Download

Table Of Contents - Yamaha YZF-R25 Service Manual

Hide thumbs Also See for YZF-R25:

Owner's manual (98 pages)

Table Of Contents

Table of Contents

Advertisement

Table of Contents

How To Use This Manual4

Table Of Contents7

General Information9

Vehicle Identification Number10

Outline Of The Fi System11

Multi-Function Meter Unit13

Coolant Temperature Meter14

Transmission Gear Display14

Multi-Function Display15

Instantaneous/Average Fuel Consumption Display15

Oil Change Tripmeter16

Shift Timing Indicator Light16

Self-Diagnosis Device17

Preparation For Removal And Disassembly18

Replacement Parts18

Gaskets, Oil Seals And O-Rings18

Lock Washers/Plates And Cotter Pins18

Important Information18

Bearings And Oil Seals19

Basic Service Information20

Quick Fasteners20

Rivet/Screw Type Fasteners20

Electrical System Service21

Electrical Parts Handling21

Checking The Electrical System22

Checking The Connections23

Special Tools26

Specifications33

General Specifications34

Engine Specifications35

Chassis Specifications40

Electrical Specifications43

Tightening Torques45

General Tightening Torques Specifications45

Engine Tightening Torques45

Crankcase Bolt48

Chassis Tightening Torques50

Connecting Rod Bolt50

Lubrication Points And Lubricant Types54

Lubrication System Chart And Diagrams56

Engine Oil Lubricatoin Chart56

Lubrication Diagrams58

Crankcase, Cylinder, And Cylinder Head (Right Side View) Lubrication Diagrams58

Crankcase And Cylinder (Left Side View) Lubrication Diagram60

Oil Pump (Right Side View) Lubrication Diagram61

Oil Strainer (Bottom View) Lubrication Diagram62

Camshaft (Top View) Lubrication Diagram63

Crankshaft (Rear View) Lubrication Diagram64

Crankshaft And Transmission (Top View) Lubrication Diagram65

Cooling System Diagrams66

Cable Routing68

Handlebar (Font View) Cable Routing68

Engine (Right Side View) Cable Routing70

Rear Fender (Right Side View) Cable Routing72

Engine (Left Side View) Cable Routing74

Rear Fender (Left Side View) Cable Routing76

Engine (Top View)78

Rear Fender (Top View) Cable Routing80

Front Brake (Right Side View) Cable Routing82

Rear Brake (Right Side View) Cable Routing83

Fuel Tank (Left Side View) Cable Routing85

Throttle Bodies (Left And Right View) Cable Routing87

Air Induction System (Top View) Cable Routing89

Radiator (Top View) Cable Routing91

Radiator (Left Side View) Cable Routing93

Radiator (Right Side View) Cable Routing95

Periodic Checks And Adjustments97

Periodic Maintenance100

Periodic Maintenance Chart For The Emission Control System100

General Maintenance And Lubrication Chart100

Checking The Fuel Line102

Checking The Fuel Filter/Spark Plugs103

Adjusting The Valve Clearance104

Checking The Engine Idling Speed107

Synchronizing The Throttle Bodies107

Checking The Throttle Body Synchronization107

Adjusting The Throttle Body Synchronization108

Checking The Throttle Body Joint/The Exhaust System109

Adjusting The Exhaust Gas Volume110

Checking The Crankcase Breather Hose110

Replacing The Air Filter Element And Cleaning The Check Hose110

Adjusting The Clutch Lever Free Play111

Checking The Brake Operaton/The Front Brake Pads112

Checking The Rear Brake Pads113

Checking The Front/Rear Brake Hoses113

Bleeding The Hydraulic Brake System113

Checking The Brake Fluid Level114

Checking The Wheels/Tires115

Never Overload The Vehicle115

Checking The Wheel Bearings/Swingarm Operation116

Lubricating The Swingarm Pivot116

Adjusting The Drive Chain Slack116

Lubricating The Drive Chain117

Checking And Adjusting The Steering Head118

Lubricating The Steering Head/The Brake Lever/The Pedal/The Clutch Lever119

Checking/Lubricating The Sidestand119

Checking The Front Fork119

Adjusting The Rear Shock Absorber Assembly120

Checking The Engine Oil Level120

Changing The Engine Oil121

Checking The Coolant Level122

Checking The Cooling System123

Changing The Coolant123

Checking The Brake Light Switches125

Adjusting The Rear Brake Light Switch125

Checking And Lubricating The Cables125

Checking The Trhottle Grip Operation125

Checking The Switches, Lights And Signals126

Adjusting The Headlight Beam127

General Chassis (1)132

Removing The Seats And Battery132

Removing The Center Cover133

Installing The Battery/Rider Seat/Center Cover/Passenger Seat133

General Chassis (2)134

Removing The Rear Side Cowlings134

Removing/Installing The Side Panels135

Removing/Installing The Upper Tail Panel135

General Chassis (3)136

Removing The Fuel Tank Covers136

Removing The Cowlings137

Removing/Installing The Front Panels138

Disassembling/Assembling The Fuel Tank Cover Assembly138

Removing/Installing The Bottom Cowlings139

Removing/Installing The Front Bottom Cowlings139

Removing The Front Side Cowling Assembly140

Installing The Front Side Cowling Assembly141

Removing/Installing The Front Upper Cowling141

General Chassis (4)142

Removing The Front Cowling Assembly142

Installing The Front Cowling Assembly143

General Chassis (5)144

Disassembling The Front Cowling Assembly144

Removing/Installing The Windshield Assembly145

Removing/Installing The Front Cowling Center Cover145

General Chassis (6)147

Removing The Air Filter Case147

Installing The Air Filter Case148

Removing The Front Wheel And Brake Disc149

Disassembling The Front Wheel150

Removing/Disassembling/Checking The Front Wheel151

Assembling The Front Wheel152

Adjusting The Front Wheel Static Balance152

Installing The Front Wheel (Front Brake Discs)153

Removing The Rear Wheel155

Removing The Rear Brake Disc And Rear Wheel Sprocket156

Disassembling The Rear Wheel157

Removing/Disassembling/Checking The Rear Wheel158

Checking The Rear Wheel Drive Hub158

Checking And Replacing The Rear Wheel Sprocket158

Assembling The Rear Wheel159

Adjusting The Rear Wheel Static Balance159

Installing The Rear Wheel (Rear Brake Disc)159

Removing The Front Brake Pads161

Removing The Front Brake Master Cylinder162

Disassembling The Front Brake Master Cylinder163

Removing The Front Brake Caliper164

Disassembling The Front Brake Caliper165

First Aid For Brake Fluid Entering The Eyes166

Checking The Front Brake Disc166

Replacing The Front Brake Pads167

Removing/Disassembling The Front Brake Caliper168

Checking/Assembling/Installing The Front Brake Caliper169

Removing/Checking The Front Brake Master Cylinder170

Assembling/Installing The Front Brake Master Cylinder171

Removing The Rear Brake Pads173

Removing The Rear Brake Master Cylinder174

Disassembling The Rear Brake Master Cylinder176

Removing The Rear Brake Caliper177

Disassembling The Rear Brake Caliper178

Checking/Replacing The Rear Brake Disc179

Removing/Disassembling/Checking The Rear Brake Caliper181

Assembling/Installing The Rear Brake Caliper182

Removing/Checking The Rear Brake Master Cylinder183

Assembling/Installing The Rear Brake Master Cylinder184

Removing The Handlebar (Right)186

Removing The Handlebar (Left)187

Removing/Checking/Installing The Handlebars188

Removing The Front Fork Legs192

Disassembling The Front Fork Legs193

Removing/Disassembling The Front Fork Legs195

Checking/Assembling The Front Fork Legs196

Installing The Front Fork Legs199

Steering Head201

Removing The Upper Bracket And Lower Bracket201

Removing The Lower Bracket203

Checking/Installing The Steering Head203

Swingarm And Rear Shock Absorber Assembly205

Removing The Swingarm And Rear Shock Absorber Assembly205

Removing/Checking The Rear Shock Absorber Assembly207

Removing/Checking The Swingarm207

Installing The Swingarm/Rear Shock Absorber Assembly208

Removing The Drive Sprocket And Drive Chain210

Removing/Checking The Drive Chain211

Checking/Installing The Drive Sprocket212

Installing The Drive Chain213

Engine Inspection218

Measure The Compression Pressure218

Engine Removal220

Removing The Muffler And Exhaust Pipe220

Disconnecting The Leads And Cable222

Removing The Engine224

Installing The Engine225

Assembling The Muffler226

Installing The Exhaust Pipe And Muffler Assembly226

Removing The Cylinder Head Cover228

Removing The Camshafts229

Checking The Camshafts231

Checking The Camshaft Sprockets232

Checking The Timing Chain Tensioner233

Installing The Camshafts233

Installing The Cylinder Head Cover237

Cylinder Head238

Removing The Cylinder Head238

Checking The Timing Chain Guide (Exhaust Side)/Cylinder Head241

Installing The Cylinder Head241

Valves And Valve Springs243

Removing The Valves And Valve Springs243

Removing The Valves244

Checking The Valves And Vave Guides244

Checking The Valve Seats246

Checking The Valve Springs247

Checking The Valve Lifters248

Installing The Valves248

Cylinder And Pistons251

Removing The Cylinder And Pistons251

Removing The Pistons252

Checking The Cylinders And Pistons252

Checking The Piston Rings253

Checking The Pistion Pins254

Installing The Pistons And Cylinder254

Generator And Starter Clutch257

Removing The Stator Coil, Generator Rotor And Starter Clutch257

Removing The Generator/Starter Clutch259

Checking The Starter Clutch259

Installing The Starter Clutch260

Installing The Generator261

Electric Starter262

Removing The Starter Motor262

Disassembling The Starter Motor263

Checking The Starter Motor264

Assembling/Installing The Starter Motor265

Removing The Clutch Cover And Pull Lever Shaft266

Removing The Clutch268

Checking The Friction Plates269

Checking The Clutch Plates/Clutch Springs/Clutch Housing270

Checking The Clutch Boss/Pressure Plate/Primary Driven Gear/The Pull Lever Shaft And Pull Rod271

Installing The Clutch271

Removing The Shift Pedal274

Removing The Shift Shaft And Stopper Lever275

Checking The Shift Shaft/Stopper Lever277

Installing The Shift Shaft/Shift Rod277

Removing The Oil Pump279

Disassembling The Oil Pump280

Checking The Oil Pump Idle Gear/Oil Pump/Relief Valve281

Assembling The Oil Pump281

Installing The Oil Pump282

Removing The Oil Pan283

Checking The Oil Strainer284

Installing The Oil Pan284

Removing The Crankcase Breather Cover And Switches285

Separating The Crankcase287

Disassembling The Crankcase288

Checking The Balancer Drive Gear/The Timing Chain And Timing Chain Guide (Intake Side)289

Checking The Crankcase/The Oil Nozzles289

Assembling The Crankcase289

Installing The Oil Pressure Switch And Gear Position Switch292

Crankshaft And Balancer Shaft294

Removing The Crankshaft, Connecting Rod And Balancer Shaft294

Removing The Balancer Shaft Journal Bearings/Crankshaft Journal Bearings/The Connecting Rods295

Checking The Balancer Shaft Assembly295

Checking The Crankshaft297

Checking The Connecting Rods298

Installing The Connecting Rods300

Installing The Crankshaft301

Installing The Balancer Shaft Assembly302

Transmission303

Removing The Transmission, Shift Drum Assembly, And Shift Forks303

Disassembly The Main Axle Assembly305

Disassembly The Drive Axle Assembly306

Checking The Shift Forks/The Shift Drum Assembly/The Transmission307

Assembling The Main Axle And Drive Axle308

Installing The Transmission308

Cooling System311

Removing The Radiator312

Checking/Installing The Radiator314

Removing The Thermostat315

Checking/Installing The Thermostat316

Removing The Water Pump317

Disassembling/Checking/Assembling The Water Pump319

Installing The Clutch Cover320

Removing The Fuel Tank And Fuel Pump324

Removing The Fuel Tank/The Fuel Pump/The Fuel Filter326

Checking The Fuel Pump Body/Fuel Filter327

Installing The Fuel Filter/Fuel Pump327

Installing The Fuel Tank328

Throttle Bodies329

Removing The Throttle Bodies329

Removing The Fuel Injectors And Isc Valve330

Checking The Injectors (Before Removing)331

Removing/Checking The Injectors331

Checking The Throttle Bodies And Isc (Idle Speed Control) Valve331

Cleaning The Throttle Bodies331

Cleaning The Isc (Idle Speed Control) Valve332

Resetting The Isc (Idle Speed Control) Learning Values333

Checking The Throttle Body Joint/Injector Pressure334

Installing The Fuel Injectors334

Checking The Fuel Pressure335

Installing The Throttle Body Joint335

Air Induction System338

Removing The Air Cut-Off Valve And Reed Valve340

Checking/Installing The Air Induction System341

Air Injection341

Air Cut-Off Valve341

Electrical System343

Ignition System346

Circuit Diagram346

Ignition System Troubleshooting348

Electric Starting System/Circuit Diagram350

Starting Circuit Cut-Off System Operation352

Electric Starting System Troubleshooting353

Charging System/Circuit Diagram356

Charging System Troubleshooting358

Lighting System/Circuit Diagram360

Lighting System Troubleshooting362

Signaling System/Circuit Diagram364

Signaling System Troubleshooting366

Cooling System/Circuit Diagram372

Cooling System Troubleshooting374

Fuel Injection System/Circuit Diagram376

Ecu Self-Diagnostic Function378

Engine Trouble Warning Light Indication And Fuel Injection System Operation378

Checking The Engine Trouble Warning Light/Ecu Detects An Abnormal Signal From A Sensor378

Troubleshooting Method378

Yamaha Diagnostic Tool379

The Engine Operation Is Not Normal, But The Engine Trouble Warning Light Does Not Come On379

Connecting/Operation Of The Yamaha Diagnostic Tool380

Fuel Injection System: Troubleshooting Detail382

Crankshaft Position Sensor: No Normal Signals Are Received From The Crankshaft Position Sensor382

Intake Air Pressure Sensor: Open Or Short Circuit Detected383

Intake Air Pressure Sensor: Hose System Malfunction (Clogged Or Detached Hose)385

Throttle Position Sensor: Open Or Short Circuit Detected386

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 Detected388

Coolant Temperature Sensor: Open Or Short Circuit Detected389

Intake Temperature Sensor: Open Or Short Circuit Detected390

O2 Sensor: No Normal Signals Are Received From The O2 Sensor391

Latch Up Detected393

Cylinder #1 Ignition Coil: Open Or Short Circuit Detected In The Primary Lead Of The Cylinder #1 Ignition Coil393

Cylinder #2 Ignition Coil: Open Or Short Circuit Detected In The Primary Lead Of The Cylinder #2 Ignition Coil394

Fuel Injector: Open Or Short Circuit Detected396

Lean Angle Sensor: Open Or Short Circuit Detected397

Speed Sensor: No Normal Signals Are Received From The Speed Sensor398

Gear Position Switch: Open Or Short Circuit Is Detected398

Clutch Switch: Open Or Short Circuit Is Detected398

Fuel System Voltage: Incorrect Voltage Supplied To The Fuel Injector And Fuel Pump404

Eeprom Fault Code Number: An Error Is Detected While Reading Or Writing On Eeprom405

Charging Voltage Is Abnormal406

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 Meter407

Ecu Internal Malfunction (Output Signal Error): Signals Cannot Be Transmitted Between The Ecu And Yamaha Diagnostic Tool408

Ecu Internal Malfunction (Output Signal Error): No Signals Are Received From The Ecu Within The Specified Duration409

Ecu Internal Malfunction (Output Signal Error): Data From The Ecu Cannot Be Received Correctly410

Ecu Internal Malfunction (Output Signal Error): Non-Registered Data Has Been Received From The Meter411

Ecu Internal Malfunction (Output Signal Error): No Normal Signals Are Received From The Yamaha Diagnostic Tool412

Fuel Pump System/Circuit Diagram414

Fuel Pump System Troubleshooting416

Eletrical Components Diagram418

Electrical Components418

Electrical Components Diagram (Cont.)420

Checking The Switches422

Checking The Bulbs And Bulb Sockets424

Types Of Bulbs425

Checking The Condition Of The Bulbs/Bulb Sockets425

Checking The Fuses426

Replacing/Removing The Ecu (Engine Control Unit)426

Installing The Ecu (Engine Control Unit)427

Checking And Charging The Battery427

Charging Method Using A Variable-Current (Voltage) Charger/Constant Voltage Charger429

Checking The Relays430

Starter Relay430

Starting Circuit Cut-Off Relay430

Checking The Diodes431

Headlight/Radiator Fan Motor/Turn Signal Relays431

Checking The Spark Plug Caps/Ignition Coils433

Checking The Ignition Spark Gap434

Checking The Crankshaft Position Sensor/Lean Angle Sensor434

Checking The Starter Motor Operation/Stator Coil435

Checking The Rectifier/Regulator/Fuel Sender436

Checking The Fuel Meter/Speed Sensor/Radiator Fan Motor/Coolant Temperature Sensor437

Checking The Air Induction System Solenoid/The Gear Position Switch438

Checking The Fuel Injectors439

Troubleshooting441

Starting Failure442

Incorrect Engine Idling Speed442

Poor Medium-And-High-Speed Performance443

Faulty Gear Shifting/Shift Pedal Does Not Move443

Jumps Out Of Gear443

Faulty Clutch443

Overheating/Overcooling444

Poor Braking Performance444

Faulty Front Fork Legs444

Unstable Handling444

Faulty Lighting Or Signaling System445

Self-Diagnostic Function And Diagnostic Code Table446

Self-Diagnostic Function Table446

Communication Error With The Meter Or Yamaha Diagnostic Tool446

Diagnostic Code: Sensor Operation Table447

Diagnostic Code: Actuator Operation Table449

Wiring Diagram Items List452

Color Codes List452

Wiring Diagram455

Advertisement

Table of Contents

Troubleshooting