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EAM20082

HOW TO USE THIS MANUAL

In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.

•

The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.

•

Sub-section titles “2” appear in smaller print than the 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 the exploded diagram. A number indicates a removal
or a disassembly step.

•

Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.

•

A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the names
of parts, the notes in jobs, etc. This step explains removal and disassembly procedure only. For in-
stallation and assembly procedure, reverse the steps.

•

Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.

EASB29B238

CLUTCH

5-39

CLUTCH

Removing the clutch

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Engine oil

Drain.
Refer to “CHANGING THE ENGINE OIL”  on 
page 3-15.

.

1

-

5

 

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2

1

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3

5

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5

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1

 

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6

1

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7

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8

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B

9

1

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2

 

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1

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4

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2

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3

1

New

New

New

2

3

4

5

(5)

(6)

7

8

9

6 10

11

12

22

1

15

12

13

13

18

19

20

17

16

14

13

LT

21

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)  

75 N

・

m (7.5 kgf

・

m, 55 lb

・

ft)  

CLUTCH

5-42

EASB29B239

REMOVING THE  CLUTCH

1. Remove:

• Clutch boss nut “1”
• Lock washer “2”
• Clutch boss “3”

TIP

• Straighten the lock washer tab.
• While holding the clutch boss with the clutch 

holder “4”, loosen the clutch boss nut.

EASB29B240

CHECKING THE FRICTION PLATES

1. Check:

• Friction plate

Damage/wear 

 Replace the friction plates 

as a set.

2. Measure:

• Friction plate thickness

Out of specification 

 Replace the friction 

plates as a set.

TIP

Measure it at four points on the friction plate.

EASB29B241

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 specification 

 Replace the clutch 

plates as a set.

EASB29B242

CHECKING THE CLUTCH SPRINGS

1. Check:

• Clutch spring

Damage 

 Replace the clutch springs as a 

set.

2. Measure:

• Clutch spring free length

Out of specification 

 Replace the clutch 

springs as a set.

Universal clutch holder

90890-04086

Universal clutch holder

YM-91042

Friction plate 1 thickness

2.90–3.10 mm (0.114–0.122 in)

Wear limit

2.85 mm (0.112 in)

Friction plate 2 thickness

2.90–3.10 mm (0.114–0.122 in)

Wear limit

2.85 mm (0.112 in)

3

4

1

2

Warpage limit

0.10 mm (0.004 in)

Clutch spring free length

47.80 mm (1.88 in)

Limit

45.41 mm (1.79 in)

1

7

3

4

6

2

5

Содержание YZ 2019 Series

Страница 1: ...17 Read this manual carefully before operating this vehicle YZ250FXK OWNER S SERVICE MANUAL YZ250FX 2019 PRINTED IN JAPAN 2018 04 0 3 1 E PRINTED ON RECYCLED PAPER 2019 YZ250FXK B29 28199 14_13mm ind...

Страница 2: ...uals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly thro...

Страница 3: ...019 by Yamaha Motor Corporation U S A 1st Edition March 2018 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib...

Страница 4: ...equested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MAN...

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

Страница 7: ...p e r u s s e r P 5 1 1 d o r h s u P 6 1 p i l c r i C 7 1 r e h s a W 8 1 g n i r a e B 9 1 l l a B 0 1 1 2 d o r h s u P 1 1 4 1 e t a l p n o i t c i r F 2 1 8 e t a l p h c t u l C 3 1 New New N...

Страница 8: ...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 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: ...RTS 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 INFORMATION 1 7 ELECTRICAL SYSTEM 1 7 SPECIAL TOOLS 1 11 CONTROL...

Страница 12: ...BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 22 MAJOR MAINTENANCE 1 22 TORQUE CHECK POINTS 1 23 MOTORCYCLE CARE AND STORAGE 1 25 CARE 1 25 STORAGE 1 26...

Страница 13: ...soline 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: ...e you have purchased 4 2 3 1 9 10 11 8 7 6 5 13 12 19 18 1716 15 14 1 Clutch lever 2 Engine trouble warning light 3 Fuel level warning light 4 Front brake lever 5 Throttle grip 6 Start switch 7 Radiat...

Страница 15: ...positive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicl...

Страница 16: ...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 s...

Страница 17: ...for each 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 t...

Страница 18: ...M30013 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces the...

Страница 19: ...ead 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 battery terminals Reversing the...

Страница 20: ...n push the starter switch Be sure to wait for five seconds or longer before pushing the start switch after the engine is stopped Checking the electrical system TIP Before checking the electrical syste...

Страница 21: ...re to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disco...

Страница 22: ...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 quick remedy us...

Страница 23: ...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 tachom...

Страница 24: ...403 Exhaust flange nut wrench YU A9472 3 34 4 51 Timing light 90890 03141 Timing light YU 03141 3 37 Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 4 39 4 39 4 40 4 43 4 46 4 48 Cap bo...

Страница 25: ...M 04108 5 23 5 28 Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 25 Valve guide installer 5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 25 Valve guide reamer 5 90890 0...

Страница 26: ...set 90890 01304 Piston pin puller YU 01304 5 30 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 42 5 45 Rotor puller 90890 04142 Rotor puller YM 04142 5 60 Crankcase separating...

Страница 27: ...t 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 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 4 Fuel pressure ad...

Страница 28: ...3212 FI diagnostic tool sub lead YU 03212 8 24 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 61 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P...

Страница 29: ...hecked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the start switch is pushed or if the warning...

Страница 30: ...down on the brake pedal to acti vate the rear brake EAM30190 SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it WARNING EWA18980 Never apply additional for...

Страница 31: ...over 2 Remove the fuel tank cap cover to open the fuel tank cap TIP To remove the fuel tank cap cover insert fin gers under part a and then use both hands to lift it up towards the rear of the vehicle...

Страница 32: ...ery short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine pe...

Страница 33: ...DURES A break in is important so that rotating portion sliding surfaces and mounted areas may fit one another and that the rider may become accus tomed to the machine NOTICE ECA25811 Before running do...

Страница 34: ...or is not being discon nected 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 an...

Страница 35: ...ink to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of w...

Страница 36: ...l tank Fuel sender to fuel tank 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...

Страница 37: ...hemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhib...

Страница 38: ...aust system are cool before covering the mo torcycle NOTICE ECA24250 Storing the motorcycle in a poorly ventilat ed room or covering it with a tarp while it is still wet will allow water and humidity...

Страница 39: ...he battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery refer to CHECKING AND CHARGING THE BAT TERY on page 8 57 TIP Mak...

Страница 40: ...MOTORCYCLE CARE AND STORAGE 1 28...

Страница 41: ...ICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 19...

Страница 42: ...del Model B29M 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 clearance 325 mm 12 80...

Страница 43: ...US qt 0 73 Imp qt With oil filter removal 0 85 L 0 90 US qt 0 75 Imp qt Quantity disassembled 1 10 L 1 16 US qt 0 97 Imp qt Oil filter Oil filter type Paper Oil pump Inner rotor to outer rotor tip cl...

Страница 44: ...meter intake 5 000 5 012 mm 0 1969 0 1973 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance in take 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080...

Страница 45: ...limit 0 10 mm 0 004 in Clutch spring free length 47 80 mm 1 88 in Limit 45 41 mm 1 79 in Push rod bending limit 0 30 mm 0 012 in Drivetrain Primary reduction ratio 3 353 57 17 Transmission type Const...

Страница 46: ...ONS 2 5 Engine oil temperature 70 80 C 158 176 F Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Throttle grip free play 3 0 6 0 mm 0 12 0 24 in Front brake lever free play 2 7 11...

Страница 47: ...ed 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 Disc outside diameter thickness 270 0 3 0 mm 10 63 0 12 in Brake disc thi...

Страница 48: ...ing system Mechanical adjustable type Unit for compression damping adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 14 Adjustment value fr...

Страница 49: ...stment value from the start position Soft 20 Adjustment value from the start position STD 13 Adjustment value from the start position Hard 0 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in...

Страница 50: ...sistance 0 528 0 792 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 23 0 A Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah 10 HR Indicator lig...

Страница 51: ...resistance 290 389 at 80 C 290 389 at 176 F Coolant temperature sensor resistance 2513 2777 at 20 C 2513 2777 at 68 F Coolant temperature sensor resistance 210 221 at 100 C 210 221 at 212 F Fuse s Mai...

Страница 52: ...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 speci...

Страница 53: ...ain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant...

Страница 54: ...2 kgf m 8 9 lb ft Clutch cable holder bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Crankshaft end accessing screw M36 1 10 N m 1 0 kgf m 7 4 lb ft Timing mark accessing screw M14 1 6 N m 0 6 kgf m 4 4 lb ft D...

Страница 55: ...1 0 kgf m 7 4 lb ft Starter clutch bolt M6 6 16 N m 1 6 kgf m 12 lb ft Starter motor bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Coolant temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Neutral switch bolt...

Страница 56: ...ork and base valve M5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Front fork protector and brake hose holder bolt M6 2 9 N m 0 9 kgf m 6 6 lb ft Throttle g...

Страница 57: ...nut M8 6 50 N m 5 0 kgf m 37 lb ft Nipple spoke 72 2 5 N m 0 25 kgf m 1 8 lb ft Rear brake disc cover bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb...

Страница 58: ...bracket and fuel tank 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 Left side cover bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Right side cover bolt M6 2 7 N m 0 7 kgf m 5 2 l...

Страница 59: ...oximately 38 N m 3 8 kgf m 28 lb ft by using the steering nut wrench then loosen the lower ring nut one turn 2 Retighten the lower ring nut 7 N m 0 7 kgf m 5 2 lb ft Rear fender and relay bracket scre...

Страница 60: ...ston pin outer surface Balancer shaft journal left Balancer nut threads left Decompression system moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump sha...

Страница 61: ...Lower bearings and oil seal lip steering head Steering stem threads and nut contacting surface Pivot shaft bearing Swingarm pivot portion collar side surface and thrust bearing Swingarm pivot portion...

Страница 62: ...hrottle grip inner surface and throttle cable end Front brake caliper piston Front brake caliper piston seal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper...

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

Страница 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAM20151 LUBRICATION SYSTEM CHART AND DIAGRAMS EAM30331 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 EAM20152 CABLE ROUTING DIAGRAM...

Страница 73: ...lead under the starter clutch cover N Pass the neutral switch lead to the inside of the front engine bracket the side of the vehi cle O Insert the plastic locking tie into the bracket hole and clamp...

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

Страница 75: ...heet metal of 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...

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

Страница 77: ...the cover C Pass the throttle position sensor lead to the outside of the tension arm the outside of the vehicle D After connecting the throttle position sensor coupler attach the cover E Pass the radi...

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

Страница 79: ...e 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 Route the diode under the cross member and place...

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

Страница 81: ...witch lead between the head pipe and the cable guide E Pass the warning light lead between the head pipe and cable guide F Pass the front brake hose to the front of the number plate G Pass the start s...

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

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

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

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

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

Страница 87: ...INE 3 13 CHECKING THE ENGINE OIL LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 ADJUSTING THE ENGINE IDLING SPEED 3 15 ADJUSTING THE VALVE CLEARANCE 3 16 VALVE CLEARANCE SHIM CHART 3 19 CHASSIS 3 21 BLEEDING...

Страница 88: ...ING THE CABLES 3 34 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDAL 3 34 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 35 CHECKING THE CHASSIS FASTENERS 3 35 ELECTRICAL SYSTEM 3 36 CH...

Страница 89: ...valve faces for wear Replace Valve spring Inspect Check the free length and the tilt Replace Valve lifter Inspect Check for scratches and wear Replace Camshaft Inspect Inspect the camshaft surface Ins...

Страница 90: ...body Inspect Air filter Clean and lubricate Use Yamaha foam air filter oil or other quality foam air filter oil Replace Breather system Inspect Check ventilation hose for cracks or damage and drain an...

Страница 91: ...lace brake fluid Every one year Swingarm Inspect lube and retighten Molybdenum disulfide grease Relay arm con necting rod Inspect lube and retighten Molybdenum disulfide grease Sidestand Lubricate Lit...

Страница 92: ...rottle body for dirt and wear Levers Adjust clutch lever free play Brake pedal foot rest Lubricate Outside nuts and bolts Retighten Refer to TORQUE CHECK POINTS on page 1 23 Battery Inspect Check term...

Страница 93: ...ive chain is lubricated properly 3 27 4 65 4 65 4 66 4 66 4 66 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 32 3 32 3 33 3 33 Steering Check th...

Страница 94: ...INSPECTION AND MAINTENANCE 3 6 TIP Perform usual maintenance enough so that in the race course a confirmation of that and simple setting adjustments may only be left in order to get enough time to us...

Страница 95: ...ew minutes until the coolant has settled EAM30211 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...

Страница 96: ...lant level Refer to CHECKING THE COOLANT LEV EL on page 3 7 EAM30213 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or repla...

Страница 97: ...oolant leaks Correct or replace Radiator hoses Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand EAM30216 ADJUSTING...

Страница 98: ...ree play a Out of specification Regulate 2 Adjust Throttle grip free play a Loosen the locknut 1 b Turn the adjuster 2 until the specified free play is obtained c Tighten the locknut WARNING EWA20330...

Страница 99: ...e cover 2 TIP Loosen the quick fastener screw 3 and remove the air filter case cover 2 Remove Air filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air filter element 3 Wash Air...

Страница 100: ...r hose 1 Crack damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly EAM30221 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe...

Страница 101: ...warm this up for 3 minutes and then stop the engine and wait about 5 minute 3 Check Oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimu...

Страница 102: ...and oil filter element 2 b Replace the O ring 3 c Install the new oil filter element and the oil fil ter element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil str...

Страница 103: ...pressure check bolt EAM30336 ADJUSTING THE ENGINE IDLING SPEED TIP Because the air pressure is lower at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the star...

Страница 104: ...l damage Make sure that the valve clearance is checked or adjusted while the engine is cold at room temperature While the valve clearance is checked or adjust ed make sure that the piston is positione...

Страница 105: ...the clearance is incorrect 5 Adjust Valve clearance a Remove the camshaft intake and exhaust Refer to CAMSHAFT on page 5 11 b Remove the valve lifter 2 and the adjusting pad 3 with a valve lapper 1 T...

Страница 106: ...d number to replace Example Pad number 148 Rounded value 150 e Install the new adjusting pads 4 and the valve lifters 5 NOTICE ECA24310 Do not twist adjusting pads and valve lifters forcibly during in...

Страница 107: ...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 108: ...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 109: ...astic hose 1 to the bleed screw 2 securely and place a container un der the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the brake pe...

Страница 110: ...cknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut WARNING EWA13050 A soft or spongy feeling in the brake lever can indi...

Страница 111: ...e brake sys tem Air in the brake system will cause brak ing performance to be reduced NOTICE ECA13510 After adjusting the brake pedal position make sure there is no brake drag EAM30231 CHECKING THE FR...

Страница 112: ...their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake...

Страница 113: ...WHEEL on page 4 7 d Remove 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 pu...

Страница 114: ...ake pad Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EAM30234 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a level surface TIP In order to ensure...

Страница 115: ...d to raise the rear wheel off the ground WARNING EWA13120 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 the driv...

Страница 116: ...ly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 37 EAM30236 CHECKING THE FRONT FORK PROTECTOR GUIDE 1 Check Protector guide 1 Out of specification Replace TIP The protector guid...

Страница 117: ...mping NOTICE ECA24340 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Rebound damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Compression damping N...

Страница 118: ...oth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 54 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground...

Страница 119: ...or b to make an adjustment Direction b Spring preload is increased suspen sion is harder Direction c Spring preload is decreased suspen sion is softer Spring preload Minimum Position in which the spr...

Страница 120: ...off its position Cor rect the tire position EAM30244 CHECKING AND TIGHTENING THE SPOKES 1 Check Spoke Bend damage Replace Loose Tighten Fast compression damping Minimum soft 2 turn s in direction b S...

Страница 121: ...ING THE FRONT WHEEL on page 4 4 and CHECKING THE REAR WHEEL on page 4 8 EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1 Use a maintenance stand to raise the front wheel off the ground WARNING EWA1...

Страница 122: ...e following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and...

Страница 123: ...efore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubrica...

Страница 124: ...rk 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 5 Clean Spark plug with a spark...

Страница 125: ...firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EAM30256 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CH...

Страница 126: ...ELECTRICAL SYSTEM 3 38...

Страница 127: ...RAKE CALIPER 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 BRAK...

Страница 128: ...MBLY 4 54 HANDLING THE REAR SHOCK ABSORBER 4 57 DISPOSING OF A REAR SHOCK ABSORBER 4 57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 REMOVING THE BEARING 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Страница 129: ...Air scoop right 1 4 Side cover left 1 5 Side cover right 1 6 Side cover 2 left 1 7 Number plate 1 8 Rear fender 1 4 2 6 8 5 1 3 7 2 1 3 N m 0 13 kgf m 0 95 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0...

Страница 130: ...seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 19 2 Remove Seat 1 EAM30371 REMOVING THE NUMBER PLATE 1 Remove Bolt number plate N...

Страница 131: ...se the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 LT LS LS LS 5...

Страница 132: ...32 and CHECKING THE WHEELS on page 3 33 3 Check Spoke 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...

Страница 133: ...ing 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 its man...

Страница 134: ...ont wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 NOTICE ECA24430 Before tightening the front wheel axle nut push down hard on the handl...

Страница 135: ...round 1 Nut rear wheel axle 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 6 2 5 7 9 LS LS 6 4 6 1...

Страница 136: ...n page 3 33 3 Check Spoke Refer to 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 EAM30024 DISASSEMBLING THE REAR...

Страница 137: ...th its manufacture s marks or numbers facing outward NOTICE ECA24440 Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter of the bearing outer race and...

Страница 138: ...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 axle at thi...

Страница 139: ...M on page 3 21 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...

Страница 140: ...embling the front brake caliper Order Job Parts to remove 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 1 2 3 4 S S BF BF S 6 N...

Страница 141: ...1 2 Union 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 maste...

Страница 142: ...FRONT BRAKE 4 14 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 BF 5 4 3 2 1 S...

Страница 143: ...tention EAM30029 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 di...

Страница 144: ...icating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When the brake caliper is disassembled re place the brake caliper piston seal and the...

Страница 145: ...eservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill w...

Страница 146: ...YLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder...

Страница 147: ...1 TIP Install the front brake 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...

Страница 148: ...he brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic...

Страница 149: ...opper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake cal...

Страница 150: ...sassembling the rear brake caliper Order Job Parts to remove 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 1 2 3 4 S BF 6 N m 0...

Страница 151: ...21 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 cylinder...

Страница 152: ...REAR BRAKE 4 24 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 4 3 2 1 BF S...

Страница 153: ...M30041 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 f...

Страница 154: ...eal EAM30044 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 caliper assem...

Страница 155: ...rake caliper piston 1 TIP Apply the brake fluid on the piston outer surface NOTICE ECA24480 Install the piston with its side a facing the brake caliper Never force to insert EAM30047 INSTALLING THE RE...

Страница 156: ...el mark a or below Add Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 26 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM on page 3...

Страница 157: ...uses poor braking performance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the brake master cylinder piston 4 Install Maste...

Страница 158: ...rmance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA24510 Brak...

Страница 159: ...e cable cap 1 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 Lowe...

Страница 160: ...AM30054 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 han...

Страница 161: ...Handlebar grip 1 a Slightly coat the handlebar left end with a rub ber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive wi...

Страница 162: ...ff 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 cov...

Страница 163: ...e master cylinder assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order f...

Страница 164: ...er free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 9 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 10 Clutch lever free play 7 0 12 0 mm...

Страница 165: ...efer to FRONT WHEEL on page 4 3 Front brake 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 bolt 2 Loosen 3 Damper assem...

Страница 166: ...1 5 Stopper ring 1 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 LS 14 2 7 10 9 11 12 5 3 1 6 8 13...

Страница 167: ...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 168: ...ent 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 damage...

Страница 169: ...LEGS WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure t...

Страница 170: ...3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Locknut 1 TIP Fully finger tighten the locknut onto the damper assembly 6 Loosen Compression damping force adjuster 1 TIP...

Страница 171: ...valve side NOTICE ECA24540 Take care not to damage the 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 3...

Страница 172: ...ct the oil seal lip 15 Install Inner tube bushing 1 TIP Install the inner tube bushing onto the slot on in ner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Inner tube bushing 1 Washer 2...

Страница 173: ...rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn into the locknut 23 Install Collar 1 Fork spring 2 to the damper assembly 3 TIP Install the collar with its large...

Страница 174: ...ter 3 to the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27...

Страница 175: ...en the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts...

Страница 176: ...TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to...

Страница 177: ...FRONT FORK 4 49 1...

Страница 178: ...t fender 1 2 Steering stem nut 1 3 Front fork leg 2 Refer to FRONT FORK on page 4 37 4 Warning light 1 5 Upper bracket 1 6 Steering ring nut 1 7 Lower bracket 1 8 Bearing race cover 1 9 Upper bearing...

Страница 179: ...ace 3 Replace Bearing Bearing race 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...

Страница 180: ...steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 33 5 Check the steering ste...

Страница 181: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Страница 182: ...r 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 shock absorber assembly 1 4 Loc...

Страница 183: ...15 Stopper ring 1 16 Bearing 1 Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9 9 10 10 11 1 13 LS LS M M M M M 53 N m 5 3 kgf m 3...

Страница 184: ...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 5 6 6 5 4 3 2 4 6 6 3 4 4 M M M...

Страница 185: ...f run ning EAM30064 DISPOSING OF A REAR SHOCK ABSORBER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 WARNING EWA19340 Wear protective glasses to prevent you...

Страница 186: ...Damage wear Replace Bearing Damage wear Replace Bolt Bends damage wear Replace EAM30068 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay arm Damage wear Replace 2 Check Bearing S...

Страница 187: ...swingarm bolt circumference and threaded portion Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt 6 Install Rear shock absorber assembly TIP When installing the rear sh...

Страница 188: ...EAR SHOCK ABSORBER ASSEMBLY 4 60 Rear shock absorber assembly lower bolt Relay arm bolt swingarm side 70 N m 7 0 kgf m 52 lb ft Rear shock absorber assembly lower bolt 53 N m 5 3 kgf m 39 lb ft T R T...

Страница 189: ...e the front wheel off the ground Brake 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 Collar 2 2 Oil seal 2 3 Thrust be...

Страница 190: ...ving 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 EAM30072 REMOVING THE BEARING 1 Remove Bearing 1 TIP Rem...

Страница 191: ...garm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Recommended lubric...

Страница 192: ...4 64 EAM20104 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 1 75 N m 7 5 kgf m 55 lb ft 7 N m 0 7 kgf...

Страница 193: ...h a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a diff...

Страница 194: ...CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety...

Страница 195: ...this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 NOTICE ECA24590 A drive chain that is too tight will overload th...

Страница 196: ...CHAIN DRIVE 4 68...

Страница 197: ...OMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE...

Страница 198: ...49 INSTALLING THE STOPPER LEVER 5 49 INSTALLING THE SEGMENT 5 50 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 50 INSTALLING THE SHIFT SHAFT 5 51 INSTALLING THE SHIFT PEDAL 5 51 OIL PUMP AND B...

Страница 199: ...NG THE CRANKSHAFT ASSEMBLY 5 70 INSTALLING THE CRANKSHAFT ASSEMBLY 5 70 INSTALLING THE BALANCER SHAFT 5 71 TRANSMISSION 5 72 REMOVING THE TRANSMISSION 5 73 CHECKING THE SHIFT FORKS 5 73 CHECKING THE S...

Страница 200: ...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 Exhaust pipe 2 protector 1 9 Silencer body 1 10 Si...

Страница 201: ...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 switch 1 5 AC magne...

Страница 202: ...HROTTLE BODY on page 7 6 Clutch cable Refer to CLUTCH on page 5 39 Shift pedal Refer to SHIFT SHAFT on page 5 48 Starter motor Refer to ELECTRIC STARTER on page 5 34 1 Engine guard 1 2 Brake pedal 1 3...

Страница 203: ...Parts to remove Q ty Remarks New New LS M 8 8 7 6 13 4 5 New 1 12 3 2 11 11 10 9 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 55 N m 5 5 kgf m 41 lb ft 45 N m 4 5 kgf m 33 lb ft 45 N m 4 5 kgf...

Страница 204: ...2 TIP Put the exhaust pipe 2 into the state as shown by moving this and then remove it EAM30160 REMOVING THE DRIVE SPROCKET 1 Straighten the lock washer tab 2 Remove Nut drive sprocket 1 Lock washer 2...

Страница 205: ...e and remove this from its low er part toward the right of the chassis EAM30163 CHECKING THE SILENCER AND EXHAUST PIPE 1 Check Gasket 1 Damage Replace EAM30373 CHANGING THE SILENCER FIBER 1 Remove Bol...

Страница 206: ...care not to allow the fiber out of place when installing the silencer body 3 EAM30164 INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from the right side Pivot shaft 2 Engine mounting bolt...

Страница 207: ...ET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 TIP Tighten the nut while applying the rear brake...

Страница 208: ...2 0 kgf m 15 lb ft 2 Install Clamp Exhaust pipe 2 1 Bolt exhaust pipe 2 2 TIP Install and temporarily tighten the exhaust pipe 2 with its end positioned as shown with respect to the exhaust pipe 1 3 I...

Страница 209: ...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 20 N m 2 0 kgf m 15 lb ft Clamp 12 N m 1 2 kgf m 8 9 lb ft...

Страница 210: ...CHASSIS on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cy...

Страница 211: ...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 5 8 3 4 1 2 7 6 5 4 4 6 M M E New New New E E 10 N m 1 0 kgf m 7 4...

Страница 212: ...mshaft sprocket with 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 ca...

Страница 213: ...to the camshaft journal as shown c Install the dowel pins and the camshaft caps TIP Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps Do not turn the camshaft when me...

Страница 214: ...the camshaft and the timing chain as a set EAM30083 CHECKING THE TIMING CHAIN TENSIONERS 1 Check Timing chain tensioner Crack damage Replace a While pressing the tensioner rod lightly with your finge...

Страница 215: ...head TIP Make sure that the alignment mark c on the ex haust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head NOTICE ECA24620...

Страница 216: ...Turn Crankshaft Counterclockwise 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 al...

Страница 217: ...CAMSHAFT 5 18 Spark plug Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R...

Страница 218: ...1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 6 Camshaft Refer...

Страница 219: ...ent 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 VALVE...

Страница 220: ...e 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 221: ...es and valve springs Order Job Parts to remove 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 spri...

Страница 222: ...act width Refer to CHECKING THE VALVE SEATS on page 5 25 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves are properly sealed TIP Check that there are no kerosene lea...

Страница 223: ...n 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 remov er 1 Valve stem to valve guide clearance Valve g...

Страница 224: ...KING THE VALVE SEATS 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification...

Страница 225: ...es with new ones without them When replacing the valves or the 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...

Страница 226: ...spring EAM30094 CHECKING THE VALVE LIFTERS 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head EAM30095 INSTALLING THE VALVES 1 Clean Valve stem end 2 Lubricate Valve st...

Страница 227: ...CA13800 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 smoothly...

Страница 228: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 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 1 1 2...

Страница 229: ...lift 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 rep...

Страница 230: ...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 exces sive replac...

Страница 231: ...ston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the F mark a on it point ing to its intake front side Before installing the piston pin clip cover the crankcase openi...

Страница 232: ...TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a Top ring b Up...

Страница 233: ...RIC STARTER 5 34 EAM20110 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 1 12 N m 1 2 kgf m 8 9 l...

Страница 234: ...5 Disassembling 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 3 5 N m 0...

Страница 235: ...specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Bru...

Страница 236: ...the part that has a smaller step differ ence a with the magnet of the starter motor yoke facing the starter motor front cover TIP Align the match mark a on the starter motor yoke with the match mark b...

Страница 237: ...ELECTRIC STARTER 5 38...

Страница 238: ...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 rod 2 1 12 Friction plate 1 4 13 Clutch plate 8 14 Cushion spring 1 15 Fric...

Страница 239: ...ring 1 21 Washer 1 22 Push lever shaft 1 Removing the clutch Order Job Parts to remove Q ty Remarks New New New 2 3 4 5 5 6 7 8 9 6 10 11 12 22 1 15 12 13 13 18 19 20 17 16 14 13 LT 21 10 N m 1 0 kgf...

Страница 240: ...Drain Refer to CHANGING THE COOLANT on page 3 7 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 39 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiato...

Страница 241: ...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 specification Replace the clutch plates as a set EAM30111...

Страница 242: ...KING THE PRESSURE PLATE 1 Check Pressure plate Crack damage Replace EAM30115 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EAM30116 CHECKING THE CLUTCH PUSH RODS 1 Check P...

Страница 243: ...ll Oil seal 1 Washer 2 Circlip 3 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal in parallel with its manufac ture s marks or numbers facing inward EAM30120 INSTALLING...

Страница 244: ...oil on the primary driven gear inner circumference 3 Install Lock washer 1 Clutch boss nut 2 NOTICE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas...

Страница 245: ...te 1 2 friction plate 2 identification color purple 5 and friction plate 1 2 Apply the engine oil on the friction plates and clutch plates 6 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 TIP Ap...

Страница 246: ...CLUTCH 5 47 10 Install Gasket 1 11 Install Clutch cover 1 Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 New T R 1...

Страница 247: ...Collar 1 2 Shift pedal 1 3 Shift shaft 1 4 Oil seal 1 5 Collar 1 6 Shift shaft spring 1 7 Roller 1 8 Shift guide 1 9 Shift lever assembly 1 10 Shift lever 1 11 Pawl 2 12 Pawl pin 2 13 Spring 2 14 Sto...

Страница 248: ...egment gets an impact the stopper le ver may be damaged Take care not to give an impact to it when removing the bolt EAM30125 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace S...

Страница 249: ...NSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 t...

Страница 250: ...t shaft 4 TIP Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EAM30132 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on...

Страница 251: ...ty Remarks Primary driven gear Refer to CLUTCH on page 5 39 Right crankcase cover Refer to CLUTCH on page 5 39 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6...

Страница 252: ...TOR AND STARTER CLUTCH on page 5 58 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer weight gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Bala...

Страница 253: ...EAR 1 Check Primary drive gear 1 Balancer drive gear 2 Balancer weight gear 3 Wear damage Replace EAM30135 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EAM30136 CHECKING THE OIL PUMP 1...

Страница 254: ...ine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 EAM30138 INSTALLING THE OIL PUMP AND BALANCER GEAR 1 Install Oil pump assembly 1 Inner rotor to outer rotor tip clearance 0...

Страница 255: ...er 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 contact surface and threaded portion of the p...

Страница 256: ...OIL PUMP AND BALANCER GEAR 5 57 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 257: ...pedal Refer to SHIFT SHAFT on page 5 48 1 Cover Damper assembly 1 2 Damper assembly 1 3 Breather hose 1 4 Left crankcase cover 1 5 Gasket 1 6 Dowel pin 2 7 Starter idle gear 1 8 Bearing 1 9 Starter id...

Страница 258: ...ing the generator Order Job Parts to remove Q ty Remarks T R T R 6 6 11 9 8 7 2 3 1 14 4 5 12 10 13 T R T R T R LT T R T R 15 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4...

Страница 259: ...pitting wear Replace the damper assembly Check the gear of the starter motor armature 5 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch and hold the st...

Страница 260: ...tor 2 EAM30142 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the crankshaft and generator rotor When installing the woo...

Страница 261: ...switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using a crisscross pattern 5 Install Washer 1 Damper assembly 2 Washer 3 TIP Apply the...

Страница 262: ...GENERATOR AND STARTER CLUTCH 5 63 1 a 3 3 2 4...

Страница 263: ...e 5 48 Stator Refer to GENERATOR AND STARTER CLUTCH on page 5 58 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45 mm 1 77 in 7 5 Bolt L 60 mm 2 36...

Страница 264: ...arks Transmission Refer to TRANSMISSION on page 5 72 Shift cam and shift fork Refer to TRANSMISSION on page 5 72 1 Circlip 2 2 Oil seal 3 3 Bearing 11 LT LT 2 3 3 3 3 3 3 3 3 3 New 1 1 2 3 New New LT...

Страница 265: ...r to tap on the case half 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 c...

Страница 266: ...ly the lithium soap based grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be posit...

Страница 267: ...CRANKCASE 5 68 4 45 mm 1 77 in 5 60 mm 2 36 in 6 75 mm 2 95 in a Hexagon socket head bolt without flange b Hexagon socket head bolt with flange 5 4 5 4 4 4 6 6 6 4 a b 2 1 LT 2 3 6...

Страница 268: ...SEMBLY 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 64 Transmission Refer to TRANSMISSI...

Страница 269: ...2 Measure Crank assembly width a Out of specification Replace the crank shaft 3 Check Crankshaft sprocket 1 Damage Replace the crankshaft 4 Check Crankshaft journal oil passage Obstruction Blow out wi...

Страница 270: ...ankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing EAM30381 INSTALLING THE BALANCER SHAFT 1 Install Balancer shaft 1 T...

Страница 271: ...Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 64 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring...

Страница 272: ...xle lightly with a soft hammer EAM30154 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll...

Страница 273: ...pinion gear 27T 1 3rd 4th pinion gear 18T 21T 2 Collar 3 5th pinion gear 23T 4 2nd pinion gear 16T 5 to the main axle 6 TIP Before installation apply molybdenum disulfide oil to the inner and end sur...

Страница 274: ...Main axle 1 Drive axle 2 TIP Install to the left crankcase 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 Shif...

Страница 275: ...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 276: ...TRANSMISSION 5 77...

Страница 277: ...OOLING SYSTEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 5 CHECKING THE WATER PUMP 6 5 CHECKING THE BEARING 6 5 INSTALLING THE OIL SEAL 6 5 ASSEMBL...

Страница 278: ...Refer to FUEL TANK on page 7 1 Air filter case Refer to THROTTLE BODY on page 7 6 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Right radiator 1 4 Radiator hose 2 1 5 Radiator hose 3 1 6 Radiato...

Страница 279: ...g the radiator Order Job Parts to remove Q ty Remarks 11 12 LS LS 3 4 5 6 7 8 9 10 2 2 2 2 2 2 2 1 1 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 1 5 N m 0 15 kgf m...

Страница 280: ...he radi ator cap EAM30341 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radia tor Damage Repair or replace TIP Correct any flattened fins wit...

Страница 281: ...il Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 39 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 Impel...

Страница 282: ...Replace EAM30261 INSTALLING THE OIL SEAL 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...

Страница 283: ...3 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 2 1 1 New T...

Страница 284: ...WATER PUMP 6 7...

Страница 285: ...VING THE FUEL SENDER 7 3 CHECKING THE FUEL SENDER 7 3 INSTALLING THE FUEL SENDER 7 3 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 4 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROT...

Страница 286: ...eft right Refer to GENERAL CHASSIS on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump 1 6 Fuel pump gasket 1 7 Fuel sender 1 4 6 2 2...

Страница 287: ...uded fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnected fuel hose and the fuel pump 3 Remove Side cover left right Seat Air scoop left right Fuel tank TIP Do not set the...

Страница 288: ...tall the fuel sender make sure that the projection a faces the rear of the vehicle EAM30267 INSTALLING THE FUEL TANK 1 Install Fuel tank 2 Connect Fuel hose NOTICE ECA24740 Connect the fuel hose secur...

Страница 289: ...he fuel hose is disconnected by hand Do not forcibly disconnect the hose with tools d Connect the pressure gauge 1 and the fuel pressure adapter 2 to the fuel hose e Start the engine f Measure the fue...

Страница 290: ...FUEL TANK 7 5 A Left B Right 1 1 A 0 mm 0 in B 1 1 15 mm 0 59 in...

Страница 291: ...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 Intake ai...

Страница 292: ...e body joint 1 Removing the throttle body Order Job Parts to remove Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 3 5 N m 0...

Страница 293: ...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 2 5 4 3 5 N m 0 5 kgf m 3 7 lb ft 3 4 N m 0 34 kgf...

Страница 294: ...foreign 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 cleaning solution Do not directl...

Страница 295: ...r to YAMAHA DIAGNOSTIC TOOL on page 8 23 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 S...

Страница 296: ...THROTTLE BODY 7 11...

Страница 297: ...8 23 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL 8 23 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 8 23 TROUBLESHOOTING DETAILS 8 25 FUEL PUMP SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 47 ELECTRICAL CO...

Страница 298: ...KING THE RESISTOR 8 65 CHECKING THE COOLANT TEMPERATURE SENSOR 8 66 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 8 66 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 67 CHECKING THE FUEL INJECTOR...

Страница 299: ......

Страница 300: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R...

Страница 301: ...nt connector 4 AC magneto 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 29 Joint connector 34 Lean angle sensor 35 Engine stop switch...

Страница 302: ...spark plug Refer to CHECKING THE SPARK PLUG on page 3 36 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 61 OK The ignition s...

Страница 303: ...IGNITION SYSTEM 8 4 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU...

Страница 304: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W...

Страница 305: ...Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 12 Starter motor 13 Starter relay diode 21 ECU Engine Control Unit 29 Joint connector 35 Engine stop switch 36 Neutral switch 37 Diod...

Страница 306: ...r 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 been met In this instance th...

Страница 307: ...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 308: ...tion 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 step 5 NG 4 Check the starter motor Refer to...

Страница 309: ...G Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the engine stop switch OK 12 Check the start switch Refer to CHECKING THE SWITCHES...

Страница 310: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R...

Страница 311: ...CHARGING SYSTEM 8 12 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 43 Negative battery lead...

Страница 312: ...ARGING 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 assembly...

Страница 313: ...CHARGING SYSTEM 8 14...

Страница 314: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R...

Страница 315: ...nector 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 14 Warning light 16 Fuel level warning light 17 Resistor 18 Fuel sender 21 ECU Engine Control Unit 29 Joint...

Страница 316: ...ls Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 60 NG Replace the main relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGR...

Страница 317: ...SIGNALING SYSTEM 8 18 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 15 NG Properly connect or repair the signaling system s wiring OK Replace the ECU...

Страница 318: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Страница 319: ...4 Warning light 15 Engine trouble warning light 21 ECU Engine Control Unit 24 Injector 29 Joint connector 30 Intake air temperature sensor 31 Coolant temperature sensor 32 Throttle position sensor 33...

Страница 320: ...ation and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warnin...

Страница 321: ...nstatement action for the fuel injection system Refer to Confirmation of service com pletion in the appropriate table in TROUBLESHOOTING DETAILS on page 8 25 4 After pushing the engine stop switch pus...

Страница 322: ...he diagnostic tool cannot be used to freely change the basic vehicle functions such as ad justing the ignition timing EAM30356 CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting...

Страница 323: ...w to connect and use the Yamaha diagnostic tool refer to YAMAHA DIAGNO STIC TOOL OPERATION MANUAL FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 1 2 3 2 4 5 6 1 Vehicle 2...

Страница 324: ...terminals and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Crank the engine Fault code number is not dis played Service is finis...

Страница 325: ...ake air pres sure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Co...

Страница 326: ...value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Push the start switch Fault code number is not dis played Service is finished...

Страница 327: ...n position Procedure Check with throttle valve fully closed Check with throttle valve fully open Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Con...

Страница 328: ...n sensor lead Check the applied voltage black blue blue Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 Location of discon nec...

Страница 329: ...ondition of throttle position sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 10 Push the...

Страница 330: ...nect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or repair replace the wire harness Push the start swit...

Страница 331: ...ess Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of th...

Страница 332: ...output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 45 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation...

Страница 333: ...ngine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Connection of sub wire harness coupler Check the...

Страница 334: ...place the wire harness Execute the diagnostic mode Code No 36 No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector resis tance Replace if out of...

Страница 335: ...t switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconn...

Страница 336: ...or broken terminals and 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...

Страница 337: ...2 07 Go to item 3 2 01 is indicated in diagnostic mode Code No 60 EEPROM data error for adjust ment of CO concentration Change the CO concentration and rewrite in EEPROM After this adjustment push th...

Страница 338: ...ayed Go to item 2 2 Wire harness continuity Open or short circuit Replace the wire harness Between rectifier regulator cou pler and ECU coupler red red Between battery terminal and ECU coupler red red...

Страница 339: ...e wire harness Push the start switch Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking cond...

Страница 340: ...ault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the co...

Страница 341: ...r is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Страница 342: ...code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler...

Страница 343: ...FUEL INJECTION SYSTEM 8 44...

Страница 344: ...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 Br Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R...

Страница 345: ...PUMP SYSTEM 8 46 1 Joint connector 2 Joint connector 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU Engine Control Unit 25 Fuel pump 29 Joint connector 35 Engine stop switch 41 Frame gr...

Страница 346: ...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 53 NG...

Страница 347: ...FUEL PUMP SYSTEM 8 48...

Страница 348: ...ELECTRICAL COMPONENTS 8 49 EAM20147 ELECTRICAL COMPONENTS 9 10 1 3 2 4 5 6 7 8...

Страница 349: ...ELECTRICAL COMPONENTS 8 50 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU Engine Control Unit 5 Fuel sender 6 Fuel pump 7 Battery 8 Resistor 9 Neutral switch 10 Injector...

Страница 350: ...ELECTRICAL COMPONENTS 8 51 11 10 9 2 3 1 6 7 8 4 5...

Страница 351: ...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 352: ...ELECTRICAL COMPONENTS 8 53 EAM30289 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Страница 353: ...ELECTRICAL COMPONENTS 8 54 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Страница 354: ...al circuit tester to the range 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 connection diagr...

Страница 355: ...n the bulb section however note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to the respective leads of the bulb socket c Check the bulb socket...

Страница 356: ...severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large qu...

Страница 357: ...rage current into the battery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overchar...

Страница 358: ...current is lower than the standard charging current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage for 3 5 minutes to check the battery d Adjust the v...

Страница 359: ...f the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital circuit tester and bat tery 12 V to the relay terminal as shown Check the re...

Страница 360: ...ion the ignition system circuit is operating normally a Remove the spark plug cap from the spark plug b Connect the ignition checker 1 as shown 1 Positive battery terminal 2 Negative battery terminal...

Страница 361: ...the sub wire harness Spark plug cap from the ignition coil 2 Check Primary coil resistance Out of specification Replace a Connect the digital circuit tester to the ig nition coil b Measure the primary...

Страница 362: ...rcuit tester DC to the lean angle sensor coupler as shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Ignition coil terminal 1 1 Negati...

Страница 363: ...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 coupler from the wire harness 2 Check Stator coil...

Страница 364: ...uel sender EAM30360 CHECKING THE RESISTOR 1 Disconnect Resister coupler from the wire harness 2 Check Resister resistance Out of specification Replace the resister a Connect the digital circuit tester...

Страница 365: ...olant d Slowly heat the coolant and then let it cool to the specified temperature indicated in the ta ble e Check the coolant temperature sensor for continuity at the temperatures indicated in the tab...

Страница 366: ...r terminal EAM30308 CHECKING THE FUEL INJECTOR 1 Remove Fuel injector Refer to THROTTLE BODY on page 7 6 2 Check Fuel injector resistance Out of specification Replace a Disconnect the fuel injector co...

Страница 367: ...S 8 68 c Measure the fuel injector resistance Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Inj...

Страница 368: ...ELECTRICAL COMPONENTS 8 69...

Страница 369: ...IFT 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 9 3 FRONT FORK OIL LEAKING 9 3 FAULTY FRONT FORK LEGS 9 3 U...

Страница 370: ...riorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark...

Страница 371: ...Improperly returned stopper lever 2 Shift forks Worn shift fork 3 Shift drum Incorrect axial play Worn shift drum groove 4 Transmission Worn gear dog EAM30316 CLUTCH SLIPS Engine 1 Clutch Improperly a...

Страница 372: ...Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring EAM30321 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork...

Страница 373: ...ected 8 31 22 Intake air temperature sensor open or short circuit detected 8 32 30 Latch up detected 8 33 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 34...

Страница 374: ...ant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Displays the output voltage Remove the lean angle sen sor and incline it more than 45 degrees Upright Overturned 0 4...

Страница 375: ...rocedure 30 Ignition coil Actuates the ignition coil five times at one second intervals WARNING on the Yamaha diagnostic tool blinks five times when the ignition coil is actu ated Check that a spark i...

Страница 376: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Страница 377: ...10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETTING PARTS 10 4 SUSPENSION SETTING FRONT FORK 1...

Страница 378: ...ed 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 from...

Страница 379: ...y too large oil amount will cause the air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork wit...

Страница 380: ...he engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rid...

Страница 381: ...the rebound damping force will be fol lowed more or less by a change in the compres sion damping force For correction adjust to decrease compression damping force WARNING EWA19200 When using a rear s...

Страница 382: ...n page 3 30 Spring preload adjusting position 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 10 0 mm 0 39 in f...

Страница 383: ...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 384: ...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 385: ...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 386: ...3410 20038 1 6 Ratchet wheel 2S2 15671 00 1 7 Spring 90501 160A2 1 8 Washer 90201 167P7 1 Thickness 1 5 mm 0 059 in 9 Circlip 99009 16400 1 10 Spring guide 5NL 15664 00 1 11 Torsion spring 90508 30743...

Страница 387: ...ever boss 1SM 15621 00 1 21 Spring 90501 147A5 1 22 Ball 93507 32009 1 23 Screw 90151 06045 1 M6 24 O ring 93210 17570 1 25 Bolt 90110 08051 1 M8 26 Washer 90201 08048 1 27 Crankcase cover gasket 1SM...

Страница 388: ...LUTCH on page 5 39 1 Circlip 1 Remove Do not use the circlip installed originally 2 Washer 1 Remove Do not use the washer installed originally 3 Collar 1 Remove Do not use the collar installed origina...

Страница 389: ...aft assembly 1 TIP Before installation apply molybdenum disul fide grease to the contacting surfaces of the kick shaft ratchet wheel guide 2 and the kick shaft stopper a Apply the engine oil on the ki...

Страница 390: ...kstarter lever Order Part name Q ty Remarks 1 Plug 1 Remove Do not use the plug installed originally 2 Oil seal 1 3 Gasket 1 4 Right crankcase cover 1 Refer to CLUTCH on page 5 39 5 Kickstarter lever...

Страница 391: ...ollow the procedures as described below 1 Fold out the kickstarter lever push it down lightly with your foot until resistance is felt 2 With the throttle fully closed push the kick starter down lightl...

Страница 392: ...thium soap based grease to the pivoting point and metal to metal moving parts TIP Check the kickstarter lever movement and lubri cation for every race Installing the kickstarter kit 1 Install Kick gea...

Страница 393: ...3 Install Spring guide 1 TIP Slide the spring guide into the kick shaft make sure the groove a in the spring guide fits on the stopper of the torsion spring 4 Install Kick shaft assembly Refer to SET...

Страница 394: ...connector 30 Intake air temperature sensor 31 Coolant temperature sensor 32 Throttle position sensor 33 Intake air pressure sensor 34 Lean angle sensor 35 Engine stop switch 36 Neutral switch 37 Diod...

Страница 395: ...uals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manuals are available through your Yamaha dealer or you can order them directly thro...

Страница 396: ...17 Read this manual carefully before operating this vehicle YZ250FXK OWNER S SERVICE MANUAL YZ250FX 2019 PRINTED IN JAPAN 2018 04 0 3 1 E PRINTED ON RECYCLED PAPER 2019 YZ250FXK B29 28199 14_13mm ind...

Страница 397: ...Br Br Br Br Br Br L Y Y R L Y Y R G Y G Y G Y G Y Br B B B B B B R R R R L Br 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 Br R W...

Страница 398: ...ON OFF ON OFF B B B B Gy Gy B B Gy B B B L L B B B B YZ250FXK 2019 WIRING DIAGRAM B29 28199 14_W D indd 2 2018 03 29 17 51 16...

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