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FRONT FORK

4-14

EAM20100

FRONT FORK

EAM30055

REMOVING THE FRONT FORK LEGS

1. Use a maintenance stand to raise the front

wheel off the ground.

WARNING

EWA13120

Securely support the vehicle so that there is

no danger of it falling over.

TIP

Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.

2. Loosen:

•

Upper bracket pinch bolt

•

Damper assembly

•

Lower bracket pinch bolt

WARNING

EWA20350

Before loosening the upper and lower brack-

et pinch bolts, support the front fork leg.

TIP

Before removing the front fork leg from the vehi-
cle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.

3. Remove:

•

Front fork leg

EAM30056

DISASSEMBLING THE FRONT FORK LEGS

1. Drain:

•

Fork oil

2. Remove:

•

Adjuster “1”
(from the inner tube)

TIP

•

While compressing the inner tube “2”, set the
cap bolt ring wrench “4” between the inner tube
and locknut “3”.

•

Hold the locknut and remove the adjuster.

NOTICE

ECA24520

Do not remove the locknut as the damper rod

may go into the damper assembly and not be

taken out.

3. Remove:

•

Dust seal “1”

•

Stopper ring “2”
(with a flat-head screwdriver)

NOTICE

ECA14180

Do not scratch the inner tube.

4. Remove:

•

Inner tube “1”
a. Push in slowly “a” the inner tube just be-

fore it bottoms out and then pull it back
quickly “b”.

b. Repeat this step until the inner tube can be

pulled out from the outer tube.

Cap bolt ring wrench

90890-01501

Cap bolt ring wrench

YM-01501

Cap bolt ring wrench

90890-01501

Cap bolt ring wrench

YM-01501

G088920

Содержание YZ250X 2023

Страница 1: ...this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule YZ250XP PRINTED IN JAPAN 2022 05 0 1 1 E F YZ250X 2023 YZ250X...

Страница 2: ...is manual should stay with this vehicle if it is sold Q Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule Le manuel doit tre remis avec le v hicule en cas de vente...

Страница 3: ...Read this manual carefully before operating this vehicle 2023 OWNER S MANUAL YZ250X YZ250XP BRY 28199 70 E0...

Страница 4: ...ceives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However Transport Canada cannot beco...

Страница 5: ...OWNER S MANUAL 2023 by Yamaha Motor Co Ltd First edition April 2022 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited...

Страница 6: ...uested 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 MANUA...

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

Страница 8: ......

Страница 9: ...REMOVAL AND DISASSEMBLY 1 10 REPLACEMENT PARTS 1 10 INSTRUMENT AND CONTROL FUNCTIONS 1 11 ENGINE STOP SWITCH 1 11 SHIFT PEDAL 1 11 KICKSTARTER LEVER 1 11 FRONT BRAKE LEVER 1 11 REAR BRAKE PEDAL 1 11...

Страница 10: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Страница 11: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Страница 12: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Страница 13: ...LOCATION OF IMPORTANT LABELS 1 4 EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CAN 1 2 3 4 5 6 7 8 9 10 11...

Страница 14: ...LOCATION OF IMPORTANT LABELS 1 5...

Страница 15: ...LOCATION OF IMPORTANT LABELS 1 6 AUS NZL ZAF...

Страница 16: ...or the vehicle you have purchased 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Kickstarter l...

Страница 17: ...r 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 vehi...

Страница 18: ...ng out and is installed to the fuel tank breather hose NOTICE ECA27110 In this installation make sure the arrow fac es the fuel tank and also downward EAM30535 SET PIN tool for YPVS This set pin 1 is...

Страница 19: ...t to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 6 If coolant is left adhered to the chassis paint and plating will be damaged Therefore rinse it out with wate...

Страница 20: ...as a primary kickstarter lever so the engine can be started in any gear if the clutch is disengaged In normal practices however shift to neutral be fore starting EAM30188 FRONT BRAKE LEVER The front b...

Страница 21: ...ble EAM30444 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter knob 1 sup plies this mixture Pull th...

Страница 22: ...ush the engine stop switch TIP Continue pushing the engine stop switch till the engine comes to a full stop EAM30197 STARTING A WARM ENGINE Do not operate the starter knob CHOKE Open the throttle slig...

Страница 23: ...owing parts are replaced a break in is required Cylinder and Crankshaft A break in is re quired for about an hour Piston Piston ring Valve Camshaft and Gear A break in is required for about 30 minutes...

Страница 24: ...nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket a...

Страница 25: ...to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle ho...

Страница 26: ...ES on page 2 6 Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening...

Страница 27: ...structed Also thorough ly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields...

Страница 28: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Страница 29: ...th the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of...

Страница 30: ...MOTORCYCLE CARE AND STORAGE 1 21...

Страница 31: ...PECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 4 TIGHTENING TORQUES 2 6 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 6 ENGINE TIGHTENING TORQUES 2 7 CHASSIS...

Страница 32: ...S Model Model BRY1 CAN BRY3 AUS NZL Dimensions Overall length 2185 mm 86 0 in Overall width 825 mm 32 5 in Overall height 1290 mm 50 8 in Seat height 975 mm 38 4 in Wheelbase 1485 mm 58 5 in Ground cl...

Страница 33: ...80 L 0 85 US qt 0 70 Imp qt Quantity 0 75 L 0 79 US qt 0 66 Imp qt Cooling system Coolant quantity Radiator including all routes 1 20 L 1 27 US qt 1 06 Imp qt Spark plug s Manufacturer model NGK BR8E...

Страница 34: ...ement Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Carburetor Type quantity PWK38 1 ID mark BRY1 00 Main jet 178 Main air jet 200 Jet needle NYHW 2 Needle jet 2...

Страница 35: ...limit 1 0 mm 0 04 in Specified brake fluid DOT 4 Rear brake Type Hydraulic single disc brake Brake pad lining thickness limit 1 0 mm 0 04 in Specified brake fluid DOT 4 Front suspension Type Telescop...

Страница 36: ...Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Co...

Страница 37: ...o 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 specifi...

Страница 38: ...Governor fork screw M4 2 5 N m 0 5 kgf m 3 7 lb ft Power valve housing bolt M5 4 4 5 N m 0 45 kgf m 3 3 lb ft Impeller M8 1 14 N m 1 4 kgf m 10 lb ft Water pump housing cover bolt M6 4 10 N m 1 0 kgf...

Страница 39: ...M6 6 10 N m 1 0 kgf m 7 4 lb ft Primary drive gear bolt M10 1 55 N m 5 5 kgf m 41 lb ft Clutch boss nut M20 1 75 N m 7 5 kgf m 55 lb ft Use a Lock washer Clutch spring bolt M6 6 10 N m 1 0 kgf m 7 4 l...

Страница 40: ...t Throttle cable cap screw M4 2 0 5 N m 0 05 kgf m 0 37 lb ft Grip cap bolt M6 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever holder bolt M6 2 5 N m 0 5...

Страница 41: ...m 6 4 kgf m 47 lb ft Engine mounting nut front side M10 1 64 N m 6 4 kgf m 47 lb ft Engine mounting nut lower side M10 1 64 N m 6 4 kgf m 47 lb ft Pivot shaft nut M16 1 85 N m 8 5 kgf m 63 lb ft Rela...

Страница 42: ...7 kgf m 5 2 lb ft Seat bolt M6 1 11 N m 1 1 kgf m 8 1 lb ft Side cover bolt front side M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt rear side M6 2 9 N m 0 9 kgf m 6 6 lb ft Air scoop bolt fuel tank...

Страница 43: ...NG THE COOLANT 3 11 CHASSIS 3 13 ADJUSTING THE FRONT DISC BRAKE 3 13 ADJUSTING THE REAR DISC BRAKE 3 13 CHECKING THE BRAKE FLUID LEVEL 3 14 CHECKING THE FRONT BRAKE PADS 3 14 CHECKING THE REAR BRAKE P...

Страница 44: ...LUBRICATING THE BRAKE LEVER 3 24 LUBRICATING THE CLUTCH LEVER 3 24 LUBRICATING THE PEDAL 3 24 CHECKING THE SIDESTAND 3 24 LUBRICATING THE SIDESTAND 3 24...

Страница 45: ...ce about 7 5 hours Every fifth race about 12 5 hours As required 1 Piston Check piston for carbon deposits and cracks or damage Clean Replace 2 Piston rings Check piston ring end gap and rings for dam...

Страница 46: ...17 Cooling system Check coolant level and for leak age Check hoses for cracks or dam age Check radiator cap spring opera tion Change coolant Every 2 years 18 Chassis fasteners Check all chassis fittin...

Страница 47: ...earing assemblies for looseness Lubricate with molybdenum disul fide grease 28 Sidestand Lubricate with lithium soap based grease 29 Steering head Check operation free play and tighten if necessary Cl...

Страница 48: ...3 13 3 13 3 14 3 14 3 14 3 14 3 15 3 15 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 16 4 30 4 30 4 31 4 31 4 31 Wheels Check for excessive we...

Страница 49: ...ble speed EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 Check Throttle grip free play a Out of specification Regulate...

Страница 50: ...ed straight up when inspecting the oil level WARNING EWA21090 Never attempt to remove the oil check bolt just after high speed operation The heated oil could spout out causing danger Wait un til the o...

Страница 51: ...ever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until th...

Страница 52: ...ne squeeze and dry it completely WARNING EWA19110 Do not use gasoline or organic acid alka line volatile oil for washing NOTICE ECA24280 Do not twist the element when squeezing the element 4 Check Air...

Страница 53: ...y become excessively worn EAM30541 CHECKING THE CARBURETOR JOINT 1 Check Carburetor joint 1 Cracks damage Replace EAM30542 CHECKING THE CARBURETOR HOSES The following procedure applies to all of the f...

Страница 54: ...is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap an...

Страница 55: ...nd steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator...

Страница 56: ...If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may b...

Страница 57: ...TICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the lo...

Страница 58: ...brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower th...

Страница 59: ...linder cap Reservoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough brake flui...

Страница 60: ...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 drive chain up above the drive chain g...

Страница 61: ...alling over 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Upper bracket 4 Adjust Steering...

Страница 62: ...ube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly U...

Страница 63: ...urn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a da...

Страница 64: ...bly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 28 3 Check Rear shock absorber assembly smooth ac tion Rear suspension link smooth action Sit astride the seat and shake your body up and down seve...

Страница 65: ...specifications as necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compres...

Страница 66: ...h damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGARM on page 4...

Страница 67: ...looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to mak...

Страница 68: ...to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHECKING THE SIDESTAND 1...

Страница 69: ...4 9 REMOVING THE HANDLEBAR 4 9 CHECKING THE HANDLEBAR 4 9 INSTALLING THE HANDLEBAR 4 9 FRONT FORK 4 14 REMOVING THE FRONT FORK LEGS 4 14 DISASSEMBLING THE FRONT FORK LEGS 4 14 CHECKING THE FRONT FORK...

Страница 70: ...CHECKING THE DRIVE CHAIN 4 30 CHECKING THE DRIVE SPROCKET 4 31 CHECKING THE REAR WHEEL SPROCKET 4 31 INSTALLING THE DRIVE CHAIN 4 31...

Страница 71: ...le guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert...

Страница 72: ...wheel TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 NOTI...

Страница 73: ...oth wear a Replace the rear wheel sprocket and the drive sprocket as a set Bent tooth Replace the rear wheel sprock et and the drive sprocket as a set 2 Replace Rear wheel sprocket a Remove the self l...

Страница 74: ...stall Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 16 6 Tig...

Страница 75: ...cation Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw and push t...

Страница 76: ...ECKING THE BRAKE FLUID LEVEL on page 3 14 5 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 Front brake caliper b...

Страница 77: ...ification Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw and pus...

Страница 78: ...r to CHECKING THE BRAKE FLUID LEVEL on page 3 14 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 Brake pad pin...

Страница 79: ...en it EAM30054 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 Lower handl...

Страница 80: ...Apply the adhesive to the handlebar 2 TIP Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line...

Страница 81: ...e adhesive on the tube guide 2 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Align the mating mark b on the right grip with the slot c in...

Страница 82: ...stall Throttle cable cap 1 Throttle cable cap screw 2 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 5 16 Install Cap cover 1 17 Install Brake master cylinder 1 Brake...

Страница 83: ...18 Install Grip cap bolt 1 WARNING EWA21080 After tightening the bolts check that the throttle grip 2 moves smoothly If it does not retighten the bolts for adjustment Grip cap bolt 3 8 N m 0 38 kgf m...

Страница 84: ...e Front fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the i...

Страница 85: ...sly weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Repla...

Страница 86: ...ner tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTIC...

Страница 87: ...etting position Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First brin...

Страница 88: ...age 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 35 Imp oz 13 Check Damper assembly smooth moveme...

Страница 89: ...al 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube TIP Press the slide metal into the outer t...

Страница 90: ...rough spots Repeat the steps 14 to 20 22 Measure Distance a Out of specification Turn the locknut to specification 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install th...

Страница 91: ...the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure...

Страница 92: ...damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the lower bracket pinch bolts Do not tighten the upper bracket pinch...

Страница 93: ...ce 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 94: ...FRONT FORK 4 24 1...

Страница 95: ...lace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe 1 with a long rod 2 and a hammer b Remove the bearing race from the lower bracket 3 with a chisel 4 and a ham...

Страница 96: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 17 5 Check the steering...

Страница 97: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If t...

Страница 98: ...1 TIP While removing the rear shock absorber assem bly lower bolt hold the swingarm so that it does not drop down 3 Remove Rear shock absorber assembly upper bolt Rear shock absorber assembly EAM30067...

Страница 99: ...ent a Measure the tightening torque of the pivot shaft nut b Check the swingarm side play A by mov ing the swingarm from side to side If the swingarm has side to side play check the bushings the beari...

Страница 100: ...ngth b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Che...

Страница 101: ...HECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 3 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the maste...

Страница 102: ...dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital...

Страница 103: ...HE CLUTCH PLATES 5 1 CHECKING THE CLUTCH SPRINGS 5 1 CHECKING THE CLUTCH HOUSING 5 1 CHECKING THE CLUTCH BOSS 5 2 CHECKING THE PRESSURE PLATE 5 2 CHECKING THE PUSH LEVER SHAFT 5 2 CHECKING THE PUSH RO...

Страница 104: ...he clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clu...

Страница 105: ...ace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary dri...

Страница 106: ...nce 3 Install Thrust washer D 44 mm 1 73 in 1 Clutch boss 2 4 Install Lock washer 1 Clutch boss nut 2 TIP Use the clutch holder 3 to hold the clutch boss 5 Bend the lock washer 1 tab 6 Install Frictio...

Страница 107: ...ransmission oil on the bearing wash er and push rod 1 8 Install Push rod 2 1 Push rod 1 2 TIP Apply the transmission oil on the ends of the push rod 2 Install the push rod 2 with its smaller end a to...

Страница 108: ...CLUTCH 5 5 TIP Tighten the bolts in stage using a crisscross pat tern 13 Install O ring 1 Clutch cable 2 TIP Apply the lithium soap based grease on the O ring New 2 1...

Страница 109: ...1 2 3 4 5 6 7 8 9 10 ELECTRICAL SYSTEM WIRING DIAGRAM 6 1 COLOR CODE 6 1...

Страница 110: ...ngine stop switch 3 Ignition coil 4 Throttle position sensor 5 Solenoid valve 6 Neutral switch 7 CDI magneto 8 Spark plug B Black L Blue O Orange R Red Sb Sky blue Y Yellow B L Black Blue B R Black Re...

Страница 111: ...ERAL INFORMATION 7 1 TROUBLESHOOTING OF ENGINE 7 1 TROUBLESHOOTING OF CLUTCH 7 6 TROUBLESHOOTING OF TRANSMISSION 7 7 TROUBLESHOOTING OF COOLING SYSTEM 7 8 TROUBLESHOOTING OF BRAKE 7 9 TROUBLESHOOTING...

Страница 112: ...icult to start but it cranks Symptom Possible cause Actions Spark plug does not produce a spark Have a Yamaha dealer check the electrical system Fuel not supplied Empty fuel tank Fill the fuel tank wi...

Страница 113: ...cap Defective ignition coil Replace the ignition coil CDI unit failure Replace the CDI unit Fuel not supplied Fuel leakage Check the fuel passage Repair or replace as necessary Clogged carburetor fue...

Страница 114: ...hose Replace the vacuum hose Damaged carburetor joint Replace the carburetor joint Loose carburetor joint Tighten the carburetor joint bolts to the specified torque Clogged air filter element Clean or...

Страница 115: ...hten the main jet to the speci fied torque Bent damaged or worn jet needle Replace the jet needle Cracks or damage in the piston valve diaphragm Replace the piston valve dia phragm Problem with piston...

Страница 116: ...rings as a set Worn or damaged piston Replace the piston and piston rings as a set Worn piston piston pin hole Replace the piston and piston pin as a set Worn or damaged piston pin Replace the piston...

Страница 117: ...ne oil Deteriorated oil Change to recommended engine oil Clutch drags Faulty clutch spring Replace the clutch springs as a set Warped pressure plate Replace the pressure plate Swollen friction plate R...

Страница 118: ...the shift drum Seized shift fork Replace the shift fork and shift fork guide bar as a set Bent shift fork guide bar Replace the shift fork guide bar Foreign object between transmis sion gears Remove...

Страница 119: ...the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Clogged air f...

Страница 120: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Страница 121: ...per rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged...

Страница 122: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Страница 123: ...d or incorrect tire Replace the tire Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or...

Страница 124: ...TROUBLESHOOTING 7 13...

Страница 125: ...ION AND EXAMPLES OF CARBURETOR SETTING 8 7 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 8 7 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 8 9 CHASSIS 8 10 SELECTION OF THE SECONDARY REDUCTION RATIO S...

Страница 126: ...le to make a note of settings atmo spheric conditions road surface condition lap time etc so that the memorandum can be used as a reference useful for future EAM30591 ATMOSPHERIC CONDITIONS AND CARBUR...

Страница 127: ...richness of air fuel mixture under 8500 r min to the extent of 1 2 to full opened throttle can be set by changing the power jet 1 A larger size jet results in a richer mixture and a smaller size in a...

Страница 128: ...per angle are available in different straight portion diameters and in different taper start ing positions 2 Effects of changing the jet needle reference Diameter of straight portion Changing the diam...

Страница 129: ...ip by one groove and move up the needle to enrich the mixture EAM30605 RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the carburetor main system is controlled by the main jet and then...

Страница 130: ...14948 08 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14948 02 Jet needle 3 Rich N3CG 4SR 14916 CG N3EG 4SR 14916 EG NYHG BRY 14916 HG N8RH 4SR 14916 RH...

Страница 131: ...ENGINE 8 6...

Страница 132: ...e main jet calibration no Gradually Discoloration of spark plug If tan color it is in good condition If cannot be corrected Clogged float valve seat Clogged fuel hose Clogged fuel cock At full throttl...

Страница 133: ...ger diameter Unstable at low speeds Pinking noise Lower jet needle clip position 1 groove down Turn in pilot air screw Poor response at extremely low speed Reduce pilot jet calibration No Turn out pil...

Страница 134: ...No of the main jet must be changed by 15 it is advisable to change the heat range of spark plugs and newly select the proper main jet TIP When checking the discoloration of spark plugs be sure to stop...

Страница 135: ...t such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the perform...

Страница 136: ...ir spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTIN...

Страница 137: ...rear fender 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and mark of rear fender 3 Loosen the locknut 1...

Страница 138: ...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 shock absorber other than currently...

Страница 139: ...REAR SHOCK ABSORBER AS SEMBLY on page 3 20 Type Spring rate N mm Part number I D mark Q ty SOFT 44 5UN 22212 A0 Silver Green 2 46 5UN 22212 B0 Silver Red 2 48 5UN 22212 C0 Silver Black 2 50 5UN 22212...

Страница 140: ...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 141: ...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 142: ...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 143: ......

Страница 144: ...PRINTED IN JAPAN E...

Страница 145: ...is manual should stay with this vehicle if it is sold Q Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule Le manuel doit tre remis avec le v hicule en cas de vente...

Страница 146: ...this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la premi re utilisation du v hicule YZ250XP PRINTED IN JAPAN 2022 05 0 1 1 E F YZ250X 2023 YZ250X...

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