N m 9 5 kgf m 70 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft...

Страница 250: ...NE OIL on page 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Brake pedal Refer to ENGINE REMOVAL on page 5 6 Clutch cover Refer to CLUTCH on page 5 47 1 Oil filter element cover 1 2 Oi...

Страница 251: ...pecification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specifi...

Страница 252: ...cation Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the...

Страница 253: ...ICE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away fr...

Страница 254: ...tification color orange 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TI...

Страница 255: ...ts in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7...

Страница 256: ...l 1 2 Shift shaft 1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper...

Страница 257: ...T 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOP...

Страница 258: ...lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide 6 Tighten Shift guide bolt 1 7 Install Ro...

Страница 259: ...SHIFT SHAFT 5 58 TIP Align the punch mark a on the shift shaft with the punch mark b in the shift pedal 1 1 2 2 a b...

Страница 260: ...mary driven gear Refer to CLUTCH on page 5 47 Right crankcase cover Refer to CLUTCH on page 5 47 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive...

Страница 261: ...r 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer weight 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer drive gear 1 10 Conical washer 1 11 B...

Страница 262: ...ce 4 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1 Check Oil pump cover Oil pump drive shaft Oil pump housing Cracks damage wear Replace the oil pump assembly 2 Check Oil pump o...

Страница 263: ...f valve before installing the pri mary drive gear and collar 2 Install Collar 1 Balancer weight gear 2 TIP Install the balancer weight gear and balancer shaft with their lower splines a aligning with...

Страница 264: ...inum plate a between the teeth of the balancer drive gear 9 and balancer weight gear 10 Install the conical washer with its convex sur face b outward Align the balancer flat portion c with the flat po...

Страница 265: ...OIL PUMP 5 64 A Primary drive gear side B Crankcase cover side 5 7 mm 0 02 0 28 in 5 c d 6 8 b 8 6 7 E...

Страница 266: ...fer to GENERATOR on page 5 37 1 Timing chain guide stopper plate 1 2 Timing chain guide exhaust side 1 3 Timing chain 1 4 Bolt 7 L 45 mm 1 77 in 5 Bolt 3 L 60 mm 2 36 in 6 Bolt 3 L 75 mm 2 95 in 7 Rig...

Страница 267: ...s Transmission Refer to TRANSMISSION on page 5 72 Shift cam Shift fork Refer to TRANSMISSION on page 5 72 1 Circlip 2 2 Oil seal 3 3 Bearing 13 1 2 3 3 3 3 3 3 3 E E E E LT 3 3 3 3 LT E LT E 3 E 1 2 2...

Страница 268: ...nly on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt...

Страница 269: ...oft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross pattern in two stages with 1 4 turn each Installed depth a 4 5...

Страница 270: ...AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 Transmission Refer to TRANSMISSION on p...

Страница 271: ...HAFT 1 Measure Crankshaft runout a Out of specification Replace the crank shaft TIP Turn the crankshaft slowly 2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Cra...

Страница 272: ...pply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bo...

Страница 273: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 6 Crankcase Separate Refer to CRANKCASE on page 5 65 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Sprin...

Страница 274: ...1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to stra...

Страница 275: ...oil to the inner and end surface of the idler gear and to the inner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 22T 2 3rd wheel gear 26T 3 4th wheel gear 24...

Страница 276: ...ase simultaneously Apply engine oil to the main axle and the drive axle bearing 6 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 to the main axle and the drive axle TIP Apply e...

Страница 277: ...k guide bar 2 Spring 3 TIP Screw the spring into the shift fork guide bar lightly beforehand Apply the engine oil on the shift fork guide bars 8 Check Operation of shift cam and shift fork Transmissio...

Страница 278: ...TRANSMISSION 5 77...

Страница 279: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 4 INSTALLING THE RADIATOR 6 4 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING...

Страница 280: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator hose 3 6 Radiator left...

Страница 281: ...Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 4 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator fan 1 4 Radiator right 1 5 Radiator hose 2 1 6 Radiator h...

Страница 282: ...1 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 New 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 15 N m 1 5 kgf m...

Страница 283: ...e 3 Check Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 3 to the radi ator cap 1 and activate the tester to check whether it can stay for...

Страница 284: ...s of warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connection...

Страница 285: ...l Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 47 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Circlip 1 6 Washer 2 7 Impeller...

Страница 286: ...e EAM30262 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the right cran...

Страница 287: ...Gasket 2 5 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New 1 1...

Страница 288: ...WATER PUMP 6 9...

Страница 289: ...UEL PUMP 7 2 CHECKING THE FUEL PUMP BODY 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THR...

Страница 290: ...left right 1 Fuel pump coupler Fuel hose 1 1 Disconnect 2 Fuel tank 1 3 Fuel pump bracket 1 4 Fuel pump 1 5 Fuel filter 1 6 Thermistor cover 1 7 Fuel pump gasket 1 8 Rubber damper 4 3 5 2 2 4 7 2 7 N...

Страница 291: ...or cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the...

Страница 292: ...nstall Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose securely and check that the orientation of the installed fuel hose holder is correct Take care not to kink or pinch the fuel...

Страница 293: ...2 Ignition coil 1 3 Intake air temperature sensor coupler 1 Disconnect 4 Breather hose 1 5 Air filter case 1 6 Fuel injector coupler 1 Disconnect 7 Intake air pressure sensor coupler 1 Disconnect 8 Th...

Страница 294: ...y 1 14 Exhaust pipe bracket 1 15 Throttle body joint 1 2 2 2 11 11 11 11 13 15 14 12 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0...

Страница 295: ...the injector Order Job Parts to remove Q ty Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 1 2 2 5 4 3 3 5 N m 0 35 kgf m 2 6 lb ft 3...

Страница 296: ...f the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor cleaning solution Do not directly push the throttle valves to open them Do not...

Страница 297: ...sor Refer to CHECKING THE THROTTLE PO SITION SENSOR INPUT VOLTAGE on page 8 70 2 Adjust Throttle position sensor angle a Connect the Yamaha diagnostic tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 31...

Страница 298: ...THROTTLE BODY 7 9...

Страница 299: ...8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 25 FUEL INJECTION SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 ECU SELF DIAGNOSTIC FUNCTION 8 29 TROUBLESHOOTING METHOD 8 30 YAMAHA DIAGNOSTIC TOOL 8 31 CONNECTING THE...

Страница 300: ...67 CHECKING THE RECTIFIER REGULATOR 8 67 CHECKING THE SPEED SENSOR 8 68 CHECKING THE FUEL SENDER 8 68 CHECKING THE RESISTOR 8 68 CHECKING THE RADIATOR FAN MOTOR 8 69 CHECKING THE COOLANT TEMPERATURE S...

Страница 301: ......

Страница 302: ...IGNITION SYSTEM 8 1 EAM20142 IGNITION SYSTEM EAM30277 CIRCUIT DIAGRAM...

Страница 303: ...egulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 19 ECU Engine Control Unit 20 Ignition coil 21 Spark plug 33 En...

Страница 304: ...page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 13 NG Correct or replace the spark plug OK 5 Check the ign...

Страница 305: ...coil assembly Refer to CHECKING THE STA TOR COIL on page 8 67 NG Replace the stator coil assembly OK 10 Check the ignition system wire har ness Refer to CIRCUIT DIAGRAM on page 8 1 NG Repair or repla...

Страница 306: ...ELECTRIC STARTING SYSTEM 8 5 EAM20143 ELECTRIC STARTING SYSTEM EAM30279 CIRCUIT DIAGRAM...

Страница 307: ...ry 9 Frame ground 10 Main fuse 11 Starter relay 12 Starter motor 13 Diode 3 14 Diode 5 19 ECU Engine Control Unit 33 Engine stop switch 34 Gear position switch 35 Diode 1 36 Starting circuit cut off r...

Страница 308: ...ch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has...

Страница 309: ...SSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Diode 3 5 Starting circuit cut off relay 6 Start switch 7 Diode 1 8 Clutch switch 9 Gear po...

Страница 310: ...THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 67 OK Starter motor is OK Perform the electric start...

Страница 311: ...rt switch Refer to CHECKING THE SWITCHES on page 8 57 NG Replace the start switch OK 10 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 NG Properly connect or repair the...

Страница 312: ...CHARGING SYSTEM 8 11 EAM20144 CHARGING SYSTEM EAM30282 CIRCUIT DIAGRAM...

Страница 313: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse A Battery sub lead B Wire harness...

Страница 314: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULA...

Страница 315: ...CHARGING SYSTEM 8 14...

Страница 316: ...SIGNALING SYSTEM 8 15 EAM20154 SIGNALING SYSTEM EAM30348 CIRCUIT DIAGRAM...

Страница 317: ...Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 16 Resistor 17 Diode 2 18 Yamaha diagnostic tool coupler 19 ECU Engine Control Unit 23 Fuel sender 32 Speed sensor 41 Multi function d...

Страница 318: ...RGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check...

Страница 319: ...UEL SENDER on page 8 68 NG Replace the fuel pump assembly OK 2 Check the resistor Refer to CHECKING THE RESIS TOR on page 8 68 NG Replace the resistor OK 3 Check the entire signaling system s wiring R...

Страница 320: ...LIGHTING SYSTEM 8 19 EAM20153 LIGHTING SYSTEM EAM30346 CIRCUIT DIAGRAM...

Страница 321: ...20 4 Joint connector 5 Headlight relay 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 40 Taillight 41 Multi function display 42 Headlight A Battery sub l...

Страница 322: ...FUSES on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the m...

Страница 323: ...LIGHTING SYSTEM 8 22...

Страница 324: ...COOLING SYSTEM 8 23 EAM20155 COOLING SYSTEM EAM30350 CIRCUIT DIAGRAM...

Страница 325: ...r 6 Main relay 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 25 Radiator fan motor 26 Radiator fan motor fuse 27 Radiator fan motor relay 29 Coolant temperature sens...

Страница 326: ...ain relay Refer to CHECKING THE RE LAYS on page 8 62 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 69 NG Replace the radiator fan moto...

Страница 327: ...COOLING SYSTEM 8 26...

Страница 328: ...FUEL INJECTION SYSTEM 8 27 EAM20145 FUEL INJECTION SYSTEM EAM30284 CIRCUIT DIAGRAM...

Страница 329: ...diagnostic tool coupler 19 ECU Engine Control Unit 20 Ignition coil 21 Spark plug 22 Fuel injector 24 Fuel pump 28 Intake air temperature sensor 29 Coolant temperature sensor 30 Throttle position sens...

Страница 330: ...rning light Engine trouble warning 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 switc...

Страница 331: ...system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS FAULT CODE on page 8 33 4 After pushing the engine stop switch push the start switch to check w...

Страница 332: ...TIP When connected to Yamaha diagnostic tool the vehicle speed signal line between the meter and ECU is disconnected and Er_1 is always shown on the meter display Yamaha diagnostic tool USB US 90890 0...

Страница 333: ...e sub lead can catch fire and the battery could be damaged TIP For information on how to connect and use the Yamaha diagnostic tool refer to YAMAHA DIAGNOS TIC TOOL OPERATION MANUAL FI diagnostic tool...

Страница 334: ...Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Diagnostic tool d...

Страница 335: ...of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor...

Страница 336: ...ng the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Mounted condition of intake air pressure sensor Ch...

Страница 337: ...ensor hose Start the engine and let it idle for approximately 5 seconds fully close the throttle valve Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Co...

Страница 338: ...Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Improperly connected Con nect the coupler securely...

Страница 339: ...ned 86 92 displays Incorrect display range Replace the throttle position sensor Push the start switch main relay ON and then check the condition of the fault code using the malfunction mode of the Yam...

Страница 340: ...nostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Faulty ECU Replace the ECU Service is finished 4 Delete the fault code Confirm that the faul...

Страница 341: ...condition of coolant temperature sensor Check for looseness or pinch ing Check the mounted position for correctness Improperly mounted sensor Remount or replace the sensor Push the start switch main r...

Страница 342: ...cted Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of...

Страница 343: ...ble to drive vehicle Diagnostic code No 08 Diagnostic tool display Displays the lean angle sensor output voltage 0 4 1 4 V upright 3 7 4 4 V overturned Procedure Remove the ECU and incline it 45 or mo...

Страница 344: ...ion 1 Connection of ignition coil cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins for bent or bro ken terminals and locking condi tion of the pins Imprope...

Страница 345: ...on of ignition coil Check for looseness or pinch ing Check the mounted condition for correctness Improperly mounted sensor Remount or replace the ignition coil Start the engine and let it idle for app...

Страница 346: ...jector Refer to CHECKING THE INJECTOR on page 8 71 Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnosti...

Страница 347: ...relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Diagnostic tool display Fuel system voltage Approximately 12 0 V Procedure Disconnect the main relay and push th...

Страница 348: ...d the engine stop switch alternately to switch the power supply main relay from ON OFF ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Re...

Страница 349: ...n Change the CO concentration and rewrite in EEPROM After this adjustment push the engine stop switch and then push the start switch Push the start switch main relay ON and then check the condition of...

Страница 350: ...nd locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition...

Страница 351: ...e No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Faulty ECU Replace the ECU Push the start switch main relay O...

Страница 352: ...he fault code Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No 70 Item Engine forcibly stops when the vehicle is l...

Страница 353: ...FUEL INJECTION SYSTEM 8 52...

Страница 354: ...FUEL PUMP SYSTEM 8 53 EAM20146 FUEL PUMP SYSTEM EAM30287 CIRCUIT DIAGRAM...

Страница 355: ...STEM 8 54 2 AC magneto 3 Rectifier regulator 4 Joint connector 7 Engine ground 8 Battery 9 Frame ground 10 Main fuse 19 ECU Engine Control Unit 24 Fuel pump 33 Engine stop switch A Battery sub lead B...

Страница 356: ...on page 8 59 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 60 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the engine s...

Страница 357: ...Injector 4 Rectifier regulator 5 Intake air temperature sensor 6 ECU Engine Control Unit 7 Ignition coil 8 Coolant temperature sensor 9 Resistor 10 Starter relay 11 Main fuse 12 Battery 13 Radiator f...

Страница 358: ...ELECTRICAL COMPONENTS 8 57 EAM30289 CHECKING THE SWITCHES Y W P Sb 2 1 3 P Sb Y W 4 1 Engine stop switch 2 Gear position switch 3 Engine start switch 4 Clutch switch...

Страница 359: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Страница 360: ...1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check Main fuse 1 Radiator fan motor fuse 2 a Connect the digital circuit tester to the fuse and check the continuity TIP Set the digital circuit t...

Страница 361: ...lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is o...

Страница 362: ...comes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illu...

Страница 363: ...ve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the battery s charging voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the...

Страница 364: ...egative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 2 1 3 4 R W Br W R Y L 1 2 3 4 L R Br R R R W 1 Positive battery terminal 2 Negative battery t...

Страница 365: ...L R L R W Br R W No continuity Positive tester probe Sky blue 1 Negative tester probe Green Black 2 Continuity Positive tester probe Green Black 2 Negative tester probe Sky blue 1 No continuity Posit...

Страница 366: ...curs EAM30295 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from the spark plug lead 2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the sp...

Страница 367: ...igital circuit tester to the crankshaft position sensor coupler b Measure the crankshaft position sensor resistance Primary coil resistance 2 16 2 64 Digital circuit tester CD732 90890 03243 Model 88...

Страница 368: ...oduce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAM30300 CHECKING THE STATOR COIL 1 Disconnect Stator coil assembly coupler from the w...

Страница 369: ...ter motor lead from the starter relay 2 Connect Fuel pump coupler 3 Push the start switch 4 Check Fuel level warning light Out of specification Replace the fuel pump EAM30360 CHECKING THE RESISTOR 1 D...

Страница 370: ...sor resistance Out of specification Replace a Connect the digital circuit tester to the coolant temperature sensor b Immerse the coolant temperature sensor in a container filled with coolant TIP Make...

Страница 371: ...G EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Chec...

Страница 372: ...hom eter YU A1927 Continuity Positive tester probe Sky blue 1 Negative tester probe Sensor terminal a Continuity Positive tester probe Pink 2 Negative tester probe Sensor terminal b Continuity Positiv...

Страница 373: ...7 TROUBLESHOOTING OF BRAKE 9 8 TROUBLESHOOTING OF SUSPENSION 9 8 TROUBLESHOOTING OF STEERING HANDLING 9 10 TROUBLESHOOTING OF CHARGING SYSTEM 9 11 TROUBLESHOOTING OF LIGHTING SYSTEM 9 11 TROUBLESHOOT...

Страница 374: ...TEM on page 8 5 Starter motor operates but the engine does not crank Starter clutch malfunction Replace the starter clutch Improper oil grade starter clutch slipping Change to recommended engine oil S...

Страница 375: ...ace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Sympt...

Страница 376: ...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 va...

Страница 377: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Страница 378: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Страница 379: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Страница 380: ...tor Faulty radiator fan motor Refer to TROUBLESHOOTING under COOLING SYSTEM on page 8 23 Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly...

Страница 381: ...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...

Страница 382: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Страница 383: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Страница 384: ...or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Refer to TROUBLESHOOTING under CHARGING SYSTEM on page 8 11 Symptom P...

Страница 385: ...ry lead of the ignition coil 8 43 39 Injector open or short circuit detected 8 45 41 ECU built in lean angle sensor malfunction 8 46 43 Fuel system voltage incorrect voltage supplied to the main relay...

Страница 386: ...Displays the fuel system volt age Approximately 12 0 V 21 Neutral switch Operate the shift pedal Gear in neutral ON Gear not in neutral OFF 25 Gear position switch Operate the shift pedal Gear in 1st...

Страница 387: ...nd intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition checker 36 Injector Actuates th...

Страница 388: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 15...

Страница 389: ...1 FRONT FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH...

Страница 390: ...t such that it can develop its maximum revolutions toward the 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 perform...

Страница 391: ...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 REPLACEMEN...

Страница 392: ...the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bo...

Страница 393: ...ing force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never...

Страница 394: ...BER AS SEMBLY on page 3 30 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 8...

Страница 395: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Страница 396: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Страница 397: ...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...

Страница 398: ...CHASSIS 10 9...

Страница 399: ...nsor 31 Intake air pressure sensor 32 Speed sensor 33 Engine stop switch 34 Gear position switch 35 Diode 1 36 Starting circuit cut off relay 37 Clutch switch 38 Start switch 39 Diode 4 40 Taillight 4...

Страница 400: ......

Страница 401: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Страница 402: ......

Страница 403: ...R Y B B W R L B Br W Sb B P L Br Lg L W L P B Y G P Y B O R L R L R L R L R L P L R L R W R W Br R W Br R L R L R L R L B L B L B L B L B L B L B L B L B L B L B L R L B L B L B B B L B B R L Br B L...

Страница 404: ...WR250FN1 2022 WIRING DIAGRAM 35W 35W 1 2 4 3 5 5A 15A B B B B B B Dl Gy B B B Gy B ON OFF ON OFF B B BAK 2819U 12_W D indd 2 2021 06 09 16 55 54...

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