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Yamaha Manuals
Motorcycle
YZF-R25
Service manual
Table Of Contents - Yamaha YZF-R25 Service Manual
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Owner's manual
(98 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
How To Use This Manual
4
Symbols
5
Table Of Contents
7
General Information
9
Vehicle Identification Number
10
Features
11
Outline Of The Fi System
11
Fi System
12
Multi-Function Meter Unit
13
Speedometer
13
Tachometer
13
Clock
13
Fuel Meter
14
Coolant Temperature Meter
14
Transmission Gear Display
14
Multi-Function Display
15
Instantaneous/Average Fuel Consumption Display
15
Oil Change Tripmeter
16
Shift Timing Indicator Light
16
Self-Diagnosis Device
17
Preparation For Removal And Disassembly
18
Replacement Parts
18
Gaskets, Oil Seals And O-Rings
18
Lock Washers/Plates And Cotter Pins
18
Important Information
18
Bearings And Oil Seals
19
Circlips
19
Rubber Parts
19
Basic Service Information
20
Quick Fasteners
20
Rivet/Screw Type Fasteners
20
Electrical System Service
21
Electrical Parts Handling
21
Checking The Electrical System
22
Checking The Connections
23
Special Tools
26
Specifications
33
General Specifications
34
Engine Specifications
35
Chassis Specifications
40
Electrical Specifications
43
Tightening Torques
45
General Tightening Torques Specifications
45
Engine Tightening Torques
45
Crankcase Bolt
48
Chassis Tightening Torques
50
Connecting Rod Bolt
50
Lubrication Points And Lubricant Types
54
Lubrication System Chart And Diagrams
56
Engine Oil Lubricatoin Chart
56
Lubrication Diagrams
58
Crankcase, Cylinder, And Cylinder Head (Right Side View) Lubrication Diagrams
58
Crankcase And Cylinder (Left Side View) Lubrication Diagram
60
Oil Pump (Right Side View) Lubrication Diagram
61
Oil Strainer (Bottom View) Lubrication Diagram
62
Camshaft (Top View) Lubrication Diagram
63
Crankshaft (Rear View) Lubrication Diagram
64
Crankshaft And Transmission (Top View) Lubrication Diagram
65
Cooling System Diagrams
66
Cable Routing
68
Handlebar (Font View) Cable Routing
68
Engine (Right Side View) Cable Routing
70
Rear Fender (Right Side View) Cable Routing
72
Engine (Left Side View) Cable Routing
74
Rear Fender (Left Side View) Cable Routing
76
Engine (Top View)
78
Rear Fender (Top View) Cable Routing
80
Front Brake (Right Side View) Cable Routing
82
Rear Brake (Right Side View) Cable Routing
83
Fuel Tank (Left Side View) Cable Routing
85
Throttle Bodies (Left And Right View) Cable Routing
87
Air Induction System (Top View) Cable Routing
89
Radiator (Top View) Cable Routing
91
Radiator (Left Side View) Cable Routing
93
Radiator (Right Side View) Cable Routing
95
Periodic Checks And Adjustments
97
Periodic Maintenance
100
Periodic Maintenance Chart For The Emission Control System
100
General Maintenance And Lubrication Chart
100
Checking The Fuel Line
102
Checking The Fuel Filter/Spark Plugs
103
Adjusting The Valve Clearance
104
Checking The Engine Idling Speed
107
Synchronizing The Throttle Bodies
107
Checking The Throttle Body Synchronization
107
Adjusting The Throttle Body Synchronization
108
Checking The Throttle Body Joint/The Exhaust System
109
Adjusting The Exhaust Gas Volume
110
Checking The Crankcase Breather Hose
110
Replacing The Air Filter Element And Cleaning The Check Hose
110
Adjusting The Clutch Lever Free Play
111
Checking The Brake Operaton/The Front Brake Pads
112
Checking The Rear Brake Pads
113
Checking The Front/Rear Brake Hoses
113
Bleeding The Hydraulic Brake System
113
Checking The Brake Fluid Level
114
Checking The Wheels/Tires
115
Never Overload The Vehicle
115
Checking The Wheel Bearings/Swingarm Operation
116
Lubricating The Swingarm Pivot
116
Adjusting The Drive Chain Slack
116
Lubricating The Drive Chain
117
Checking And Adjusting The Steering Head
118
Lubricating The Steering Head/The Brake Lever/The Pedal/The Clutch Lever
119
Checking/Lubricating The Sidestand
119
Checking The Front Fork
119
Adjusting The Rear Shock Absorber Assembly
120
Checking The Engine Oil Level
120
Changing The Engine Oil
121
Checking The Coolant Level
122
Checking The Cooling System
123
Changing The Coolant
123
Checking The Brake Light Switches
125
Adjusting The Rear Brake Light Switch
125
Checking And Lubricating The Cables
125
Checking The Trhottle Grip Operation
125
Checking The Switches, Lights And Signals
126
Adjusting The Headlight Beam
127
Chassis
129
General Chassis (1)
132
Removing The Seats And Battery
132
Removing The Center Cover
133
Installing The Battery/Rider Seat/Center Cover/Passenger Seat
133
General Chassis (2)
134
Removing The Rear Side Cowlings
134
Removing/Installing The Side Panels
135
Removing/Installing The Upper Tail Panel
135
General Chassis (3)
136
Removing The Fuel Tank Covers
136
Removing The Cowlings
137
Removing/Installing The Front Panels
138
Disassembling/Assembling The Fuel Tank Cover Assembly
138
Removing/Installing The Bottom Cowlings
139
Removing/Installing The Front Bottom Cowlings
139
Removing The Front Side Cowling Assembly
140
Installing The Front Side Cowling Assembly
141
Removing/Installing The Front Upper Cowling
141
General Chassis (4)
142
Removing The Front Cowling Assembly
142
Installing The Front Cowling Assembly
143
General Chassis (5)
144
Disassembling The Front Cowling Assembly
144
Removing/Installing The Windshield Assembly
145
Removing/Installing The Front Cowling Center Cover
145
General Chassis (6)
147
Removing The Air Filter Case
147
Installing The Air Filter Case
148
Front Wheel
149
Removing The Front Wheel And Brake Disc
149
Disassembling The Front Wheel
150
Removing/Disassembling/Checking The Front Wheel
151
Assembling The Front Wheel
152
Adjusting The Front Wheel Static Balance
152
Installing The Front Wheel (Front Brake Discs)
153
Rear Wheel
155
Removing The Rear Wheel
155
Removing The Rear Brake Disc And Rear Wheel Sprocket
156
Disassembling The Rear Wheel
157
Removing/Disassembling/Checking The Rear Wheel
158
Checking The Rear Wheel Drive Hub
158
Checking And Replacing The Rear Wheel Sprocket
158
Assembling The Rear Wheel
159
Adjusting The Rear Wheel Static Balance
159
Installing The Rear Wheel (Rear Brake Disc)
159
Front Brake
161
Removing The Front Brake Pads
161
Removing The Front Brake Master Cylinder
162
Disassembling The Front Brake Master Cylinder
163
Removing The Front Brake Caliper
164
Disassembling The Front Brake Caliper
165
First Aid For Brake Fluid Entering The Eyes
166
Checking The Front Brake Disc
166
Replacing The Front Brake Pads
167
Removing/Disassembling The Front Brake Caliper
168
Checking/Assembling/Installing The Front Brake Caliper
169
Removing/Checking The Front Brake Master Cylinder
170
Assembling/Installing The Front Brake Master Cylinder
171
Rear Brake
173
Removing The Rear Brake Pads
173
Removing The Rear Brake Master Cylinder
174
Disassembling The Rear Brake Master Cylinder
176
Removing The Rear Brake Caliper
177
Disassembling The Rear Brake Caliper
178
Checking/Replacing The Rear Brake Disc
179
Removing/Disassembling/Checking The Rear Brake Caliper
181
Assembling/Installing The Rear Brake Caliper
182
Removing/Checking The Rear Brake Master Cylinder
183
Assembling/Installing The Rear Brake Master Cylinder
184
Handlebards
186
Removing The Handlebar (Right)
186
Removing The Handlebar (Left)
187
Removing/Checking/Installing The Handlebars
188
Front Fork
192
Removing The Front Fork Legs
192
Disassembling The Front Fork Legs
193
Removing/Disassembling The Front Fork Legs
195
Checking/Assembling The Front Fork Legs
196
Installing The Front Fork Legs
199
Steering Head
201
Removing The Upper Bracket And Lower Bracket
201
Removing The Lower Bracket
203
Checking/Installing The Steering Head
203
Swingarm And Rear Shock Absorber Assembly
205
Removing The Swingarm And Rear Shock Absorber Assembly
205
Removing/Checking The Rear Shock Absorber Assembly
207
Removing/Checking The Swingarm
207
Installing The Swingarm/Rear Shock Absorber Assembly
208
Chain Drive
210
Removing The Drive Sprocket And Drive Chain
210
Removing/Checking The Drive Chain
211
Checking/Installing The Drive Sprocket
212
Installing The Drive Chain
213
Engine
215
Engine Inspection
218
Measure The Compression Pressure
218
Engine Removal
220
Removing The Muffler And Exhaust Pipe
220
Disconnecting The Leads And Cable
222
Removing The Engine
224
Installing The Engine
225
Assembling The Muffler
226
Installing The Exhaust Pipe And Muffler Assembly
226
Camshafts
228
Removing The Cylinder Head Cover
228
Removing The Camshafts
229
Checking The Camshafts
231
Checking The Camshaft Sprockets
232
Checking The Timing Chain Tensioner
233
Installing The Camshafts
233
Installing The Cylinder Head Cover
237
Cylinder Head
238
Removing The Cylinder Head
238
Checking The Timing Chain Guide (Exhaust Side)/Cylinder Head
241
Installing The Cylinder Head
241
Valves And Valve Springs
243
Removing The Valves And Valve Springs
243
Removing The Valves
244
Checking The Valves And Vave Guides
244
Checking The Valve Seats
246
Checking The Valve Springs
247
Checking The Valve Lifters
248
Installing The Valves
248
Cylinder And Pistons
251
Removing The Cylinder And Pistons
251
Removing The Pistons
252
Checking The Cylinders And Pistons
252
Checking The Piston Rings
253
Checking The Pistion Pins
254
Installing The Pistons And Cylinder
254
Generator And Starter Clutch
257
Removing The Stator Coil, Generator Rotor And Starter Clutch
257
Removing The Generator/Starter Clutch
259
Checking The Starter Clutch
259
Installing The Starter Clutch
260
Installing The Generator
261
Electric Starter
262
Removing The Starter Motor
262
Disassembling The Starter Motor
263
Checking The Starter Motor
264
Assembling/Installing The Starter Motor
265
Clutch
266
Removing The Clutch Cover And Pull Lever Shaft
266
Removing The Clutch
268
Checking The Friction Plates
269
Checking The Clutch Plates/Clutch Springs/Clutch Housing
270
Checking The Clutch Boss/Pressure Plate/Primary Driven Gear/The Pull Lever Shaft And Pull Rod
271
Installing The Clutch
271
Shift Shaft
274
Removing The Shift Pedal
274
Removing The Shift Shaft And Stopper Lever
275
Checking The Shift Shaft/Stopper Lever
277
Installing The Shift Shaft/Shift Rod
277
Oil Pump
279
Removing The Oil Pump
279
Disassembling The Oil Pump
280
Checking The Oil Pump Idle Gear/Oil Pump/Relief Valve
281
Assembling The Oil Pump
281
Installing The Oil Pump
282
Oil Pan
283
Removing The Oil Pan
283
Checking The Oil Strainer
284
Installing The Oil Pan
284
Chankcase
285
Removing The Crankcase Breather Cover And Switches
285
Separating The Crankcase
287
Disassembling The Crankcase
288
Checking The Balancer Drive Gear/The Timing Chain And Timing Chain Guide (Intake Side)
289
Checking The Crankcase/The Oil Nozzles
289
Assembling The Crankcase
289
Installing The Oil Pressure Switch And Gear Position Switch
292
Crankshaft And Balancer Shaft
294
Removing The Crankshaft, Connecting Rod And Balancer Shaft
294
Removing The Balancer Shaft Journal Bearings/Crankshaft Journal Bearings/The Connecting Rods
295
Checking The Balancer Shaft Assembly
295
Checking The Crankshaft
297
Checking The Connecting Rods
298
Installing The Connecting Rods
300
Installing The Crankshaft
301
Installing The Balancer Shaft Assembly
302
Transmission
303
Removing The Transmission, Shift Drum Assembly, And Shift Forks
303
Disassembly The Main Axle Assembly
305
Disassembly The Drive Axle Assembly
306
Checking The Shift Forks/The Shift Drum Assembly/The Transmission
307
Assembling The Main Axle And Drive Axle
308
Installing The Transmission
308
Cooling System
311
Radiator
312
Removing The Radiator
312
Checking/Installing The Radiator
314
Thermostat
315
Removing The Thermostat
315
Checking/Installing The Thermostat
316
Water Pump
317
Removing The Water Pump
317
Disassembling/Checking/Assembling The Water Pump
319
Installing The Clutch Cover
320
Fuel System
323
Fuel Tank
324
Removing The Fuel Tank And Fuel Pump
324
Removing The Fuel Tank/The Fuel Pump/The Fuel Filter
326
Checking The Fuel Pump Body/Fuel Filter
327
Installing The Fuel Filter/Fuel Pump
327
Installing The Fuel Tank
328
Throttle Bodies
329
Removing The Throttle Bodies
329
Removing The Fuel Injectors And Isc Valve
330
Checking The Injectors (Before Removing)
331
Removing/Checking The Injectors
331
Checking The Throttle Bodies And Isc (Idle Speed Control) Valve
331
Cleaning The Throttle Bodies
331
Cleaning The Isc (Idle Speed Control) Valve
332
Resetting The Isc (Idle Speed Control) Learning Values
333
Checking The Throttle Body Joint/Injector Pressure
334
Installing The Fuel Injectors
334
Checking The Fuel Pressure
335
Installing The Throttle Body Joint
335
Air Induction System
338
Removing The Air Cut-Off Valve And Reed Valve
340
Checking/Installing The Air Induction System
341
Air Injection
341
Air Cut-Off Valve
341
Electrical System
343
Ignition System
346
Circuit Diagram
346
Ignition System Troubleshooting
348
Electric Starting System/Circuit Diagram
350
Starting Circuit Cut-Off System Operation
352
Electric Starting System Troubleshooting
353
Charging System/Circuit Diagram
356
Charging System Troubleshooting
358
Lighting System/Circuit Diagram
360
Lighting System Troubleshooting
362
Signaling System/Circuit Diagram
364
Signaling System Troubleshooting
366
Cooling System/Circuit Diagram
372
Cooling System Troubleshooting
374
Fuel Injection System/Circuit Diagram
376
Ecu Self-Diagnostic Function
378
Engine Trouble Warning Light Indication And Fuel Injection System Operation
378
Checking The Engine Trouble Warning Light/Ecu Detects An Abnormal Signal From A Sensor
378
Troubleshooting Method
378
Yamaha Diagnostic Tool
379
The Engine Operation Is Not Normal, But The Engine Trouble Warning Light Does Not Come On
379
Connecting/Operation Of The Yamaha Diagnostic Tool
380
Fuel Injection System: Troubleshooting Detail
382
Crankshaft Position Sensor: No Normal Signals Are Received From The Crankshaft Position Sensor
382
Intake Air Pressure Sensor: Open Or Short Circuit Detected
383
Intake Air Pressure Sensor: Hose System Malfunction (Clogged Or Detached Hose)
385
Throttle Position Sensor: Open Or Short Circuit Detected
386
Throttle Position Sensor: Stuck Throttle Position Sensor Is Detected (Signal From Throttle Position Sensor Will Not Change)
387
Black/Red Lead Of The Ecu: A Break Or Disconnection Of The Black/Red Lead Of The Ecu Is Detected
388
Coolant Temperature Sensor: Open Or Short Circuit Detected
389
Intake Temperature Sensor: Open Or Short Circuit Detected
390
O2 Sensor: No Normal Signals Are Received From The O2 Sensor
391
Latch Up Detected
393
Cylinder #1 Ignition Coil: Open Or Short Circuit Detected In The Primary Lead Of The Cylinder #1 Ignition Coil
393
Cylinder #2 Ignition Coil: Open Or Short Circuit Detected In The Primary Lead Of The Cylinder #2 Ignition Coil
394
Fuel Injector: Open Or Short Circuit Detected
396
Lean Angle Sensor: Open Or Short Circuit Detected
397
Speed Sensor: No Normal Signals Are Received From The Speed Sensor
398
Gear Position Switch: Open Or Short Circuit Is Detected
398
Clutch Switch: Open Or Short Circuit Is Detected
398
Fuel System Voltage: Incorrect Voltage Supplied To The Fuel Injector And Fuel Pump
404
Eeprom Fault Code Number: An Error Is Detected While Reading Or Writing On Eeprom
405
Charging Voltage Is Abnormal
406
Faulty Ecu Memory. (When This Malfunction Is Detected In The Ecu, The Fault Code Number Might Not Appear On The Meter Display)
407
Ecu Internal Malfunction (Output Signal Error): Signals Cannot Be Transmitted Between The Ecu And The Multi-Function Meter
407
Ecu Internal Malfunction (Output Signal Error): Signals Cannot Be Transmitted Between The Ecu And Yamaha Diagnostic Tool
408
Ecu Internal Malfunction (Output Signal Error): No Signals Are Received From The Ecu Within The Specified Duration
409
Ecu Internal Malfunction (Output Signal Error): Data From The Ecu Cannot Be Received Correctly
410
Ecu Internal Malfunction (Output Signal Error): Non-Registered Data Has Been Received From The Meter
411
Ecu Internal Malfunction (Output Signal Error): No Normal Signals Are Received From The Yamaha Diagnostic Tool
412
Fuel Pump System/Circuit Diagram
414
Fuel Pump System Troubleshooting
416
Eletrical Components Diagram
418
Electrical Components
418
Electrical Components Diagram (Cont.)
420
Checking The Switches
422
Checking The Bulbs And Bulb Sockets
424
Types Of Bulbs
425
Checking The Condition Of The Bulbs/Bulb Sockets
425
Checking The Fuses
426
Replacing/Removing The Ecu (Engine Control Unit)
426
Installing The Ecu (Engine Control Unit)
427
Checking And Charging The Battery
427
Charging Method Using A Variable-Current (Voltage) Charger/Constant Voltage Charger
429
Checking The Relays
430
Starter Relay
430
Starting Circuit Cut-Off Relay
430
Checking The Diodes
431
Headlight/Radiator Fan Motor/Turn Signal Relays
431
Checking The Spark Plug Caps/Ignition Coils
433
Checking The Ignition Spark Gap
434
Checking The Crankshaft Position Sensor/Lean Angle Sensor
434
Checking The Starter Motor Operation/Stator Coil
435
Checking The Rectifier/Regulator/Fuel Sender
436
Checking The Fuel Meter/Speed Sensor/Radiator Fan Motor/Coolant Temperature Sensor
437
Checking The Air Induction System Solenoid/The Gear Position Switch
438
Checking The Fuel Injectors
439
Troubleshooting
441
Starting Failure
442
Incorrect Engine Idling Speed
442
Poor Medium-And-High-Speed Performance
443
Faulty Gear Shifting/Shift Pedal Does Not Move
443
Jumps Out Of Gear
443
Faulty Clutch
443
Overheating/Overcooling
444
Poor Braking Performance
444
Faulty Front Fork Legs
444
Unstable Handling
444
Faulty Lighting Or Signaling System
445
Self-Diagnostic Function And Diagnostic Code Table
446
Self-Diagnostic Function Table
446
Communication Error With The Meter Or Yamaha Diagnostic Tool
446
Diagnostic Code: Sensor Operation Table
447
Diagnostic Code: Actuator Operation Table
449
Wiring Diagram Items List
452
Color Codes List
452
Wiring Diagram
455
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1
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457
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Table of Contents
Troubleshooting
Ignition System Troubleshooting
348
Electric starting system troubleshooting
353
Charging system troubleshooting
358
Lighting system troubleshooting
362
Signaling system troubleshooting
366
Cooling system troubleshooting
374
ECU self-diagnostic function
378
Fuel injection system: troubleshooting detail
382
Fuel pump system troubleshooting
416
Troubleshooting
441
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