Yamaha YZ 2018 Series, Owner'S Service Manual

Page 1: ...25 Read this manual carefully before operating this vehicle YZ250FXJ OWNER S SERVICE MANUAL YZ250FX 2018 PRINTED IN JAPAN 2017 04 0 3 1 E PRINTED ON RECYCLED PAPER 2018 YZ250FXJ B29 28199 13_cover in...

Page 2: ...lity and performance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lu...

Page 3: ...2017 by Yamaha Motor Corporation U S A 1st Edition April 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Page 4: ...e requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage EWA WARNING PLEASE READ THIS MANUA...

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

Page 6: ...EASB916006 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 7: ...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 New 2 3 4 5 5 6...

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

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

Page 10: ......

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

Page 12: ...1 20 AIR FILTER MAINTENANCE 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 21 BREAK IN PROCEDURES 1 21 MAINTENANCE AFTER BREAK IN 1 22 MAJOR MAINTENANCE 1 22 TORQUE CHECK POINTS 1 23 MOTOR...

Page 13: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D...

Page 14: ...e you have pur chased 1 Clutch lever 11 Radiator 2 Engine trouble warning light 12 Coolant drain bolt 3 Fuel level warning light 13 Rear brake pedal 4 Front brake lever 14 Air filter 5 Throttle grip 1...

Page 15: ...ositive iden tification of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EASB29B011 VEHICLE IDENTIFICATION NUMBER The vehic...

Page 16: ...hose joint covers 1 are used to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EASB29B018 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1...

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

Page 18: ...ASB29B023 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...

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

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

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

Page 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...

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

Page 24: ...This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 Cap bolt wrench YM 01500 This tool is used to remove or tighten the base valve Cap bolt ring wrench 90890 01501 Cap...

Page 25: ...s S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 This tool is used to check the throttle position sensor input voltage Test harness lean angle sensor 6P 90890 03209 Test h...

Page 26: ...ch holder YM 91042 This tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is us...

Page 27: ...5 mm YM 04116 This tool is used to replace the valve guide Valve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer 4...

Page 28: ...ck the spark performance of the ig nition coil Digital tachometer 90890 06760 Digital tachometer YU 39951 B This tool is used to measure the engine speed Yamaha bond No 1215 90890 85505 Three bond No...

Page 29: ...s refuel as soon as possible The electrical circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning l...

Page 30: ...9B036 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on the brake pedal to ac tivate the rear brake EASB29B037 SIDESTAND This sidestand 1 is used to support only the...

Page 31: ...cover 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 vehicl...

Page 32: ...y short time Always operate the ma chine in a well ventilated area ECA NOTICE If the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform t...

Page 33: ...portion sliding surfaces and mounted areas may fit one another and that the rider may become ac customed to the machine ECA NOTICE Before running do maintenance on the air filter element Refer to CLEA...

Page 34: ...is connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets...

Page 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...

Page 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...

Page 37: ...may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or...

Page 38: ...ill wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EASB29B052 STORAGE Short term Always store your motorcycle in a cool dry place and if necessary protect it agains...

Page 39: ...es from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charg...

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

Page 41: ...IFICATIONS 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 18 ENGINE 2...

Page 42: ...odel Model B29G 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...

Page 43: ...0 83 L 0 88 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 r...

Page 44: ...1756 0 1762 in Limit 4 430 mm 0 1744 in Valve guide inside diameter 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...

Page 45: ...85 mm 0 112 in Plate quantity 5 pcs Clutch plate thickness 1 10 1 30 mm 0 043 0 051 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 47 80 mm 1 88 in Limit 45 41 mm 1 7...

Page 46: ...B291 00 Idling condition Engine idling speed 1900 2100 r min Coolant temperature 70 90 C 158 194 F Engine oil temperature 70 80 C 158 176 F Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm2 43 5...

Page 47: ...easured on cold tires Front 100 kPa 1 00 kgf cm2 15 psi Rear 100 kPa 1 00 kgf cm2 15 psi Front brake Type Hydraulic single disc brake Disc outside diameter thickness 270 0 3 0 mm 10 63 0 12 in Brake d...

Page 48: ...osition Soft 20 Adjustment value from the start position STD 14 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydr...

Page 49: ...limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 0 2 0 9 mm 0 01 0 04 in Drive chain Size DID520VM2 Chain type Sealed type Number of links 114 Drive chain slack Maintenance stand 50 0 6...

Page 50: ...se 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 light Fuel level warning light 12 V 1 7 W Engine trouble warning lig...

Page 51: ...ELECTRICAL SPECIFICATIONS 2 10 Fuse s Main fuse 15 0 A Spare fuse 15 0 A Radiator fan motor fuse 5 0 A...

Page 52: ...l To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque speci...

Page 53: ...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 drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose c...

Page 54: ...aft 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 Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover pl...

Page 55: ...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 16 N m 1 6 kgf m 12 lb ft Neutral switch bolt M5 2 3 5 N m 0 35 kgf m 2 6 lb ft Intake air te...

Page 56: ...t 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 grip cap screw M5 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lev...

Page 57: ...tor bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33 lb ft Engine mounting bolt front side M10 1 55 N m 5 5 kgf m 41 lb ft Engine mounting bolt lower side...

Page 58: ...w 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 lb ft Side cover 2 screw 1...

Page 59: ...ing parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Ratchet wheel and ratchet wheel guide contacting portion Primary drive gear nut threads and contac...

Page 60: ...r surface Swingarm pivot portion oil seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surf...

Page 61: ...eal Front brake caliper dust seal Front brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake cal...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EASB29B063 LUBRICATION SYSTEM CHART AND DIAGRAMS EASB29B064 LUBRICATION DIAGRAMS...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 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...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

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

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

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

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Page 70: ...CABLE ROUTING DIAGRAM 2 29 EASB29B065 CABLE ROUTING DIAGRAM...

Page 71: ...under the starter clutch cover N Pass the neutral switch lead to the inside of the front engine bracket the side of the vehicle O Insert the plastic locking tie into the bracket hole and clamp the cl...

Page 72: ...CABLE ROUTING DIAGRAM 2 31...

Page 73: ...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...

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

Page 75: ...throttle position sensor lead to the out side of the tension arm the outside of the vehi cle D After connecting the throttle position sensor cou pler attach the cover E Pass the radiator breather hos...

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

Page 77: ...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...

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

Page 79: ...itch 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 num ber plate G Pass the start s...

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

Page 81: ...all the two breather hoses so that the yellow paint mark is pointing forwards C Align the white paint mark to the protruding por tion of the pipe to install breather hose 3 D Protruding portion of the...

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

Page 83: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

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

Page 85: ...CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 VALVE CLEARANCE SHIM CHART 3 20 CHASSIS 3 22 BLEEDING THE BRAK...

Page 86: ...ING THE CABLES 3 35 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 36 CHECKING THE CHASSIS FASTENERS 3 36 ELECTRICAL SYSTEM 3 37 CH...

Page 87: ...to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold...

Page 88: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Page 89: ...air filter oil or equiv alent oil Replace BREATHER SYSTEM Inspect Check ventilation hose for cracks or damage and drain any deposits Replace Every two years SPARK PLUG Inspect and clean Check the ele...

Page 90: ...ls and dust seals Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grease pillow balls and bear ings Retighten Check for tightening t...

Page 91: ...ithium soap based grease STEERING HEAD Inspect free play and retighten Check for tightening torques Clean and lube After rain ride Replace bearings TIRE WHEELS Inspect air pres sure wheel run out tire...

Page 92: ...les on the throttle body for dirt and wear LEVERS Adjust clutch lever free play BRAKE PEDAL FOOTREST Lubricate OUTSIDE NUTS AND BOLTS Retighten Refer to TORQUE CHECK POINTS on page 1 23 BATTERY Inspec...

Page 93: ...Check the play of front brake and effect of front and rear brake 3 22 28 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 28 4 66 67 Wheels Check f...

Page 94: ...minutes until the coolant has settled EASB29B072 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer t...

Page 95: ...el Refer to CHECKING THE COOLANT LEV EL on page 3 8 EASB29B074 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS...

Page 96: ...a cloth beforehand EASB29B077 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar side a Turn the adjuster 1 i...

Page 97: ...ned c Tighten the locknut EWA WARNING After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this does not cause the en gine idling speed to change...

Page 98: ...ir filter mounting bolt 1 Air filter element 2 Air filter guide 3 from the air filter element 3 Wash Air filter element EWA WARNING Do not use gasoline or organic acid alka line volatile oil for washi...

Page 99: ...properly ECA NOTICE Make sure the cylinder head breather hose is routed correctly EASB29B083 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer...

Page 100: ...engine 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...

Page 101: ...ement and the oil fil ter element cover 5 To check the oil strainer perform the follow ing procedure a Remove the oil strainer 1 b Check the oil strainer Damage Replace Clogging due to dirt Wash with...

Page 102: ...check bolt EASB29B087 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 starter kno...

Page 103: ...justed make sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on...

Page 104: ...chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad po sition very carefully so that they can be rein stalled in their original place...

Page 105: ...Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lift...

Page 106: ...85 190 195 200 205 210 215 220 225 230 235 240 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 84 185 190 195 200...

Page 107: ...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...

Page 108: ...the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the br...

Page 109: ...b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA WARNING A soft or spongy feeling in the brake lever can indicate the pre...

Page 110: ...ir in the brake system will cause braking performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EASB29B094 CHECKING THE FRONT BRAKE PADS 1...

Page 111: ...ojections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid le...

Page 112: ...move the pad pin 6 and the brake pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper pi...

Page 113: ...AR BRAKE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EASB29B097 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on...

Page 114: ...stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the driv...

Page 115: ...ck Protector guide 1 Out of specification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EASB29B101 CLEANING...

Page 116: ...ond its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 N m 0 13 kgf m 0 95 lb ft Direction a Rebound damping is...

Page 117: ...STING THE REAR SHOCK ABSORB ER ASSEMBLY Use a suitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over Spring preloa...

Page 118: ...o make an adjustment Locknut 30 N m 3 0 kgf m 22 lb ft Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping Min...

Page 119: ...o be slipping off its position Cor rect the tire position EASB29B108 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will emit a clear ringing ton...

Page 120: ...Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 31 Upper bracket Refer to STEERING H...

Page 121: ...points and metal to metal moving parts of the following parts Brake lever Clutch lever EASB29B114 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to metal moving parts of the pedal EAS...

Page 122: ...ivoting point and metal to metal moving parts of the sidestand EASB29B117 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TOR...

Page 123: ...oving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan...

Page 124: ...left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EASB29B121 CHECKING AND CHARGING...

Page 125: ...PER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER...

Page 126: ...MBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 58 DISPOSING OF A REAR SHOCK ABSORBER 4 58 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 REMOVING THE BEARING 4 58 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 127: ...er left 1 5 Side cover right 1 6 Side cover 2 left 1 7 Number plate 1 8 Rear fender 1 For installation reverse the removal proce dure 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...

Page 128: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 19 2 Remove Seat 1 EASB29B126 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 129: ...1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dur...

Page 130: ...CHECKING THE WHEELS on page 3 34 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Ti...

Page 131: ...2 Bearing right side 3 Oil seals 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with i...

Page 132: ...l Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA NOTICE Before tightening the front wheel axle nut push down hard on the handle...

Page 133: ...2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 2...

Page 134: ...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 EASB29B136 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing...

Page 135: ...talled first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter...

Page 136: ...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...

Page 137: ...2 Copper washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation...

Page 138: ...ke caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Page 139: ...hers 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front b...

Page 140: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Page 141: ...ion EASB29B142 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc...

Page 142: ...clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When...

Page 143: ...hat the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA WARNIN...

Page 144: ...r cylinder and the end of the brake hose EASB29B150 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master...

Page 145: ...29B152 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the...

Page 146: ...o poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause v...

Page 147: ...se 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 springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installat...

Page 148: ...r brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1...

Page 149: ...shers 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 reservoir diaphragm 1 10 Rea...

Page 150: ...4 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Page 151: ...9B155 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a fe...

Page 152: ...158 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brak...

Page 153: ...with its side a facing the brake caliper Never force to insert EASB29B161 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR...

Page 154: ...to CHECKING THE BRAKE FLUID LEVEL on page 3 27 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM on page 3 22 EASB29B162 REMOVING THE RE...

Page 155: ...as shown Wrong orientation in installation causes poor braking perfor mance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to t...

Page 156: ...may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling p...

Page 157: ...ble 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 Lower ha...

Page 158: ...g the handlebar Order Part name Q ty Remarks 0 5 N m 0 05 kgf m 0 37 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 40 N m 4 0 kgf m 30 lb ft 28 N m 2 8 kgf m 21 lb ft 3 8 N m 0 38 k...

Page 159: ...SB29B169 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower handleb...

Page 160: ...tall Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive...

Page 161: ...f grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 7 Install Rubber cove...

Page 162: ...assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the...

Page 163: ...er to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 10 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Clutch lever free play 7 0 12 0 mm 0 28 0 47 in T...

Page 164: ...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 bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket p...

Page 165: ...tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seals 1 13 Base valve 1 14 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 14 2 7 10 9 11 12 5 3 1...

Page 166: ...fork leg s EASB29B172 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...

Page 167: ...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 Replace O ring...

Page 168: ...G THE FRONT FORK LEGS EWA WARNING 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 l...

Page 169: ...essive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 1 to 3 4 Measure Oil level left and right a Out of specification Regulate 5 Tighten Locknut 1...

Page 170: ...nd down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side ECA NOTICE Ta...

Page 171: ...ll the scraper to the inner tube as shown in the illustration When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Inner tube bushing 1 TIP Instal...

Page 172: ...outer tube 20 Install Scraper 1 Dust seal 2 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 Measure...

Page 173: ...juster is fully loosened correct damping characteristic can not be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While compressi...

Page 174: ...en disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly...

Page 175: ...ssembly 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued too much it may cause the fro...

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

Page 177: ...1 3 Front fork leg s 2 Refer to FRONT FORK on page 4 38 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 1 10 Bearing lower side 1 11...

Page 178: ...e 3 Replace Bearing Bearing races a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c I...

Page 179: ...e steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 34 5 Check the steering st...

Page 180: ...steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued...

Page 181: ...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 Locknut...

Page 182: ...16 Bearing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Part name Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3 9 9 10 10 11 1 New New 13 New LS...

Page 183: ...ay arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3...

Page 184: ...km of run ning EASB29B182 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA WARNING Wear protective glasses to prevent...

Page 185: ...ng Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EASB29B186 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay ar...

Page 186: ...ck absorber assembly lower side TIP Install the dust seals with their lips facing in ward 5 Lubricate Connecting arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circum...

Page 187: ...m side Rear shock absorber assembly lower bolt Rear shock absorber assembly upper bolt 56 N m 5 6 kgf m 41 lb ft Connecting arm bolt frame side 80 N m 8 0 kgf m 59 lb ft Connecting arm bolt relay arm...

Page 188: ...d 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 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil sea...

Page 189: ...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 EASB29B191 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 190: ...wingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 Recommended lub...

Page 191: ...Removing the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 75 N m 7 5...

Page 192: ...gth b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Che...

Page 193: ...eel sprocket as a set EASB29B196 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EASB29B197 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NO...

Page 194: ...install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 ECA NOT...

Page 195: ...G THE DECOMPRESSION SYSTEM 5 16 INSTALLING THE CAMSHAFTS 5 16 CYLINDER HEAD 5 18 REMOVING THE CYLINDER HEAD 5 20 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTAL...

Page 196: ...ING THE SEGMENT 5 50 CHECKING THE SHIFT SHAFT 5 50 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 5 50 CHECKING THE STOPPER LEVER 5 50 INSTALLING THE STOPPER LEVER 5 51 INSTALLING THE SEGMENT 5 51...

Page 197: ...SSEMBLING THE CRANKCASE 5 69 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 71 REMOVING THE CRANKSHAFT ASSEMBLY 5 72 CHECKING THE CRANKSHAFT ASSEMBLY 5 72 INSTALLING THE CRANKSHAFT ASSEMBLY 5 73 INSTALLING...

Page 198: ...Silencer 1 3 Exhaust pipe 2 clamp 1 Loosen 4 Exhaust pipe 2 1 5 Exhaust pipe 1 1 6 Gaskets 3 7 Exhaust pipe 1 protector 1 8 Exhaust pipe 2 protector 1 9 Silencer body 1 10 Silencer cap 1 For installat...

Page 199: ...ERAL 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 magneto coupler 1 Disconnect 6 Cranksh...

Page 200: ...THROTTLE 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 For JPN 2 Brake...

Page 201: ...l proce dure Removing the engine Order Part name Q ty Remarks New New LS M 8 8 7 6 13 4 5 New 1 12 3 2 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...

Page 202: ...silencer EASB29B201 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EASB29B202 REMOVING THE DRIVE SPROCKET 1 St...

Page 203: ...e TIP Make sure that the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EASB29B204 CHECKING THE SILENCER AND...

Page 204: ...t 2 TIP Apply heat resistant sealant to the areas a shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 3 E...

Page 205: ...O rings and brake pedal bracket EASB29B208 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1...

Page 206: ...tall Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 13 N m 1 3 kgf m 9 6 lb ft Then retighten them to 20 N m 2 0 kgf m 15 lb ft 2 Install Clamp Exhaust pipe 2 1...

Page 207: ...t is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2...

Page 208: ...op left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylind...

Page 209: ...ap bolt 1 4 Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure 5 8 3 4 1 2 7 6 5 4 4 6 M M E New New New E E 10...

Page 210: ...et with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap i...

Page 211: ...strip of Plastigauge 1 onto 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...

Page 212: ...cket More than 1 4 tooth wear a Replace the camshaft and the timing chain as a set EASB29B214 CHECKING THE TIMING CHAIN TENSION ERS 1 Check Timing chain tensioner Crack damage Replace a While pressing...

Page 213: ...ake sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA NOTICE Do not turn the c...

Page 214: ...ns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing chain guide...

Page 215: ...to FUEL TANK on page 7 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 p...

Page 216: ...hain guide intake side 1 6 Oil check bolt 1 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 N m 1 0 kgf m 7 4 lb ft 33 N m 3 3 kgf m 24 lb...

Page 217: ...trument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE V...

Page 218: ...he cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the...

Page 219: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 18 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 220: ...akage at the valve seat Check the valve face the valve seat and the valve seat contact width Refer to CHECKING THE VALVE SEATS on page 5 25 a Pour a clean solvent a into the intake and exhaust ports b...

Page 221: ...oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 c After installing the valve guide expand the...

Page 222: ...seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head Intake Valve guide remover 5 90890 04097 Valve guide...

Page 223: ...with new valves a Apply a coarse lapping compound a to the valve face ECA NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide...

Page 224: ...CKING THE VALVE LIFTERS 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head EASB29B228 INSTALLING THE VALVES 1 Clean Valve stem end 2 Lubricate Valve stem 1 Valve stem s...

Page 225: ...5 To fasten the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA NOTICE Hitting the valve tip with excessive force could damage the valve 6 Lubricate Adjusting p...

Page 226: ...y Remarks Cylinder head Refer to CYLINDER HEAD on page 5 18 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the r...

Page 227: ...ft the opposite end gap of the piston ring over the piston crown EASB29B231 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and repl...

Page 228: ...ttom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil rin...

Page 229: ...face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 TIP Apply the engine oil to the piston pin Install the piston with the F mark a on it pointing to its intake front side Before installing the...

Page 230: ...r 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 U...

Page 231: ...35 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure...

Page 232: ...ter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly reverse the disassem...

Page 233: ...bly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the digital circuit tester b If any resistance is out of spe...

Page 234: ...Install the part that has a smaller step differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark a on the starter motor yoke with the ma...

Page 235: ...ELECTRIC STARTER 5 38 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring New...

Page 236: ...tch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 12 Friction plate 1 4 13 Clutch plat...

Page 237: ...Spacer 1 20 Bearing 1 21 Washer 1 22 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks New New New 2 3 4 5 5 6 7 8 9 6 10 11 12 22 1...

Page 238: ...OOLANT on page 3 8 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 Radiator pipe 2 1 4 Right crankcase c...

Page 239: ...utch 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 CHECKI...

Page 240: ...45 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Crack damage Replace EASB29B246 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EASB29B247 CHECKING THE CLUTCH PUSH ROD...

Page 241: ...ip 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 EASB29B251 INSTALLING THE RIGHT CRANKCASE COVER...

Page 242: ...cification other wise it may damage the other part that is fastened together TIP Apply the engine oil to the threads and con tact surface of the clutch boss nut Use the clutch holding tool 3 to hold t...

Page 243: ...1 Washer 2 Circlip 3 To push rod 1 4 TIP Apply the engine oil on the bearing and washer 7 Install Push rod 2 1 Ball 2 Push rod 1 3 TIP Apply the engine oil on the push rod 1 2 and ball 8 Install Pres...

Page 244: ...CLUTCH 5 47 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 T R 1...

Page 245: ...9 1 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...

Page 246: ...removal proce dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks LS 2 4 14 16 15 LT 7 11 12 13 12 9 13 11 10 5 3 1 6 LT 8 LT E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4...

Page 247: ...oosen the bolt ECA NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EASB29B256 CHECKING THE SHIFT SHAFT 1 Check Shift...

Page 248: ...ged Take care not to give an impact to it when tightening the bolt EASB29B261 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply th...

Page 249: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EASB29B263 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift s...

Page 250: ...ar 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 Oil pump drive shaft 1 7 Oil...

Page 251: ...e 5 59 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 Balancer drive gear 1 10 Conical...

Page 252: ...EAR 1 Check Primary drive gear 1 Balancer drive gear 2 Balancer weight gear 3 Wear damage Replace EASB29B267 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EASB29B268 CHECKING THE OIL PUM...

Page 253: ...2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 Inner rotor to outer rotor tip clearance 0 000 0 150 mm 0 0000 0 0059 in Limit 0 2...

Page 254: ...ch other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the con...

Page 255: ...OIL PUMP AND BALANCER GEAR 5 58 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...

Page 256: ...ad Clutch cable Shift 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...

Page 257: ...llation reverse the removal proce dure Removing 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...

Page 258: ...h gear 4 Check Damper assembly Damage pitting wear Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive gear 1...

Page 259: ...all Starter clutch 1 To generator rotor 2 EASB29B275 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 g...

Page 260: ...ankcase cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage...

Page 261: ...AND STARTER CLUTCH 5 64 6 Install Cover damper assembly 1 Bracket 2 Bolt 3 Breather hose 2 4 TIP Install the cover damper assembly with its mark a facing upward Bolt 10 N m 1 0 kgf m 7 4 lb ft T R 1...

Page 262: ...er to SHIFT SHAFT on page 5 48 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 59 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4 Bolt L 45...

Page 263: ...assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 3 1 5 2 6 4 10 5 6 4 4 4 4 6 9 11 7 8 9 LT 12 LT 10 N m 1 0 kgf m 7 4 lb ft 5 N m 0 5 kgf m 3 7 lb ft...

Page 264: ...ANSMISSION on page 5 74 Shift cam and shift fork Refer to TRANSMISSION on page 5 74 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT LT 2 3 3 3 3 3 3 3 3 3 New...

Page 265: ...o 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 chec...

Page 266: ...pply 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 pos...

Page 267: ...CRANKCASE 5 70 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...

Page 268: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 Transmission Refer to TRANSMISSION on page 5 74 1 Balancer s...

Page 269: ...ion Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measur...

Page 270: ...ent the crankshaft seizure apply molybdenum disulfide grease TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn...

Page 271: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 65 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift for...

Page 272: ...on of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EASB29B290 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift...

Page 273: ...heck Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement...

Page 274: ...ease on the O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on...

Page 275: ...th the 5th wheel gear 5 and 3 R with the 6th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shift f...

Page 276: ...TRANSMISSION 5 79...

Page 277: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WA...

Page 278: ...1 Air filter case Refer to THROTTLE BODY on page 7 6 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator fan 1 For JPN 4 Right radiator 1 5 Radiator hose 2 1 6 Radiator hose 3 1 7 Radiator h...

Page 279: ...proce dure Removing the radiator Order Part name Q ty Remarks 12 13 New New New LS LS 3 4 5 6 7 8 9 10 11 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 l...

Page 280: ...ra diator cap EASB29B297 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins with...

Page 281: ...ngine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 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...

Page 282: ...g 1 11 Oil seal 1 For installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 New New New 11 New E LS LS 10 N m 1 0 kgf m 7 4 lb ft 10...

Page 283: ...spot seizure Replace EASB29B302 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers f...

Page 284: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 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...

Page 285: ...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 PROTECTOR 7 4...

Page 286: ...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 For installation reverse the removal proce dure 4 6 2 2 2 2 2 5 6 3 1 New 7...

Page 287: ...l hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover left right Seat Air scoop left right Fuel tank TIP Do not set the fuel t...

Page 288: ...that the projection a faces the rear of the vehicle EASB29B313 INSTALLING THE FUEL TANK 1 Install Fuel tank 2 Connect Fuel hose ECA NOTICE Connect the fuel hose securely and check that the orientation...

Page 289: ...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 fuel pressure Out of specification Repla...

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

Page 291: ...GINE REMOVAL on page 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Breather hose 3 1 3 Air filter case 1 4 Fuel injector coupler 1 Discon...

Page 292: ...le body joint 1 For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft...

Page 293: ...Remarks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 5 N m 0 5 kgf m 3 7 lb f...

Page 294: ...eign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly...

Page 295: ...to YAMAHA DIAGNOSTIC TOOL on page 8 27 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 Se...

Page 296: ...THROTTLE BODY 7 11...

Page 297: ...AM 8 23 ECU SELF DIAGNOSTIC FUNCTION 8 25 TROUBLESHOOTING METHOD 8 26 YAMAHA DIAGNOSTIC TOOL 8 27 FEATURES OF THE YAMAHA DIAGNOSTIC TOOL 8 27 FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL 8 27 CONNECTING TH...

Page 298: ...G THE RECTIFIER REGULATOR 8 69 CHECKING THE FUEL SENDER 8 69 CHECKING THE RESISTER 8 70 CHECKING THE RADIATOR FAN MOTOR For JPN 8 70 CHECKING THE COOLANT TEMPERATURE SENSOR 8 70 CHECKING THE THROTTLE...

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Page 300: ...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 R...

Page 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...

Page 302: ...ery terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 37 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHE...

Page 303: ...Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 67 NG Replace the lean angle sensor OK 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair...

Page 304: ...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...

Page 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...

Page 306: ...er is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance t...

Page 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...

Page 308: ...e the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 68 OK Starter motor is OK Perform the electric starting system troubleshooting starting wi...

Page 309: ...ch Refer to CHECKING THE SWITCHES on page 8 57 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 57 NG Replace the engine stop switch OK 12 Check...

Page 310: ...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 R...

Page 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...

Page 312: ...ND CHARGING THE BATTERY on page 8 61 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 68 NG Replace the stator ass...

Page 313: ...CHARGING SYSTEM 8 14...

Page 314: ...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 R R W...

Page 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...

Page 316: ...TTERY on page 8 61 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main relay Refer to CHECKING THE RE LAYS on page 8 64 NG Replace the main relay OK 4 Check the entire s...

Page 317: ...stor Refer to CHECKING THE RESIST ER on page 8 70 NG Replace the resistor OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 15 NG Properly connect or repair the signal...

Page 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...

Page 319: ...ctor 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 21 ECU engine control unit 26 Radiator fan motor relay 27 Radiator fan motor fuse 28 Radiator fan motor 29 Jo...

Page 320: ...main relay Refer to CHECKING THE RE LAYS on page 8 64 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR For JPN on page 8 70 NG Replace the radiator...

Page 321: ...COOLING SYSTEM For JPN 8 22...

Page 322: ...g 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 W...

Page 323: ...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...

Page 324: ...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...

Page 325: ...ement action for the fuel injection system Refer to Confirmation of service completion in the appropriate table in TROUBLESHOOTING DETAILS on page 8 29 4 After pushing the engine stop switch push the...

Page 326: ...agnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting setting tool Y...

Page 327: ...nect and use the Yamaha diagnostic tool refer to YAMAHA DIGNO STIC TOOL OPERATION MANUAL EASB29B341 FI diagnostic tool sub lead 90890 03212 FI diagnostic tool sub lead YU 03212 1 Vehicle 2 Coupler for...

Page 328: ...ocking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Crank the engine Fault code number is not dis played Service is finished Fault code n...

Page 329: ...s sure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the...

Page 330: ...prox 80 kPa 3000 m above sea level Ap prox 70 kPa When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure se...

Page 331: ...sea level Ap prox 80 kPa 3000 m above sea level Ap prox 70 kPa When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake a...

Page 332: ...ntinuity Open or short circuit Re place the wire harness Between throttle position sensor coupler and ECU cou pler black blue black blue yellow yellow blue blue Push the start switch Fault code number...

Page 333: ...position sensor stuck throttle position sensor is de tected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Diagnostic tool display Throttle position sensor signal 11...

Page 334: ...temperature Procedure Compare the actually measured coolant temperature with the Yamaha diagnostic tool display value Item Probable cause of malfunc tion and check Maintenance job Confirmation of ser...

Page 335: ...empera ture sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temper ature The displayed temperature is not close to the ambient tem perat...

Page 336: ...ss Between intake air tempera ture sensor coupler and ECU coupler black blue black blue brown white brown white Push the start switch Fault code number is not dis played Service is finished Fault code...

Page 337: ...art switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defectiv...

Page 338: ...curely or repair replace the sub wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to...

Page 339: ...c mode Code No 36 No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector re sistance Replace if out of specifica tion Refer to CHECKING THE FUEL IN...

Page 340: ...vice is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro...

Page 341: ...erminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code...

Page 342: ...7 Go to item 3 2 01 is indicated in Diagnostic mode Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment push the...

Page 343: ...2 Wire harness continuity Open or short circuit Re place the wire harness Between rectifier regulator coupler and ECU coupler red red Between battery terminal and ECU coupler red red Start the engine...

Page 344: ...e start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler...

Page 345: ...ber is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and ch...

Page 346: ...played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins be...

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

Page 348: ...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...

Page 349: ...PUMP SYSTEM 8 50 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...

Page 350: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 61 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 57 NG...

Page 351: ...FUEL PUMP SYSTEM 8 52 EASB29B345...

Page 352: ...ELECTRICAL COMPONENTS 8 53 ELECTRICAL COMPONENTS EASB29B346 9 10 11 1 3 2 4 5 6 7 8...

Page 353: ...ICAL COMPONENTS 8 54 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 Radiator fan motor For JPN 11 In...

Page 354: ...ELECTRICAL COMPONENTS 8 55 11 10 9 2 3 1 6 7 8 4 5...

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

Page 356: ...ELECTRICAL COMPONENTS 8 57 EASB29B347 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Page 357: ...ELECTRICAL COMPONENTS 8 58 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 358: ...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 diagram...

Page 359: ...ch bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the digital circuit tester probes to t...

Page 360: ...ilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH O...

Page 361: ...e checked by mea suring its open circuit voltage i e the voltage when the positive battery terminal is discon nected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b...

Page 362: ...open circuit voltage Charging method using a variable cur rent voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopp...

Page 363: ...battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Seat Side cover l...

Page 364: ...1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Posi...

Page 365: ...2 Check Spark plug cap resistance Out of specification Replace a Connect the digital circuit tester to the spark plug cap b Measure the spark plug cap resistance EASB29B355 CHECKING THE IGNITION COIL...

Page 366: ...an angle sensor from the bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the digital circuit tester...

Page 367: ...otor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digita...

Page 368: ...ender coupler from the fuel sender 3 Remove Fuel sender from the fuel tank 4 Check Fuel sender resistance Out of specification Replace the fuel sender a Connect the digital circuit tester to the fuel...

Page 369: ...perature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Ou...

Page 370: ...he digital circuit tester DC to the test harness S pressure sensor 3P c Start the engine d Measure the throttle position sensor input voltage EASB29B366 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check...

Page 371: ...ove Fuel injector Refer to THROTTLE BODY on page 7 6 2 Check Fuel injector resistance Out of specification Replace a Disconnect the fuel injector coupler from the fuel injector b Connect the digital c...

Page 372: ...ELECTRICAL COMPONENTS 8 73 c Measure the fuel injector resistance...

Page 373: ...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 UNSTABLE H...

Page 374: ...e Deteriorated or contaminated fuel Clogged or damaged fuel hose 2 Fuel pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged bat...

Page 375: ...ized shift fork Bent shift fork guide bar 3 Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EASB29B376 JUMPS OUT OF GEAR Engine 1 Shif...

Page 376: ...evel EASB29B382 FRONT FORK OIL LEAKING Chassis 1 Front fork Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high L...

Page 377: ...NG 9 4 7 Wheel s Incorrect wheel balance Broken or loose spoke Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8 Frame Bent frame Damaged steering head pipe Improperly installed...

Page 378: ...35 22 Intake air temperature sensor open or short circuit detected 8 36 30 Latch up detected 8 38 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 38 39 Injec...

Page 379: ...When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturned Displa...

Page 380: ...o Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals WARNING on the Yamaha diagnostic tool blinks five times when the ignition...

Page 381: ...OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SETTING OF SPRING AFTER REPLACEMENT 10 4 REAR SHOCK ABSORBER SETT...

Page 382: ...eed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies fro...

Page 383: ...oo large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within...

Page 384: ...of damping force Change the rebound damping force Change the compression damping force EASB29B396 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor...

Page 385: ...ng load Run with the rebound damping force adjuster one or two clicks turned in and readjust it to suit your preference TIP Adjusting the rebound damping force will be fol lowed more or less by a chan...

Page 386: ...preload adjusting positions TIP For the spring preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER ASSEMBLY on page 3 31 Spring preload Minimum 1 5 mm 0 06 in Standard 10 0 mm 0 39 in Maxi...

Page 387: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Page 388: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Page 389: ...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...

Page 390: ...er 90201 20685 1 5 Circlip 93410 20038 1 6 Ratchet wheel 2S2 15671 00 1 7 Spring 90501 160A2 1 8 Washer 90201 167P7 1 Thickness 1 5 mm 0 0059 in 9 Circlip 99009 16400 1 10 Spring guide 5NL 15664 00 1...

Page 391: ...5620 00 1 20 Kickstarter lever 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 C...

Page 392: ...CLUTCH 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 origin...

Page 393: ...ssembly 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 kick sh...

Page 394: ...ame 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 1 6 Washer 1 7 Bolt 1 New 3...

Page 395: ...ing with the kickstarter When using the kickstarter to start the engine follow the procedures as described below 1 Fold out the kickstarter lever push it down lightly with your foot until resistance i...

Page 396: ...ar 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace 3 Check Kickstarter lever 1 smooth movement Unsmooth movement Apply the lithium soap based grease to the pivoting point and metal...

Page 397: ...topper a of the torsion spring fits into the hole b on the kick shaft 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 sto...

Page 398: ...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 Diode 38 Starting circuit cut...

Page 399: ...lity and performance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lu...

Page 400: ...25 Read this manual carefully before operating this vehicle YZ250FXJ OWNER S SERVICE MANUAL YZ250FX 2018 PRINTED IN JAPAN 2017 04 0 3 1 E PRINTED ON RECYCLED PAPER 2018 YZ250FXJ B29 28199 13_cover in...

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Page 402: ...ON OFF ON OFF B B B B Gy Gy B B Gy B B B L L B B B B B YZ250FXJ 2018 WIRING DIAGRAM B29 28199 13_W D indd 2 2017 04 11 9 54 26...