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Yamaha Manuals
Offroad Vehicle
2009 YFM25RY
Service manual
Yamaha 2009 YFM25RY Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cable Routing
Periodic Checks and Adjustments
Periodic Maintenance
Introduction
Periodic Maintenance Chart for the Emission Control System
General Maintenance and Lubrication Chart
Engine
Adjusting the Valve Clearance
Adjusting the Engine Idling Speed
Adjusting the Throttle Cable Free Play
Adjusting the Speed Limiter
Checking the Spark Plug
Checking the Ignition Timing
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Adjusting the Clutch Cable Free Play
Cleaning the Air Filter Element
Checking the Carburetor Joint and Intake Manifold
Checking the Fuel Line
Checking the Cylinder Head Breather Hose
Checking the Exhaust System
Cleaning the Spark Arrester
Chassis
Adjusting the Front Disc Brake
Adjusting the Brake Pedal
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Front Brake Hoses
Checking the Rear Brake Hose
Adjusting the Parking Brake
Adjusting the Rear Brake Light Switch
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Drive Chain Slack
Lubricating the Drive Chain
Checking the Steering System
Adjusting the Toe-In
Checking the Front Shock Absorber Assemblies
ADJUSTING the FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3D)
ADJUSTING the FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M)
Checking the Rear Shock Absorber Assembly
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for 4D3D)
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for 4D3H, 4D3M)
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the Levers
Lubricating the Pedal
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Chassis
General Chassis
Front Wheel
Removing the Front Wheels
Checking the Front Wheels
Checking the Front Wheel Hubs
Checking the Front Brake Discs
Installing the Front Wheel Hub Bearings
Installing the Front Brake Discs
Installing the Front Wheel Hubs
Adjusting the Front Wheel Static Balance
Installing the Front Wheels
Rear Wheel
Removing the Rear Wheels
Checking the Rear Wheels
Checking the Rear Wheel Hubs
Installing the Rear Wheel Hubs
Adjusting the Rear Wheel Static Balance
Installing the Rear Wheels
Rear Axle and Rear Axle Hub
Removing the Rear Axle
Checking the Rear Axle
Checking the Rear Axle Hub
Checking the Rear Wheel Sprocket
Checking the Sprocket Bracket
Installing the Rear Wheel Sprocket
Installing the Rear Axle
Front Brake
Introduction
Checking the Front Brake Discs
Replacing the Front Brake Pads
Removing the Front Brake Calipers
Disassembling the Front Brake Caliper
Checking the Front Brake Caliper
Assembling the Front Brake Caliper
Installing the Front Brake Caliper
Removing the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Removing the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Handlebar
Removing the Handlebars
Checking the Handlebar
Installing the Handlebar
Steering Stem
Checking the Steering Stem
Installing the Steering Stem
Installing the Lock Washer
Tie-Rods and Steering Knuckles
Removing the Steering Knuckles
Checking the Tie-Rods
Checking the Steering Knuckles
Installing the Tie-Rods
Front Arms and Front Shock Absorber Assemblies
Removing the Front Arms
Checking the Front Arms
Handling the Front Shock Absorber and Gas Cylinder
Disposing of a Front Shock Absorber and Gas Cylinder
Checking the Front Shock Absorber Assemblies
Checking the Front Arm Ball Joints
Installing the Front Arms and Front Shock Absorber Assemblies
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Engine
Engine Removal
Installing the Engine
Installing the Muffler and Exhaust Pipe
Camshaft
Removing the Rocker Arms and Camshaft
Checking the Camshaft
Checking the Rocker Arms and Rocker Arm Shafts
Installing the Camshaft and Rocker Arms
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Checking the Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Installing the Valves
Cylinder and Piston
Removing the Piston
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Installing the Piston and Cylinder
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Clutch Push Rods
Checking the Primary Drive Gear
Installing the Clutch
Oil Pump
Removing the Oil Pump
Checking the Oil Pump
Assenbling the Balancer Weight Gear
Installing the Oil Pump
Installing the Balancer Weight Gear
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Pickup Coil Rotor and Starter Clutch
Removing the Pickupcoil Rotor
Checking the Starter Clutch
Installing the Pickup Coil Rotor
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Crankcase
Disassembling the Crankcase
Checking the Crankcase
Assembling the Crankcase
Crankshaft Assembly
Removing the Crankshaft Assembly
Removing the Plunger Seal
Checking the Crankshaft and Connecting Rod
Checking the Timing Chain
Checking the Crankshaft Sprocket
Checking the Timing Chain Guide
Installing the Plunger Seal
Installing the Crankshaft Assembly
Transmission
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Installing the Shift Forks and Shift Drum Assembly
Fuel System
Fuel Tank
Checking the Fuel Cock
Checking the Fuel Cock Operation
Removing the Fuel Tank
Carburetor
Checking the Carburetor
Assembling the Carburetor
Installing the Carburetor
Electrical System
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-Off System Operation
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Carburetor Heating System
Circuit Diagram
Troubleshooting
Electrical Components
Checking the Switches
Checking the Bulbs and Bulb Sockets
Checking the Fuses
Checking and Charging the Battery
Checking the Relays
Checking the Diode
Checking the Spark Plug Cap
Checking the Ignition Coil
Checking the Pickup Coil
Checking the Starter Motor Operation
Checking the Stator Coil
Checking the Rectifier/Regulator
Checking the Thermo Switch
Checking the Carburetor Warmer
Troubleshooting
General Information
General Information
Starting Failures
Troubleshooting
Faulty Clutch
Faulty Gear Shifting
Incorrect Engine Idling Speed
Jumps out of Gear
Poor Medium-And-High-Speed Performance
Shift Pedal Does Not Move
Faulty Lighting or Signaling System
Overheating
Poor Braking Performance
Unstable Handling
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Quick Links
1
Adjusting the Valve Clearance
Download this manual
2009
SERVICE MANUAL
YFM25RY
YFM25RSEY
YFM25RSE2Y
LIT-11616-22-09
4D3-28197-11
Table of
Contents
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Advertisement
Chapters
Table of Contents
7
Specifications
19
Periodic Checks and Adjustments
63
Chassis
99
Engine
163
Fuel System
231
Electrical System
241
Troubleshooting
285
Table of Contents
Troubleshooting
TROUBLESHOOTING
244
TROUBLESHOOTING
250
TROUBLESHOOTING
254
TROUBLESHOOTING
258
TROUBLESHOOTING
262
TROUBLESHOOTING
266
TROUBLESHOOTING
285
TROUBLESHOOTING
286
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This manual is also suitable for:
2009 yfm25rsey
2009 yfm25rse2y
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