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TROUBLESHOOTING

9-1

EASB296367

TROUBLESHOOTING

EASB296368

GENERAL INFORMATION

TIP

The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure
in this manual for checks, adjustments, and re-
placement of parts.

EASB296369

STARTING FAILURES

Engine

1. Cylinder and cylinder head

• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve

2. Piston and piston ring(s)

• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston

3. Air filter

• Improperly installed air filter
• Clogged air filter element

4. Crankcase and crankshaft

• Improperly assembled crankcase
• Seized crankshaft

Fuel system

1. Fuel tank

• Empty fuel tank
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose

2. Fuel pump

• Faulty fuel pump

3. Throttle body

• Deteriorated or contaminated fuel
• Sucked-in air

Electrical system

1. Spark plug

• Incorrect spark plug gap

• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator

2. Ignition coil

• Cracked or broken ignition coil body
• Broken or shorted primary or secondary

coils

3. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key

4. Switches and wiring

• Faulty ECU
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Improperly grounded circuit
• Loose connections

EASB296370

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder and cylinder head

• Incorrect valve clearance
• Damaged valve train components

2. Air filter

• Clogged air filter element

Fuel system

1. Throttle body

• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improper throttle cable free play
• Flooded throttle body

Electrical system

1. Spark plug

• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap

2. Ignition coil

• Broken or shorted primary or secondary

coils

• Cracked or broken ignition coil

3. Ignition system

• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key

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Содержание YZ 2016 Series

Страница 1: ...UAL YZ250FXG B29 28199 11 LIT 11626 29 53 YZ250FXG 2016 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015 07 0 3 1 E B29 28199 11_cover_12mm in...

Страница 2: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Страница 3: ...2015 by Yamaha Motor Corporation U S A 1st Edition June 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Страница 4: ...ANUAL 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 YO...

Страница 5: ...HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or exhaust system Never refuel in the vicinity of an open flame or while smoking GASOLINE...

Страница 6: ...EASB296006 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Страница 7: ...he section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in t...

Страница 8: ...FINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit...

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

Страница 10: ......

Страница 11: ...ON 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 BASIC SERVICE...

Страница 12: ...E 1 20 AIR FILTER MAINTENANCE 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 22 BREAK IN PROCEDURES 1 22 MAINTENANCE AFTER BREAK IN 1 23 MAJOR MAINTENANCE 1 23 TORQUE CHECK POINTS 1 24 MOTO...

Страница 13: ...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...

Страница 14: ...those for the vehicle you have pur chased 1 Clutch lever 10 Radiator 2 Front brake lever 11 Coolant drain bolt 3 Throttle grip 12 Rear brake pedal 4 Start switch 13 Air filter 5 Radiator cap 14 Drive...

Страница 15: ...ositive iden tification of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EASB296012 VEHICLE IDENTIFICATION NUMBER The vehic...

Страница 16: ...ed to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EASB296019 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the...

Страница 17: ...ach section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the li...

Страница 18: ...ASB296024 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces...

Страница 19: ...ry lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water ECA NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the b...

Страница 20: ...en push the starter switch Be sure to wait for five seconds or lon ger before pushing the start switch after the en gine is stopped Checking the electrical system TIP Before checking the electrical sy...

Страница 21: ...e to check the type of cou pler lock before disconnecting the cou pler ECA NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector and then disconnect the con n...

Страница 22: ...terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a q...

Страница 23: ...se tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This t...

Страница 24: ...01403 Exhaust flange nut wrench YU A9472 This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 YM 01500 This tool is used to remove or tighten the base valve Cap bolt rin...

Страница 25: ...is used to mount the pressure gauge Test harness S pressure sensor 3P 90890 03207 YU 03207 This tool is used to check the throttle position sensor input voltage Test harness lean angle sen sor 6P 9089...

Страница 26: ...is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is used to replace the valve guid...

Страница 27: ...Valve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 This too...

Страница 28: ...ital tachometer 90890 06760 YU 39951 B This tool is used to measure the engine speed Three bond No 1215 90890 85505 This sealant Bond is used for crankcase mating sur face etc Tool name Part number Ho...

Страница 29: ...clutch Pull the clutch lever toward the handlebar to disengage the clutch and release the lever to engage the clutch EASB296033 SHIFT PEDAL The shift pedal 1 has adopted a method of 1 down 5 ups pres...

Страница 30: ...TING SCREW Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob idle screw 1 Pulling the knob toward a turns ON the start er resulting in a larger amount...

Страница 31: ...CONTROL FUNCTIONS 1 19 a 2...

Страница 32: ...poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area ECA NOTICE Unlike a two stroke engine this engine cannot be kick sta...

Страница 33: ...rter knob idle screw to its original posi tion EWA WARNING Since exhaust gas contains harmful ingre dients do not start or warm it up at an ill ventilated place or a closed narrow place 5 To stop the...

Страница 34: ...il leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check mounted areas for looseness oil leaks or other proble...

Страница 35: ...is connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets...

Страница 36: ...absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tighten...

Страница 37: ...2 Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fend...

Страница 38: ...may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or...

Страница 39: ...ill wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EASB296053 STORAGE Short term Always store your motorcycle in a cool dry place and if necessary protect it agains...

Страница 40: ...es from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charg...

Страница 41: ...FICATIONS 2 10 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2...

Страница 42: ...8 EUR B299 AUS NZL ZAF B29A JPN Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1465 mm 57 7 in Ground cleara...

Страница 43: ...L 0 88 US qt 0 73 Imp qt With oil filter removal 0 85 L 0 90 US qt 0 75 Imp qt Oil filter Oil filter type Paper Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 kgf cm2 5 8 11 6 psi Oil pump Oil...

Страница 44: ...clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 17 0 24 mm 0 0067 0 0094 in Valve dimensions Valve head diameter intake 30 90 31 10 mm 1 2165 1 2244 in Valve head diameter exhaust 24 90...

Страница 45: ...ckwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0...

Страница 46: ...bending limit 0 10 mm 0 004 in Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 3 353 57 17 Final drive Chain Secondary reduction ratio...

Страница 47: ...injection sensor Crankshaft position sensor resistance 228 342 Intake air pressure sensor output voltage 3 61 3 67 V at 101 3 kPa 3 61 3 67 V at 1 01 kgf cm2 3 61 3 67 V at 14 7 psi Intake air tempera...

Страница 48: ...ut limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 0 02 in Front tire Type With tube Size 90 90 21 54M Manufacturer model DUNLOP AT81F Rear tire Type With tube Size 110 100 18 64M Manufacturer m...

Страница 49: ...type Coil spring Hydraulic damper Front fork travel 310 0 mm 12 20 in Fork spring free length 470 0 mm 18 50 in Limit 465 0 mm 18 31 in Fork spring installed length 470 0 mm 18 50 in Spring rate K1 4...

Страница 50: ...0 mm 0 39 in from its free length Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Minimum 30 clicks out Standard 11 clicks out...

Страница 51: ...le 3 6 4 4 V Output voltage over operating angle 0 3 1 4 V AC magneto Standard output 14 0 V 160 W at 5000 r min Stator coil resistance 0 528 0 792 W W Rectifier regulator Regulator type Three phase N...

Страница 52: ...AL SPECIFICATIONS 2 11 Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Starting circuit cut off relay Coil resistance 75 6 92 5 Fuses Main fuse 15 0 A Spare fuse 15 0 A Radiator fan motor fus...

Страница 53: ...To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Страница 54: ...Timing chain guide stopper plate exhaust side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lb...

Страница 55: ...M6 12 12 Nm 1 2 m kgf 8 7 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft end accessing screw M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing mark accessing screw M14 1 6 Nm 0 6 m...

Страница 56: ...sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Damper assembly cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch bolt M6 6 16 Nm 1 6 m kgf 12 ft lbf Starter motor bolt M6 1 12 Nm 1 2 m kgf 8 7 ft...

Страница 57: ...m kgf 0 94 ft lbf Front fork protector bolt M6 6 5 Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 38 m kg...

Страница 58: ...lt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft lbf Engine mounting bolt front side M10...

Страница 59: ...0 40 m kgf 2 9 ft lbf Seat set bracket and fuel tank screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Seat bolt M8 2 22 Nm 2 2 m kgf 16 ft lbf Left side cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Right side cover...

Страница 60: ...stem moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratc...

Страница 61: ...seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surface Relay arm bolt threads swingarm s...

Страница 62: ...brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston se...

Страница 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22...

Страница 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EASB296064 LUBRICATION SYSTEM CHART AND DIAGRAMS EASB296065 LUBRICATION DIAGRAMS...

Страница 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle...

Страница 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25...

Страница 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Страница 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Страница 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

Страница 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Страница 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Страница 72: ...CABLE ROUTING DIAGRAM 2 31 EASB296066 CABLE ROUTING DIAGRAM...

Страница 73: ...side of the front engine bracket the side of the vehicle M Insert the plastic locking tie into the bracket hole and clamp the clutch cable Clamp it so that the lock of the plastic locking tie faces do...

Страница 74: ...CABLE ROUTING DIAGRAM 2 33...

Страница 75: ...f the radiator B Route each lead so that the leads are not pinched between the tank rail and air filter joint C Insert the projection of the wire harness into the hole in the frame D Route the cylinde...

Страница 76: ...CABLE ROUTING DIAGRAM 2 35...

Страница 77: ...throttle position sensor lead to the out side of the tension arm the outside of the vehi cle D After connecting the throttle position sensor cou pler attach the cover E Pass the radiator breather hos...

Страница 78: ...CABLE ROUTING DIAGRAM 2 37...

Страница 79: ...the wire harness into the battery bracket hole and holder plate hole F After connecting the negative lead coupler place it on the right side of the battery G After installing the plastic cover to the...

Страница 80: ...CABLE ROUTING DIAGRAM 2 39...

Страница 81: ...ber plate band D Pass the engine stop switch lead between the head pipe and the cable guide E Pass the front brake hose to the front of the num ber plate F Pass the start switch lead and clutch switch...

Страница 82: ...CABLE ROUTING DIAGRAM 2 41...

Страница 83: ...all the two breather hoses so that the yellow paint mark is pointing forwards C Align the white paint mark to the protruding por tion of the pipe to install breather hose 3 D Protruding portion of the...

Страница 84: ...CABLE ROUTING DIAGRAM 2 43...

Страница 85: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

Страница 86: ...CABLE ROUTING DIAGRAM 2 45...

Страница 87: ...CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 14 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 22 BLEEDING THE BRAKE SYSTEM 3 22 CHECKING THE BRAKE...

Страница 88: ...3 35 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 36 CHECKING THE CHASSIS FASTENERS 3 36 ELECTRICAL SYSTEM 3 37 CHECKING THE SPAR...

Страница 89: ...to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold...

Страница 90: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Страница 91: ...air filter oil or equiv alent oil Replace BREATHER SYS TEM Inspect Check ventilation hose for cracks or damage and drain any deposits Replace Every two years SPARK PLUG Inspect and clean Check the el...

Страница 92: ...d adjust Replace oil Replace oil seal Clean and grease oil seals and dust seals Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grea...

Страница 93: ...en Molybdenum disulfide grease RELAY ARM CON NECTING ROD Inspect lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium soap based grease STEERING HEAD Inspect free play and retigh...

Страница 94: ...and grease Check and clean throttle cable Check throttle cables on the throttle body for dirt and wear LEVERS Adjust clutch lever free play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubricate OUTSIDE N...

Страница 95: ...Check the play of front brake and effect of front and rear brake 3 22 28 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 28 4 66 67 Wheels Check...

Страница 96: ...minutes until the coolant has settled EASB296073 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer t...

Страница 97: ...el Refer to CHECKING THE COOLANT LEV EL on page 3 8 EASB296075 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS...

Страница 98: ...a cloth beforehand EASB296078 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 i...

Страница 99: ...ned c Tighten the locknut EWA WARNING After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this does not cause the en gine idling speed to change...

Страница 100: ...r filter element 3 Wash Air filter element EWA WARNING Do not use gasoline or organic acid alka line volatile oil for washing TIP After washing the element with air filter cleaner or kerosene squeeze...

Страница 101: ...rrectly EASB296084 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace Refer to ENGINE REMOVAL on page 5 1 Exhaust gas Leaks...

Страница 102: ...ld be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level ECA NOTICE Since engine oil also lubricates the clutch t...

Страница 103: ...sh with kerosene c Replace the O 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 O...

Страница 104: ...er at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the starter knob idle screw a few clicks counterclockwise to in crease the speed before the adjustment Bef...

Страница 105: ...sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 EC...

Страница 106: ...chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad po sition very carefully so that they can be rein stalled in their original place...

Страница 107: ...Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lift...

Страница 108: ...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 84 185 190 195 200 205 210 215 2...

Страница 109: ...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 110: ...the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the br...

Страница 111: ...b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA WARNING A soft or spongy feeling in the brake lever can indicate the pre...

Страница 112: ...ir in the brake system will cause braking performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EASB296095 CHECKING THE FRONT BRAKE PADS 1...

Страница 113: ...jections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid lev...

Страница 114: ...move the pad pin 6 and the brake pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper pi...

Страница 115: ...BRAKE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EASB296098 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a...

Страница 116: ...uitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull t...

Страница 117: ...ification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EASB296102 CLEANING THE FRONT FORK OIL SEAL AND DUST...

Страница 118: ...nd its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 Nm 0 13 m kgf 0 94 ft lbf Direction a Rebound damping is...

Страница 119: ...A WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload ECA NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Remove Rear frame Refer to...

Страница 120: ...the direction of a or b to make an adjustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is...

Страница 121: ...the tire is considered to be slipping off its position Cor rect the tire position EASB296109 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will...

Страница 122: ...teering 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 31 Upper bracket Refer t...

Страница 123: ...points and metal to metal moving parts of the following parts Brake lever Clutch lever EASB296115 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to metal moving parts of the pedal EAS...

Страница 124: ...ivoting point and metal to metal moving parts of the sidestand EASB296118 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TOR...

Страница 125: ...oving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan...

Страница 126: ...nt mark a on the left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EASB296122 CHECK...

Страница 127: ...PER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER...

Страница 128: ...EMBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 58 DISPOSING OF A REAR SHOCK ABSORBER 4 58 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 REMOVING THE BEARING 4 58 CHECKING THE REAR SHOCK ABSORBER ASSEM...

Страница 129: ...this manual It may lead to servicing trouble and mechanical damage EASB296124 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop rig...

Страница 130: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 18 2 Remove Seat 1 EASB296127 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Страница 131: ...wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm...

Страница 132: ...CHECKING THE WHEELS on page 3 34 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Ti...

Страница 133: ...2 Bearing right side 3 Oil seals 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with i...

Страница 134: ...l Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA NOTICE Before tightening the front wheel axle nut push down hard on the handle...

Страница 135: ...el axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m...

Страница 136: ...CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EASB296137 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing...

Страница 137: ...talled first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter...

Страница 138: ...eel axle from the left side Apply the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel ax...

Страница 139: ...washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Страница 140: ...ke caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Страница 141: ...Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake mas...

Страница 142: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Страница 143: ...ion EASB296143 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc...

Страница 144: ...clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When...

Страница 145: ...t the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA WARNING...

Страница 146: ...cylinder and the end of the brake hose EASB296151 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master c...

Страница 147: ...296153 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the...

Страница 148: ...poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause va...

Страница 149: ...pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse...

Страница 150: ...brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2...

Страница 151: ...age 3 22 1 Union bolt 1 2 Copper washers 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 cy...

Страница 152: ...4 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Страница 153: ...96156 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a fe...

Страница 154: ...159 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brak...

Страница 155: ...ith its side a facing the brake caliper Never force to insert EASB296162 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WH...

Страница 156: ...CHECKING THE BRAKE FLUID LEVEL on page 3 27 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 22 EASB296163 REMOVING THE REA...

Страница 157: ...s shown Wrong orientation in installation causes poor braking perfor mance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the...

Страница 158: ...y result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling poin...

Страница 159: ...e 1 Disconnect 2 Clutch switch 1 3 Clutch lever holder 1 4 Engine stop switch 1 5 Brake master cylinder 1 6 Throttle cable cap 1 7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect...

Страница 160: ...HANDLEBAR 4 32 16 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Страница 161: ...296170 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower handlebar...

Страница 162: ...ll Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive w...

Страница 163: ...f 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 7 Install Rubber cove...

Страница 164: ...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...

Страница 165: ...er to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 10 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Clutch lever free play 7 0 12 0 mm 0 28 0 47 in T...

Страница 166: ...rake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bol...

Страница 167: ...n metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New N...

Страница 168: ...mbly 1 with the cap bolt ring wrench 2 3 Remove Front fork leg s EASB296173 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner t...

Страница 169: ...a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend dam...

Страница 170: ...an dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seals Copper washers Before assembling the fron...

Страница 171: ...P Fully finger tighten the locknut onto the damper assembly 6 Loosen Compression damping force adjuster 1 TIP Before loosening the damping force adjuster record the setting position Unless the damping...

Страница 172: ...rotecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side ECA NOTICE Take care not to damage the damper assem bly 12 Allow the overflow...

Страница 173: ...lip Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Inner tube bushing 1 TIP Install the inner tube bush...

Страница 174: ...e groove in the outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 M...

Страница 175: ...g force adjuster is fully loosened correct damping characteristic can not be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While...

Страница 176: ...the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly Adjuster locknut 29 Nm 2 9 m k...

Страница 177: ...he damper assembly 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued too much it may ca...

Страница 178: ...e 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...

Страница 179: ...ront fender 1 2 Steering stem nut 1 3 Front fork leg s 2 Refer to FRONT FORK on page 4 38 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing l...

Страница 180: ...3 Replace Bearing Bearing races a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c In...

Страница 181: ...e steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 34 5 Check the steering st...

Страница 182: ...steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued...

Страница 183: ...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 sho...

Страница 184: ...14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Part name Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3...

Страница 185: ...arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2...

Страница 186: ...km of run ning EASB296183 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA WARNING Wear protective glasses to prevent...

Страница 187: ...ng Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EASB296187 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay ar...

Страница 188: ...ck absorber assembly lower side TIP Install the dust seals with their lips facing in ward 5 Lubricate Connecting arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circum...

Страница 189: ...m side Rear shock absorber assembly lower bolt Rear shock absorber assembly upper bolt 56 Nm 5 6 m kgf 41 ft lbf Connecting arm bolt frame side 80 Nm 8 0 m kgf 58 ft lbf Connecting arm bolt relay arm...

Страница 190: ...ake hose holder Refer to REAR BRAKE on page 4 21 Rear brake caliper Refer to REAR BRAKE on page 4 21 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Страница 191: ...the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EASB296192 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Страница 192: ...Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 Recomm...

Страница 193: ...ving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m...

Страница 194: ...gth 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 differ ent location each time 2 Che...

Страница 195: ...eel sprocket as a set EASB296197 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EASB296198 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NO...

Страница 196: ...CE Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 2...

Страница 197: ...NG THE DECOMPRESSION SYSTEM 5 17 INSTALLING THE CAMSHAFTS 5 17 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTA...

Страница 198: ...51 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 5 51 INSTALLING THE KICK SHAFT ASSEMBLY 5 51 INSTALLING THE KICK IDLE GEAR 5 52 SHIFT SHAFT 5 53 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASS...

Страница 199: ...UIDE OIL STRAINER 5 73 CHECKING THE CRANKCASE 5 73 INSTALLING THE OIL SEAL 5 74 ASSEMBLING THE CRANKCASE 5 74 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 75 REMOVING THE CRANKSHAFT ASSEMBLY 5 76 CHECKING...

Страница 200: ...AUST PIPE AND MUFFLER on page 5 10 Side cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 Connecting arm bolt...

Страница 201: ...pipe Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 4 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm...

Страница 202: ...S 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 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Neutral switc...

Страница 203: ...ge 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTLE BODY on page 7 5 Throttle body Refer to THROTTLE BODY on...

Страница 204: ...r engine bracket 2 9 Washer 1 Thickness 2 3 mm 0 09 in 10 Washer 1 Thickness 1 0 mm 0 04 in 11 Lower engine bracket 2 12 Pivot shaft 1 13 Engine 1 For installation reverse the removal proce dure Remov...

Страница 205: ...silencer EASB296202 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EASB296203 REMOVING THE DRIVE SPROCKET 1 St...

Страница 206: ...e TIP Make sure that the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EASB296205 CHECKING THE SILENCER AND...

Страница 207: ...t 2 TIP Apply heat resistant sealant to the areas a shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 3 E...

Страница 208: ...O rings and brake pedal bracket EASB296209 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1...

Страница 209: ...stall Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 13 Nm 1 3 m kgf 9 4 ft lbf Then retighten them to 20 Nm 2 0 m kgf 14 ft lbf 2 Install Clamp Exhaust pipe 2...

Страница 210: ...t is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2...

Страница 211: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder...

Страница 212: ...Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R...

Страница 213: ...et with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap i...

Страница 214: ...the camshaft into the cylinder head b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 31 730 31 830 mm 1 2492 1 2531 in Limit 31 630 m...

Страница 215: ...1 Damage stiffness Replace the timing chain and camshaft as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft and the timing chain as a set EASB296215 CHECKING THE TIMING...

Страница 216: ...Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA NOTICE Do not turn the...

Страница 217: ...kwise several turns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Ti...

Страница 218: ...pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAF...

Страница 219: ...HEAD 5 20 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft...

Страница 220: ...trument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE V...

Страница 221: ...he cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the...

Страница 222: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Страница 223: ...e seat Check the valve face the valve seat and the valve seat contact width Refer to CHECKING THE VALVE SEATS on page 5 26 a Pour a clean solvent a into the intake and exhaust ports b Check that the v...

Страница 224: ...inder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 Valve stem to...

Страница 225: ...alve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the valve stem seal EASB296226 CHECKING THE VALVE SEATS 1 Eliminate Carbon depos...

Страница 226: ...valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face ECA NOTICE Do not let the lapping compound enter the gap...

Страница 227: ...re Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 36 69 mm 1 44 in Limit 3...

Страница 228: ...d 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 spring compres...

Страница 229: ...sting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjust ing pad are...

Страница 230: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the remov...

Страница 231: ...piston crown EASB296232 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure...

Страница 232: ...place the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP L...

Страница 233: ...CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 Top ring 4 TIP Be sure to install the piston ring so that the manufacturer s marks or numbers face up 2 Install Pisto...

Страница 234: ...lip ends are 3 mm 0 12 in c or more from the cutout in the piston 3 Lubricate Piston Piston rings Cylinder 4 Offset Piston ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressi...

Страница 235: ...ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure 1...

Страница 236: ...mbling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly rever...

Страница 237: ...stances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of specification re pla...

Страница 238: ...Starter motor yoke 2 ECA NOTICE Install the part that has a smaller step differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark a on th...

Страница 239: ...ELECTRIC STARTER 5 40 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring New...

Страница 240: ...dal Refer to ENGINE REMOVAL on page 5 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push...

Страница 241: ...7 Thrust washer 1 18 Primary driven gear 1 19 Spacer 1 20 Bearing 1 21 Washer 1 22 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks N...

Страница 242: ...Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 41 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe...

Страница 243: ...plate EASB296242 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specificati...

Страница 244: ...place EASB296247 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EASB296248 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks...

Страница 245: ...ll the oil seal in parallel with its manufac ture s marks or numbers facing inward EASB296252 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithiu...

Страница 246: ...rt that is fastened together TIP Use the clutch holding tool 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction plate 1 1 Clutch plate 2 Cushion spring 3 Friction plate 2 4 TIP...

Страница 247: ...oil on the push rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install Gasket 1 11 Install Clutch...

Страница 248: ...all Kickstarter lever 1 Washer Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever does...

Страница 249: ...haft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 41 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick...

Страница 250: ...Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EASB296259 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Страница 251: ...kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Ins...

Страница 252: ...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 lever spring 1 15...

Страница 253: ...e dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks LS 1 3 13 15 14 LT 6 10 11 12 11 8 12 10 4 2 5 LT 7 LT E 12 Nm 1 2 m kgf 8 7 ft Ibf T R 30 Nm 3 0 m kgf 22 ft T R 10 Nm 1...

Страница 254: ...oosen the bolt ECA NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EASB296264 CHECKING THE SHIFT SHAFT 1 Check Shift...

Страница 255: ...ged Take care not to give an impact to it when tightening the bolt EASB296269 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply th...

Страница 256: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EASB296271 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift sh...

Страница 257: ...Refer to CLUTCH on page 5 41 Right crankcase cover Refer to CLUTCH on page 5 41 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Rotor...

Страница 258: ...CLUTCH on page 5 64 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer shaft...

Страница 259: ...EIGHT GEAR 1 Check Primary drive gear 1 Balancer shaft drive gear 2 Balancer weight gear 3 Wear damage Replace EASB296275 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EASB296276 CHECKIN...

Страница 260: ...e in the inner rotor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 Inner rotor to outer rotor tip clearance 0 000 0 150 mm 0 000...

Страница 261: ...ch other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the con...

Страница 262: ...OIL PUMP AND BALANCER GEAR 5 63 a 2 10 b 2 9 1 b 5 3 a 4 10 5 9 3 E c d 6 7 8 8 b 6...

Страница 263: ...k Refer to GENERAL CHASSIS on page 4 1 and FUEL TANK on page 7 1 Disconnect the AC magneto lead Clutch cable Shift pedal Refer to SHIFT SHAFT on page 5 53 1 Cover Damper assembly 1 2 Damper assembly 1...

Страница 264: ...clutch 1 13 Starter clutch drive gear 1 14 Crankshaft position sensor 1 15 Stator 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks T R T...

Страница 265: ...clutch gear 4 Check Damper assembly Damage pitting wear Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive...

Страница 266: ...cumference 3 Install Starter clutch 1 To generator rotor 2 EASB296283 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the...

Страница 267: ...cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using...

Страница 268: ...AND STARTER CLUTCH 5 69 6 Install Cover damper assembly 1 Bracket 2 Bolt 3 Breather hose 2 4 TIP Install the cover damper assembly with its mark a facing upward Bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R 1...

Страница 269: ...Segment Refer to SHIFT SHAFT on page 5 53 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 64 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4...

Страница 270: ...assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1...

Страница 271: ...Transmission Refer to TRANSMISSION on page 5 78 Shift cam and shift fork Refer to TRANSMISSION on page 5 78 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT L...

Страница 272: ...lf Tap only 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 ca...

Страница 273: ...se onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross patte...

Страница 274: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 70 Transmission Refer to TRANSMISSION on page 5 78 1 Balancer s...

Страница 275: ...rankshaft slowly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crank assembly width a Out of specification Replace the...

Страница 276: ...the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms...

Страница 277: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 70 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift for...

Страница 278: ...on of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EASB296298 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift...

Страница 279: ...heck Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement...

Страница 280: ...ease on the O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on...

Страница 281: ...th the 5th wheel gear 5 and 3 R with the 6th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shift f...

Страница 282: ...TRANSMISSION 5 83...

Страница 283: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WA...

Страница 284: ...vicing trouble and mechanical damage EASB296303 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 8 Seat Refer to GENERAL CHASSIS on pag...

Страница 285: ...9 Radiator breather hose 1 10 Left radiator 1 11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 For installation reverse the removal proce dure Removing the radiator Order Par...

Страница 286: ...ra diator cap EASB296305 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins with...

Страница 287: ...efer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 41 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Washer 2 5 Collar 1 6 Gear 1 7 Pin 1 8 Impeller shaft...

Страница 288: ...For installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New...

Страница 289: ...spot seizure Replace EASB296310 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers f...

Страница 290: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2...

Страница 291: ...2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8...

Страница 292: ...icing trouble and mechanical damage EASB296313 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fuel...

Страница 293: ...ign ma terials from entering the fuel pump install the included fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover left...

Страница 294: ...ght Refer to GENERAL CHASSIS on page 4 1 EASB296319 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the side cover left right the seat and the air scoop left right Refer to GENERAL CHASSIS o...

Страница 295: ...arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EASB296321 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace T...

Страница 296: ...AL on page 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Breather hose 3 1 3 Air filter case 1 4 Fuel injector coupler 1 Disconnect 5 Int...

Страница 297: ...int 1 For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T...

Страница 298: ...ks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5...

Страница 299: ...eign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly...

Страница 300: ...YAMAHA DIAGNOSTIC TOOL on page 8 22 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set th...

Страница 301: ...8 ELECTRICAL COMPONENTS 8 50 CHECKING THE SWITCHES 8 54 CHECKING THE FUSES 8 57 CHECKING AND CHARGING THE BATTERY 8 57 CHECKING THE RELAYS 8 60 CHECKING THE DIODE 8 61 CHECKING THE IGNITION SPARK GAP...

Страница 302: ...8 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 68 CHECKING THE FUEL INJECTOR 8 68...

Страница 303: ...servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas semb...

Страница 304: ...Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Страница 305: ...nt connector 4 AC magneto 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 17 Ignition coil 18 Spark plug 24 Joint connector 29 Lean angle sensor 30 Engine stop switch...

Страница 306: ...terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE FUSES on page 8 57 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING TH...

Страница 307: ...Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 63 NG Replace the lean angle sensor OK 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 2 NG Properly connect or repair...

Страница 308: ...R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy...

Страница 309: ...Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 12 Starter motor 13 Starter relay diode 16 ECU engine control unit 24 Joint connector 30 Engine stop switch 31 Neutral switch 32 Diod...

Страница 310: ...er 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 con ditions has been met In this instance t...

Страница 311: ...E TRANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Starting circuit cut off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral sw...

Страница 312: ...battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 64 OK Starter motor is OK Perform the electric starting system troubleshooting starting with st...

Страница 313: ...ch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the start switch OK 12 Check the s...

Страница 314: ...r O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Страница 315: ...CHARGING SYSTEM 8 13 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 38 Negative battery lead...

Страница 316: ...HARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 64 NG Replace the stator assembl...

Страница 317: ...CHARGING SYSTEM 8 15...

Страница 318: ...W R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B...

Страница 319: ...ctor 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 21 Radiator fan motor relay 22 Radiator fan motor fuse 23 Radiator fan motor 24 Jo...

Страница 320: ...main relay Refer to CHECKING THE RE LAYS on page 8 60 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR For JPN on page 8 65 NG Replace the radiator...

Страница 321: ...COOLING SYSTEM For JPN 8 19...

Страница 322: ...W R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B...

Страница 323: ...ter relay 11 Main fuse 16 ECU engine control unit 19 Injector 24 Joint connector 25 Intake air temperature sensor 26 Coolant temperature sensor 27 Throttle position sensor 28 Intake air pressure senso...

Страница 324: ...e diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting setting to...

Страница 325: ...er to YAMAHA DIGNO STIC TOOL OPERATION MANUAL Operation of the Yamaha diagnostic tool Malfunction mode Malfunction results are displayed in the top part of the window area FI diagnostic tool sub lead...

Страница 326: ...ist of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displ...

Страница 327: ...he items or components that are the probable cause of the malfunction following the or der given After the check and service of the malfunctioning part have been completed reset the diagnostic tool di...

Страница 328: ...finished Fault code number is dis played Go to item 4 4 Installed condition of crank shaft position sensor Check for looseness or pinching Check the gap between the crankshaft position sensor and the...

Страница 329: ...replace the wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the...

Страница 330: ...ge 8 67 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 14 Item Intake air...

Страница 331: ...nsor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Diagnostic tool display Throttle position sensor signal 11 14 fully closed positio...

Страница 332: ...ION SEN SOR on page 7 9 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Applied voltage of throttle po sition sensor lead C...

Страница 333: ...sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Push the start switch Fault code number...

Страница 334: ...e har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking conditi...

Страница 335: ...intake air temperature Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value Item Probable cause of malfunc tion and check Maintenance job Confi...

Страница 336: ...ambient temper ature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENS...

Страница 337: ...coil is actuated Procedure Check that a spark is generated five times Connect an ignition checker Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Co...

Страница 338: ...played Service is finished Fault code number is dis played Go to item 5 5 Installed condition of ignition coil Check for looseness or pinching Improperly installed sensor Reinstall or replace the sens...

Страница 339: ...No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector re sistance Replace if out of specifica tion Refer to CHECKING THE FUEL INJECTOR on page 8 6...

Страница 340: ...vice is finished Fault code number is dis played 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 bent or bro...

Страница 341: ...bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5...

Страница 342: ...in Diagnostic mode Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment push the engine stop switch then push the...

Страница 343: ...et it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Wire harness continuity Open or short circuit Re place the...

Страница 344: ...malfunctioning Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of Yamaha diag nostic...

Страница 345: ...Yamaha diag nostic tool coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Co...

Страница 346: ...e wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking co...

Страница 347: ...is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Страница 348: ...R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B...

Страница 349: ...PUMP SYSTEM 8 47 1 Joint connector 2 Joint connector 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 20 Fuel pump 24 Joint connector 30 Engine stop switch 36 Frame gr...

Страница 350: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG...

Страница 351: ...FUEL PUMP SYSTEM 8 49...

Страница 352: ...ELECTRICAL COMPONENTS 8 50 EASB296346 ELECTRICAL COMPONENTS EASB296347 7 8 9 1 3 2 4 5 6...

Страница 353: ...ELECTRICAL COMPONENTS 8 51 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU engine control unit 5 Fuel pump 6 Battery 7 Neutral switch 8 Radiator fan motor For JPN 9 Injector...

Страница 354: ...ELECTRICAL COMPONENTS 8 52 11 10 9 2 3 1 6 7 8 4 5...

Страница 355: ...ature sensor 2 Intake air pressure sensor 3 Throttle position sensor 4 Starter relay 5 Main fuse 6 Starting circuit cut off relay 7 Lean angle sensor 8 Radiator fan motor fuse 9 Radiator fan motor rel...

Страница 356: ...ELECTRICAL COMPONENTS 8 54 EASB296348 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Страница 357: ...ELECTRICAL COMPONENTS 8 55 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Страница 358: ...et tester range to 1 to make a 0 adjustment When checking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal con...

Страница 359: ...th the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Seat Side cover left...

Страница 360: ...specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Side cover left right Seat Refer to GENERAL CHASSI...

Страница 361: ...nect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid...

Страница 362: ...ger is recommended d Charge the battery until the battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage af ter leaving the batter...

Страница 363: ...n 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 2 1 3 4 R W Br W R L G 1 2 3 4 L R Br R R R W 1 2 3 4 G B L B L G L W Result Continuity...

Страница 364: ...e ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs EASB296354 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from th...

Страница 365: ...r coupler b Measure the crankshaft position sensor re sistance EASB296357 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor output voltage Out of spe...

Страница 366: ...e coolant temperature sensor is dropped replace it b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resi...

Страница 367: ...or coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EASB296361 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor...

Страница 368: ...the table EASB296362 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body EWA WARNING Handle the throttle position sensor with special care Never subject the...

Страница 369: ...sure the throttle position sensor input voltage EASB296364 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket t...

Страница 370: ...the intake air temperature sensor terminal EASB296366 CHECKING THE FUEL INJECTOR 1 Remove Fuel injector Refer to THROTTLE BODY on page 7 5 2 Check Fuel injector resistance Out of specification Replace...

Страница 371: ...AND HIGH SPEED PERFORMANCE 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 CLUTCH SLIPS 9 2 CLUTCH DRAGS 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE...

Страница 372: ...pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or...

Страница 373: ...og EASB296375 CLUTCH SLIPS Engine 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity lo...

Страница 374: ...ked or damaged cap bolt O ring EASB296381 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorrect oil...

Страница 375: ...32 22 Intake air temperature sensor open or short circuit detected 8 33 30 Latch up detected 8 34 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 35 39 Injec...

Страница 376: ...en engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturned Displays...

Страница 377: ...o Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals WARNING on the Yamaha diagnostic tool blinks five times when the ignition...

Страница 378: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Страница 379: ...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 10 3 SET...

Страница 380: ...eed the ma chine is generally set 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 fro...

Страница 381: ...the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range EASB296391...

Страница 382: ...of damping force Change the rebound damping force Change the compression damping force EASB296394 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor...

Страница 383: ...ng load Run with the rebound damping force adjuster one or two clicks turned in and readjust it to suit your preference TIP Adjusting the rebound damping force will be fol lowed more or less by a chan...

Страница 384: ...BSORBER ASSEMBLY on page 3 31 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 i...

Страница 385: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Страница 386: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Страница 387: ...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 388: ...ensor 27 Throttle position sensor 28 Intake air pressure sensor 29 Lean angle sensor 30 Engine stop switch 31 Neutral switch 32 Diode 33 Starting circuit cut off relay 34 Clutch switch 35 Start switch...

Страница 389: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Страница 390: ...UAL YZ250FXG B29 28199 11 LIT 11626 29 53 YZ250FXG 2016 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015 07 0 3 1 E B29 28199 11_cover_12mm in...

Страница 391: ...L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R R W Br R L R B R R W Br W L G Br W Br L W R R L R Lg W B B B Gy B...

Страница 392: ...ON OFF ON OFF Gy Gy B B Gy B B B L L B B B B B YZ250FXG 2016 WIRING DIAGRAM B29 28199 11_W D indd 2 2015 06 15 13 19 32...

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