Yamaha MBK XMAX 2014 Service Manual
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Yamaha MBK XMAX 2014 Service Manual

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Table of Contents

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2014
SERVICE MANUAL
YP250R
YP250RA
2DL-F8197-E0

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Summary of Contents for Yamaha MBK XMAX 2014

  • Page 1 2014 SERVICE MANUAL YP250R YP250RA 2DL-F8197-E0...
  • Page 2 EAS20040 YP250R/YP250RA 2014 SERVICE MANUAL ©2013 by MBK Industrie First edition, November 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
  • Page 3 EAS5WWL025 IMPORTANT This manual was produced by MBK Industrie. primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There- fore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE ABS (for YP250RA) ............ 1-4 ABS COMPONENT FUNCTIONS ............. 1-8 ABS OPERATION ...................1-14 ABS WARNING LIGHT AND OPERATION..........1-17 INSTRUMENT FUNCTIONS................1-18 IMPORTANT INFORMATION ...............

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the location shown. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS37P1140 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS37P1141 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Outline Of The Abs (For Yp250Ra)

    6. Hydraulic unit assembly (ABS ECU) The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a front brake lever for operating the front brake and a rear brake lever for operating the rear brake.
  • Page 14 FEATURES • Brake force: The force applied by braking to reduce the wheel speed. • Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel. • Side force: The force on the tires which supports the vehicle when cornering.
  • Page 15 FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
  • Page 16 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.

  • Page 17: Abs Component Functions

    FEATURES ABS block diagram 1. Front brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Front brake caliper 3. Rear brake master cylinder 11. Front wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
  • Page 18 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on during the ABS self-diagnosis to check the electrical circuit of the light.
  • Page 19 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
  • Page 20 FEATURES • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston 1-11...
  • Page 21 FEATURES • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 1.
  • Page 22 FEATURES • Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS ECU fuse). • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on.

  • Page 23: Abs Operation

    FEATURES EAS2DM1131 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
  • Page 24 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
  • Page 25 FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.

  • Page 26: Abs Warning Light And Operation

    FEATURES EAS2DM1119 ABS WARNING LIGHT AND OPERATION ABS function EWA2DM1011 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the front brake lever or rear brake lever.

  • Page 27: Instrument Functions

    INSTRUMENT FUNCTIONS To switch between miles and kilometers; hold EAS37P1080 INSTRUMENT FUNCTIONS the “SELECT” switch pushed, turn the main switch to “ON”, and keep the “SELECT” switch Multi-function meter unit pushed for an additional 8 seconds. EWA12423 • For other countries, traveling speed, distance WARNING traveled and fuel consumption measurements Be sure to stop the vehicle before making...
  • Page 28 INSTRUMENT FUNCTIONS When the fuel level reaches the bottom segment When approximately 2.5 L (0.66 US gal, 0.55 near “E”, the bottom segment will flash. Refuel Imp.gal) of fuel remains in the fuel tank, the dis- as soon as possible. play will automatically change to the fuel reserve tripmeter mode “F Trip”...
  • Page 29 INSTRUMENT FUNCTIONS belt” is displayed, push the “RESET” button 2. “RESET” button for 3 seconds. The V-belt replacement trip- 3. Hold the “RESET” button pushed for 15 to 20 meter value will flash. seconds. SELECT RESET SELECT RESET TRIP INFO 1.
  • Page 30 INSTRUMENT FUNCTIONS Multi-function display Ambient temperature display: TRIP INFO This display shows the ambient temperature 1. Ambient temperature from –10 °C to 50 °C in 1 °C increments. 2. Average speed The icy road warning indicator “ ” will flash 3.
  • Page 31 INSTRUMENT FUNCTIONS Average fuel consumption mode: The instantaneous fuel consumption is dis- played “MPG”. • When the display is set to “km/L”, the distance that can be traveled on 1.0 L of fuel under the current riding conditions is shown. •...
  • Page 32 INSTRUMENT FUNCTIONS Self-diagnosis device: 1. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate a fault code.

  • Page 33: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 34: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 EAS2DM1132 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 35: Basic Service Information

    BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 36: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 37 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
  • Page 38 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 39 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...

  • Page 40: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 41 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool 4-65, 4-67, 90890-03215 8-99, 8-125 Damper rod holder 4-76, 4-78 90890-01294 Damping rod holder set YM-01300 YM-01300 T-handle 4-76, 4-78 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Fork seal driver weight...
  • Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Slide hammer bolt 5-15 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-15 90890-01084 Weight YU-01083-3 YU-01083-3 Valve spring compressor 5-19, 5-24 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-19, 5-24 90890-04108 Valve spring compressor adapter 22 mm YM-04108...
  • Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-26 90890-01304 Piston pin puller YU-01304 YU-01304 Yamaha grease G 5-32 90793-40016 Rotor holding tool 5-34, 5-39 90890-01235 Universal magneto and rotor holder YU-01235 Sheave holder 5-34, 5-38, 90890-01701...
  • Page 44 Compressor holder adapter YM-33285-6 Oil seal guide (ø41) 5-37 90890-01396 Flywheel puller 5-42 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-44, 5-61, 6-9 90890-85505 (Three Bond No.1215®) Digital circuit tester 5-47, 8-145, 90890-03174 8-147 Model 88 Multimeter with tachometer YU-A1927...
  • Page 45 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-60, 5-61 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-60, 5-61 90890-01275 Bolt YU-90060 Adapter (M14) 5-60 90890-01478 Adapter #6 YM-90066 Spacer (crankshaft installer) 5-60 90890-04081 Pot spacer YM-91044 YM-91044 Adapter (M16)
  • Page 46 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 &...
  • Page 47 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-143 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– lean angle sensor (6P) 8-144 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness– speed sensor (3P) 8-146 90890-03208 Test harness– speed sensor (3P) YU-03208 Test harness–...
  • Page 48 SPECIAL TOOLS 1-39...

  • Page 49: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE....................2-22 CHASSIS....................2-24 COOLING SYSTEM DIAGRAMS ..............

  • Page 50: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model YP250R 2DL1 (YAMAHA) YP250RA 2DL2 (YAMAHA) YP250RA 2DL3 (MBK) Dimensions Overall length 2175 mm (85.6 in) Overall width 790 mm (31.1 in) Overall height 1385 mm (54.5 in) Seat height 785 mm (30.9 in) Wheelbase 1525 mm (60.0 in)

  • Page 51: Engine Specifications

    ENGINE SPECIFICATIONS EAS20291 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 249 cm³ Cylinder arrangement Single cylinder Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) Compression ratio 10.00 : 1 Standard compression pressure (at sea level) 1400 kPa/500 r/min (14.0 kgf/cm²/500 r/min, 199.1 psi/500 r/min) Minimum–maximum...
  • Page 52 ENGINE SPECIFICATIONS Thermostat Valve opening temperature 80.5–83.5 °C (176.90–182.30 °F) Valve full open temperature 93.0–97.0 °C (199.40–206.60 °F) Valve lift (full open) 3.0 mm (0.12 in) Radiator core Width 244.0 mm (9.61 in) Height 158.0 mm (6.22 in) Depth 23.0 mm (0.91 in) Water pump Water pump type Single suction centrifugal pump...
  • Page 53 ENGINE SPECIFICATIONS Limit 0.080 mm (0.0032 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.08–0.12 mm (0.0032–0.0047 in) Exhaust 0.16–0.20 mm (0.0063–0.0079 in) Valve dimensions Valve head diameter (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter (exhaust) 28.40–28.60 mm (1.1181–1.1260 in) Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit...
  • Page 54 ENGINE SPECIFICATIONS Spring tilt (exhaust) 2.5 °/1.7 mm (0.07 in) Winding direction (intake) Counterclockwise Winding direction (exhaust) Counterclockwise Outer spring Free length (intake) 36.93 mm (1.45 in) Limit 35.00 mm (1.38 in) Free length (exhaust) 36.93 mm (1.45 in) Limit 35.00 mm (1.38 in) Installed length (intake) 31.60 mm (1.24 in)
  • Page 55 ENGINE SPECIFICATIONS Limit 16.971 mm (0.6681 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in) Limit 0.074 mm (0.0029 in) Piston ring Top ring Ring type Barrel End gap (installed) 0.15–0.30 mm (0.0059–0.0118 in) Limit 0.55 mm (0.0217 in) Ring side clearance 0.040–0.080 mm (0.0016–0.0032 in) Limit 0.130 mm (0.0051 in)
  • Page 56 ENGINE SPECIFICATIONS V-belt V-belt width 23.0 mm (0.91 in) Limit 21.0 mm (0.83 in) Transmission Transmission type V-belt automatic Primary reduction ratio 1.000 Final drive Gear 40/15 × 40/14 (7.619) Secondary reduction ratio Operation Centrifugal automatic type Gear ratio 2.440–0.830 :1 Air filter Air filter element Oil-coated paper element...

  • Page 57: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Underbone Caster angle 28.00 ° Trail 100 mm (3.9 in) Front wheel Wheel type Cast wheel 15 × MT3.5 Rim size Rim material Aluminum Wheel travel 110.0 mm (4.33 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 58 CHASSIS SPECIFICATIONS Operation Right hand operation Front disc brake Disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 6.5 mm (0.26 in) Limit 1.0 mm (0.04 in)
  • Page 59 CHASSIS SPECIFICATIONS Recommended oil Fork oil 10W or equivalent Quantity 128.0 cm³ (4.33 US oz, 4.51 Imp.oz) Level 109.0 mm (4.29 in) Rear suspension Type Unit swing Spring/shock absorber type Coil spring/oil damper Rear shock absorber assembly travel 92.0 mm (3.62 in) Spring free length 283.2 mm (11.15 in) Spring installed length...

  • Page 60: Electrical Specifications

    Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0 °/1550 r/min Engine control unit Model/manufacturer YP250R 2DL0 / YAMAHA MOTOR ELECTRONICS YP125RA 2DL1 / YAMAHA MOTOR ELECTRONICS Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 61 ELECTRICAL SPECIFICATIONS Meter lighting Indicator light Turn signal indicator light High beam indicator light Fuel level warning light Engine trouble warning light ABS warning light YP250RA LED Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.65 kW 0.0100–0.0140 Ω...
  • Page 62 ELECTRICAL SPECIFICATIONS ECU fuse 10.0 A ABS motor fuse YP250RA 30.0 A ABS ECU fuse YP250RA 10.0 A ABS solenoid fuse YP250RA 20.0 A Backup fuse 10.0 A Spare fuse 30.0 A Spare fuse 20.0 A Spare fuse 10.0 A Spare fuse 7.5 A Spare fuse...

  • Page 63: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 64: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt 65 Nm (6.5 m·kgf, 47 ft·lbf) Muffler joint bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) sensor 45 Nm (4.5 m·kgf, 33 ft·lbf) Oil check bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Transmission case cover bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Oil strainer cover 32 Nm (3.2 m·kgf, 23 ft·lbf) Engine oil drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Final transmission oil drain bolt 22 Nm (2.2 m·kgf, 16 ft·lbf)
  • Page 66 TIGHTENING TORQUES Muffler tightening sequence: 2-17...

  • Page 67: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket nut 59 Nm (5.9 m·kgf, 43 ft·lbf) Engine bracket rod nut 64 Nm (6.4 m·kgf, 46 ft·lbf) Engine mounting nut 43 Nm (4.3 m·kgf, 31 ft·lbf) Fuel tank bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Fuel tank bracket bolt...
  • Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Leg shield bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Footrest board bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Sidestand nut 56 Nm (5.6 m·kgf, 41 ft·lbf) Sidestand switch nut 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Centerstand stopper nut 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Front fender bolt...
  • Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) (for YP250RA) Rear brake caliper retaining bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) (for YP250RA) Upper handlebar holder bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Front and rear brake master cyl- 7 Nm (0.7 m·kgf, 5.1 ft·lbf) inder holder bolt...
  • Page 70 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Hydraulic unit assembly bolt (for 7 Nm (0.7 m·kgf, 5.1 ft·lbf) YP250RA) Brake hose union bolt (hydraulic 30 Nm (3.0 m·kgf, 22 ft·lbf) unit) (for YP250RA) Brake hose (hydraulic unit to front brake caliper) holder screw (for 9 Nm (0.9 m·kgf, 6.5 ft·lbf) YP250RA)

  • Page 71: Lubrication Points And Lubricant Types

    Starter clutch gear thrust surface Starter clutch gear inner surface Main axle thrust surfaces Main axle serration Drive axle serration BEL-RAY assembly Oil seal (secondary sliding sheave) lube® BEL-RAY assembly O-ring and collar (clutch housing) lube® Yamaha bond Crankcase mating surfaces No.1215 2-22...
  • Page 72 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No. Crankshaft position sensor/stator assembly lead grommet 1215 2-23...

  • Page 73: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Drive axle Engine mounting bolt Swingarm oil seal lips Steering bearings (upper and lower) Seat hinge spacer and bolt Seat lock sliding parts Front wheel oil seal lip and front wheel axle Speed sensor oil seal lip (for YP250R) Brake lever pivoting point and metal-to-metal moving parts Rear brake caliper retaining bolt...

  • Page 74: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-25...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Coolant reservoir 2. Coolant reservoir hose 3. Coolant reservoir overflow hose 4. Coolant reservoir leveling hose 5. Radiator cap 6. Radiator filler hose 7. Radiator 8. Radiator inlet hose 9. Radiator pipes 10. Thermostat outlet hose 11.
  • Page 76 COOLING SYSTEM DIAGRAMS 2-27...
  • Page 77 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet hose 2. Thermostat outlet hose 3. Thermostat cover 4. Thermostat 5. Water pump cover 6. Water pump inlet hose 2-28...

  • Page 78: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top and front view) 2-29...
  • Page 79 CABLE ROUTING 1. Front brake hose 2. Throttle cable (decelerator cable) 3. Rear brake hose 4. Left handlebar switch lead 5. Right handlebar switch lead 6. Throttle cable (accelerator cable) A. Install the brake light switch connectors so that the leads are routed outward as shown in the illustration.
  • Page 80 CABLE ROUTING Steering head (front view) 2-31...
  • Page 81 CABLE ROUTING 1. Front brake hose 2. Rear brake hose 3. Left front turn signal light lead 4. Seat lock cable 5. Fuel tank overflow hose 6. Wire harness 7. Speed sensor lead (for YP250R) 8. Front wheel sensor lead (for YP250RA) A.
  • Page 82 CABLE ROUTING Front brake (left side view) (for YP250R) 2-33...
  • Page 83 CABLE ROUTING 1. Speed sensor lead 2. Front brake hose A. Fasten the speed sensor lead to the front brake hose with the holders. Align the holders with the paint marks on the speed sensor lead. B. 20–25 mm (0.79–0.98 in) C.
  • Page 84 CABLE ROUTING Front brake (left side view) (for YP250RA) 2-35...
  • Page 85 CABLE ROUTING 1. Front wheel sensor lead 2. Brake hose (hydraulic unit to front brake caliper) A. Fasten the front wheel sensor lead to the brake hose (hydraulic unit to front brake caliper) with the holders. Align the holders with the paint marks on the front wheel sensor lead.
  • Page 86 CABLE ROUTING Engine and rear brake (left side and right side view) (for YP250R) 2-37...
  • Page 87 CABLE ROUTING 1. Fuel hose 2. Breather hose (air filter case to throttle body) 3. Cylinder head breather hose 4. Rear brake hose 5. Intake air pressure sensor hose 2-38...
  • Page 88 CABLE ROUTING Engine and rear brake (left side and right side view) (for YP250RA) 2-39...
  • Page 89 CABLE ROUTING 1. Fuel hose 2. Breather hose (air filter case to throttle body) 3. Cylinder head breather hose 4. Brake hose (hydraulic unit to rear brake caliper) 5. Rear wheel sensor lead 6. Intake air pressure sensor hose 2-40...
  • Page 90 CABLE ROUTING Steering head (right side view) (for YP250R) 2-41...
  • Page 91 CABLE ROUTING 1. Throttle cables 2. Front brake hose 3. Fuse boxes 4. Headlight lead 5. Starting circuit cut-off relay 6. Headlight relay 7. Radiator fan motor relay 8. Turn signal/hazard relay 9. Wire harness 10. Rear brake hose 11. Speed sensor lead coupler 12.
  • Page 92 CABLE ROUTING Steering head (right side view) (for YP250RA) 2-43...
  • Page 93 CABLE ROUTING 1. Throttle cables 2. Brake hose (front brake master cylinder to hydraulic unit) 3. ABS test coupler 4. Hydraulic unit assembly 5. Headlight lead 6. Starting circuit cut-off relay 1 7. Headlight relay 8. Radiator fan motor relay 9.
  • Page 94 CABLE ROUTING Frame (right side view) 2-45...
  • Page 95 CABLE ROUTING 1. Rear brake hose 2. Radiator fan motor lead 3. Wire harness 4. Rectifier/regulator 5. Radiator inlet hose 6. Radiator outlet hose A. Inside B. Outside 2-46...
  • Page 96 CABLE ROUTING Engine (right side view) 2-47...
  • Page 97 CABLE ROUTING 1. License plate light lead 2. Right tail/brake light lead 3. Seat lock cable 4. Rear brake hose (for YP250R) 5. Ignition coil 6. Wire harness 7. Right rear turn signal light lead 8. Rear wheel sensor lead (for YP250RA) 9.
  • Page 98 CABLE ROUTING Steering head (left side view) 2-49...
  • Page 99 CABLE ROUTING 1. Starter relay 2. Rear brake hose 3. Left handlebar switch lead 4. Wire harness 5. Main switch 6. Seat lock cable 7. Throttle cables 8. Starter motor lead 9. Left front turn signal light lead 10. Headlight lead 11.
  • Page 100 CABLE ROUTING Frame (left side view) 2-51...
  • Page 101 CABLE ROUTING 1. Starter motor lead 2. Throttle cables 3. Seat lock cable 4. Sidestand switch lead 5. Rectifier/regulator 6. Fuel tank overflow hose 7. Wire harness A. Position the connector housing at the location shown between the frame tubes. B.
  • Page 102 CABLE ROUTING Engine (left side view) 2-53...
  • Page 103 CABLE ROUTING 1. Seat lock cable 2. Rear brake hose 3. Wire harness 4. Left tail/brake light lead 5. Left rear turn signal light lead 6. License plate light lead 7. Starter motor lead 8. Fuel hose 9. Throttle cables A.
  • Page 104 CABLE ROUTING Frame (top view) 2-55...
  • Page 105 CABLE ROUTING 1. Right front turn signal light 2. Starting circuit cut-off relay 3. Headlight relay 4. Radiator fan motor relay 5. Turn signal/hazard relay 6. Fuse box 7. Wire harness 8. Front brake hose 9. Right handlebar switch lead 10.
  • Page 106 CABLE ROUTING Engine and frame (top view) 2-57...
  • Page 107 CABLE ROUTING 1. Wire harness 2. Rear brake hose 3. Intake air pressure sensor lead 4. ISC (idle speed control) unit lead 5. Right rear turn signal light lead 6. Right tail/brake light lead 7. License plate light lead 8. Left tail/brake light lead 9.
  • Page 108 CABLE ROUTING Rear brake (right side view) 2-59...
  • Page 109 CABLE ROUTING 1. Rear wheel sensor lead (for YP250RA) 2. Rear brake hose 3. Brake hose (hydraulic unit to rear brake caliper) A. Fasten the grommets on the rear brake hose with the holders. B. For YP250R C. For YP250RA 2-60...
  • Page 110 CABLE ROUTING Hydraulic unit (for YP250RA) 2-61...
  • Page 111 CABLE ROUTING 1. Brake hose (hydraulic unit to front brake caliper) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to rear brake caliper) 5.
  • Page 112 CABLE ROUTING 2-63...

  • Page 113: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG ............... 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD .................
  • Page 114 CHECKING THE THROTTLE GRIP OPERATION .........3-23 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-24 ADJUSTING THE HEADLIGHT BEAM ...........3-24 REPLACING THE HEADLIGHT BULB............3-24...

  • Page 116: Periodic Maintenance

    • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha and MBK dealer as they require special tools, data and technical skills.
  • Page 117 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check for cracks or damage. √ √ √ √ √...
  • Page 118 PERIODIC MAINTENANCE EAU38263 • Engine air filter and V-belt air filters • This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The engine air filter element needs to be replaced and the V-belt air filter elements need to be ser- viced more frequently when riding in unusually wet or dusty areas.

  • Page 119: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS21030 CHECKING THE FUEL LINE 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Fuel hose “1” Cracks/damage → Replace. Loose connections → Connect properly. 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 6.
  • Page 120 PERIODIC MAINTENANCE • When the valve clearance is to be measured or Valve clearance (cold) adjusted, the piston must be at top dead center Intake (TDC) on the compression stroke. 0.08–0.12 mm (0.0031–0.0047 in) 1. Remove: Exhaust 0.16–0.20 mm (0.0063–0.0079 in) •...

  • Page 121: Checking The Throttle Body Joint And Intake Manifold

    PERIODIC MAINTENANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut (valve clearance adjust- ing screw) 14 Nm (1.4 m·kgf, 10 ft·lbf) e. Measure the valve clearance again. f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ▲...

  • Page 122: Checking The Breather Hose

    PERIODIC MAINTENANCE EAS21080 CHECKING THE EXHAUST SYSTEM 1. Check: • Exhaust pipe “1” • Muffler “2” Cracks/damage → Replace. • Exhaust system connection Exhaust gas leaks → Replace the gasket “3”. 2. Check: • Tightening torque 3. Install: Exhaust pipe nut •...

  • Page 123: Replacing The Air Filter Element

    PERIODIC MAINTENANCE FI diagnostic tool 90890-03182 FI diagnostic tool FI Diagnostic Tool YU-03182 1 5 5 0 r p m C1 : 10.Change the CO adjustment volume by press- ing the “UP” and “DOWN” buttons. The CO adjustment volume and engine idling speed appears on the LCD of the FI diagnostic tool.

  • Page 124: Cleaning The V-Belt Case Air Filter Element

    PERIODIC MAINTENANCE 2. Check: • Air filter element Damage → Replace. • Replace the air filter element every 12000 km of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 3.

  • Page 125: Bleeding The Hydraulic Brake System (For Yp250R)

    PERIODIC MAINTENANCE • the brake operation is faulty. • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.

  • Page 126: Bleeding The Hydraulic Brake System (Abs) (For Yp250Ra)

    PERIODIC MAINTENANCE • When bleeding the ABS, make sure there is al- ways enough brake fluid before applying the Loosening the bleed screw will release the pres- brake. Ignoring this precaution could allow air sure and cause the brake lever to contact the to enter the ABS, considerably lengthening the throttle grip.

  • Page 127: Checking The Front Brake Pads

    PERIODIC MAINTENANCE h. Tighten the bleed screw, and then release EAS2DM1026 CHECKING THE REAR BRAKE PADS (for the brake lever. YP250R) i. Repeat steps (e) to (h) until all of the air bub- The following procedure applies to all of the bles have disappeared from the brake fluid in brake pads.

  • Page 128: Checking The Rear Brake Hose

    PERIODIC MAINTENANCE EWA13260 WARNING Never attempt to make any repairs to the wheel. After a tire or wheel has been changed or re- placed, always balance the wheel. EAS21660 CHECKING THE TIRES 2. Check: The following procedure applies to both of the •...
  • Page 129 1. Tire tread depth handling characteristics can be given if a tire 2. Side wall combination other than one approved by 3. Wear indicator Yamaha is used on this vehicle. Wear limit (front) Front tire 1.6 mm (0.06 in) Size Wear limit (rear) 120/70–15 M/C 56P(METZELER)-...

  • Page 130: Checking The Wheel Bearings

    PERIODIC MAINTENANCE 2. Check: Rear tire • Steering head Size Grasp the bottom of the front fork legs and 140/70–14 M/C 68P(METZELER)- gently rock the front fork. 68S(MICHELIN) Binding/looseness → Adjust the steering Manufacturer/model head. METZELER / FEELFREE 3. Remove: Manufacturer/model •...

  • Page 131: Checking The Chassis Fasteners

    PERIODIC MAINTENANCE c. Loosen the lower ring nut “4” 1/4 of a turn, 5. Install: and then tighten it to specification with a • Lower handlebar holder steering nut wrench “5”. Refer to “STEERING HEAD” on page 4-81. Lower ring nut (final tightening EAS1SD1006 CHECKING THE CHASSIS FASTENERS torque)

  • Page 132: Checking The Front Fork

    PERIODIC MAINTENANCE Refer to “REAR SHOCK ABSORBER AS- EAS21530 CHECKING THE FRONT FORK SEMBLIES AND SWINGARM” on page 1. Stand the vehicle on a level surface. 4-85. EWA13120 WARNING EAS21630 ADJUSTING THE REAR SHOCK ABSORBER Securely support the vehicle so that there is ASSEMBLIES no danger of it falling over.

  • Page 133: Checking The Engine Oil Level

    PERIODIC MAINTENANCE -20 -10 10 20 30 40 50 ˚C Spring preload adjusting positions Minimum SAE 10W-30 SAE 10W-40 Standard SAE 10W-50 Maximum SAE 15W-40 SAE 20W-40 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 134: Checking The Coolant Level

    PERIODIC MAINTENANCE 8. Install: • Engine oil filler cap 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • Engine (for engine oil leaks) 11.Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”...

  • Page 135: Checking The Cooling System

    PERIODIC MAINTENANCE 3. Check: Refer to “RADIATOR” on page 6-1 and • Coolant level “THERMOSTAT” on page 6-4. The coolant level should be between the min- imum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level.
  • Page 136 PERIODIC MAINTENANCE be blown out, which could cause serious in- jury. When the engine has cooled, open the The specified amount of coolant is a standard radiator cap as follows: amount. Fill the cooling system with coolant until Place a thick rag or a towel over the radiator coolant comes out of the air bleed bolt hole “1”.

  • Page 137: Changing The Final Transmission Oil

    PERIODIC MAINTENANCE 11.Fill: • Coolant reservoir (with the recommended coolant to the maxi- mum level mark “a”) 12.Install: • Coolant reservoir cap 13.Start the engine, warm it up for several min- utes, and then turn it off. 14.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- 5.

  • Page 138: Checking The Brake Light Switches

    PERIODIC MAINTENANCE 2. Check: • V-belt Hold the cable end upright and pour a few drops Cranks/damage/wear → Replace. of lubricant into the cable sheath or use a suit- Grease/oil → Clean the primary and second- able lubricating device. ary pulleys. Refer to “V-BELT AUTOMATIC TRANSMIS- EAS21740 SION”...
  • Page 139 PERIODIC MAINTENANCE 4. Adjust: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Open the front storage compartments and re- • Throttle grip free play move the plugs. b. Turn the adjusting screw “1” in direction “a” or Prior to adjusting the throttle grip free play, the “b”.
  • Page 140 PERIODIC MAINTENANCE A. Right side B. Left side EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder.

  • Page 141: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE STORAGE BOX ............4-10 REMOVING THE CENTER PANELS............4-10 INSTALLING THE CENTER PANELS ............4-10 REMOVING THE REAR UPPER COVER..........4-11 INSTALLING THE REAR UPPER COVER ..........4-11 REMOVING THE REAR PANELS............4-11 INSTALLING THE REAR PANELS ............4-12 REMOVING THE FRONT COWLING COVER AND UPPER PANEL ..................4-12 INSTALLING THE UPPER PANEL AND...
  • Page 142 FRONT BRAKE ..................... 4-31 INTRODUCTION ..................4-37 CHECKING THE FRONT BRAKE DISC ..........4-37 REPLACING THE FRONT BRAKE PADS ..........4-38 REMOVING THE FRONT BRAKE CALIPER..........4-39 DISASSEMBLING THE FRONT BRAKE CALIPER ........4-39 CHECKING THE FRONT BRAKE CALIPER ..........4-39 ASSEMBLING THE FRONT BRAKE CALIPER ........4-40 INSTALLING THE FRONT BRAKE CALIPER ........
  • Page 143 FRONT FORK....................4-74 REMOVING THE FRONT FORK LEGS..........4-76 DISASSEMBLING THE FRONT FORK LEGS ........4-76 CHECKING THE FRONT FORK LEGS ..........4-77 ASSEMBLING THE FRONT FORK LEGS ..........4-77 INSTALLING THE FRONT FORK LEGS ..........4-79 STEERING HEAD..................4-81 REMOVING THE LOWER BRACKET.............4-83 CHECKING THE STEERING HEAD ............4-83 INSTALLING THE STEERING HEAD .............4-83 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM....

  • Page 144: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and center panels 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • •...
  • Page 145 GENERAL CHASSIS Removing the rear panel and mudguard 23 Nm (2.3 m kgf, 17 ft Ibf) • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) 10 Nm (1.0 m...
  • Page 146 GENERAL CHASSIS Removing the headlight assembly 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 0.4 Nm (0.04 m kgf, 0.29 ft Ibf) • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 147 GENERAL CHASSIS Removing the windshield bracket 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 148 GENERAL CHASSIS Removing the meter assembly 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Windshield...
  • Page 149 GENERAL CHASSIS Removing the radiator cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front cowling Refer to “Removing the headlight assembly”. Front wheel Refer to “FRONT WHEEL” on page 4-17. Front fender Refer to “FRONT FORK”...
  • Page 150 GENERAL CHASSIS Removing the footrest board and leg shield 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 151 GENERAL CHASSIS Removing the air filter case assembly 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the seat and center pan- Storage box els”.
  • Page 152 GENERAL CHASSIS Removing the seat hinge 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the footrest board and...

  • Page 153: Installing The Storage Box

    GENERAL CHASSIS EAS1SD1020 INSTALLING THE STORAGE BOX 1. Install: • Storage box b. Unhook the projections on the center panel from the footrest board and sliding it upward. Storage box bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the storage box bolts in the proper tight- ening sequence as shown.

  • Page 154: Removing The Rear Upper Cover

    GENERAL CHASSIS b. Make sure that the projection on the center panel fits into the grommet in the rear panel. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the rear upper cover by fitting the pro- jection on the cover into the mudguard.

  • Page 155: Installing The Rear Panels

    GENERAL CHASSIS EAS1SD1019 INSTALLING THE REAR PANELS The following procedure applies to both of the rear panels. 1. Install: • Rear panels b. Pull the upper panel forward to remove the projections from the slots in the front cowling and the grommet in the headlight assembly. ▼...

  • Page 156: Removing The Front Upper Panel

    GENERAL CHASSIS b. Fit the projections on the front cowling cover into the holes in the upper panel and radiator cover. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the 2 projections on the upper portion of the front upper panel into the holes in the front cowling.

  • Page 157: Installing The Front Cowling

    GENERAL CHASSIS b. Pull the headlight assembly forward to re- move the projections from the grommets in the windshield bracket. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS1SD1044 REMOVING THE MAIN SWITCH COVER 1.

  • Page 158: Installing The Main Switch Cover

    GENERAL CHASSIS ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS1SD1045 EAS1SD1046 INSTALLING THE MAIN SWITCH COVER REMOVING THE FOOTREST BOARD 1.

  • Page 159: Handling The Seat Hinge Damper

    GENERAL CHASSIS in) hole through the seat hinge damper at a point 15–20 mm (0.59–0.79 in) from its end as shown. EWA13760 WARNING Wear eye protection to prevent eye damage from released gas or metal chips. ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 160: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (for YP250R) 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 161 FRONT WHEEL Removing the front wheel and brake discs (for YP250RA) 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • •...
  • Page 162 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-19...

  • Page 163: Removing The Front Wheel (For Yp250R)

    FRONT WHEEL EAS2DM1001 REMOVING THE FRONT WHEEL (for Place the vehicle on a suitable stand so that the YP250R) front wheel is elevated. 1. Stand the vehicle on a level surface. EWA13120 WARNING EAS21910 DISASSEMBLING THE FRONT WHEEL Securely support the vehicle so that there is 1.

  • Page 164: Maintenance Of The Front Wheel Sensor And Sensor Rotor (For Yp250Ra)

    FRONT WHEEL EAS2DM1003 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR (for YP250RA) ECA2DM1004 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. •...

  • Page 165: Assembling The Front Wheel

    FRONT WHEEL 3. Measure: • Wheel sensor rotor deflection Install the wheel sensor rotor with the stamped Out of specification → Clean the installation mark “a” facing outward. surface of the wheel sensor rotor and correct the wheel sensor rotor deflection, or replace the wheel sensor rotor.

  • Page 166: Adjusting The Front Wheel Static Balance

    FRONT WHEEL e. When the wheel stops, put an “X ” mark at the bottom of the wheel. Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”.

  • Page 167: Installing The Front Wheel (Front Brake Disc) (For Yp250R)

    FRONT WHEEL 4. Check: 2. Check: • Front wheel static balance • Front brake disc Refer to “CHECKING THE FRONT BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the front wheel and make sure it stays at DISC”...

  • Page 168: Installing The Front Wheel (Front Brake Discs) (For Yp250Ra)

    FRONT WHEEL 2. Check: ECA37P1030 NOTICE • Front brake disc Before tightening the wheel axle, push down Refer to “CHECKING THE FRONT BRAKE hard on the handlebar several times and DISC” on page 4-37. check if the front fork rebounds smoothly. 3.
  • Page 169 FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.7–1.5 mm (0.028–0.059 in) Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel. Do not turn the front wheel while the thickness gauge is installed.

  • Page 170: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and brake disc (for YP250R) 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 171 REAR WHEEL Removing the rear wheel and brake disc (for YP250RA) 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • •...

  • Page 172: Removing The Rear Wheel (Disc) (For Yp250R)

    REAR WHEEL EAS2DM1006 EAS2DM1008 REMOVING THE REAR WHEEL (DISC) (for MAINTENANCE OF THE REAR WHEEL YP250R) SENSOR ROTOR (for YP250RA) 1. Stand the vehicle on a level surface. ECA2DM1009 NOTICE EWA13120 WARNING • Handle the ABS components with care Securely support the vehicle so that there is since they have been accurately adjusted.
  • Page 173 REAR WHEEL 5. Measure: (for YP250RA) Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Measure the distance “a” only if the wheel bear- LOCTITE® ings, wheel sensor rotor, or both were replaced. Rear wheel sensor rotor bolt (for YP250RA) •...
  • Page 174 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 40 Nm (4.0 m kgf, 29 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 175 FRONT BRAKE Removing the front brake master cylinder 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 176 FRONT BRAKE Removing the front brake master cylinder 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 177 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-34...
  • Page 178 FRONT BRAKE Removing the front brake caliper 23 Nm (2.3 m kgf, 17 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (for YP250R)” on page Brake fluid 3-10 and “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) (for YP250RA)”...
  • Page 179 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad pin cap...

  • Page 180: Front Brake

    FRONT BRAKE EAS22220 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake ▲...

  • Page 181: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the e. If out of specification, repeat the adjustment bleed screw “2”.

  • Page 182: Removing The Front Brake Caliper

    FRONT BRAKE 5. Check: EWA1SD1006 WARNING • Brake lever operation Soft or spongy feeling → Bleed the brake sys- • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- tem. tons are expelled from the brake caliper. Refer to “BLEEDING THE HYDRAULIC •...

  • Page 183: Assembling The Front Brake Caliper

    FRONT BRAKE ECA2DM1010 NOTICE When installing the brake hose onto the brake caliper, make sure the brake pipe “a” touches the projection “b” on the brake cali- per. 2. Check: • Brake caliper bracket Cracks/damage → Replace. EAS22400 ASSEMBLING THE FRONT BRAKE CALIPER EWA37P1011 WARNING 2.

  • Page 184: Removing The Front Brake Master Cylinder

    FRONT BRAKE • When refilling, be careful that water does • Copper washers “2” not enter the brake master cylinder reser- • Front brake hose “3” voir. Water will significantly lower the boil- ing point of the brake fluid and could cause To collect any remaining brake fluid, place a vapor lock.

  • Page 185: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” • Brake master cylinder holder Brake master cylinder holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 3. Fill: • Align the projection “a” on the brake master cyl- •...
  • Page 186 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (for YP250R)” on page 3-10 and “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) (for YP250RA)” on page 3-11.

  • Page 187: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads (for YP250R) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 188 REAR BRAKE Removing the rear brake pads (for YP250RA) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 189 REAR BRAKE Removing the rear brake master cylinder 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 190 REAR BRAKE Removing the rear brake master cylinder 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 191 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-48...
  • Page 192 REAR BRAKE Removing the rear brake caliper (for YP250R) 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 193 REAR BRAKE Removing the rear brake caliper (for YP250RA) 21 Nm (2.1 m kgf, 15 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 194 REAR BRAKE Disassembling the rear brake caliper (for YP250R) 18 Nm (1.8 m kgf, 13 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 195 REAR BRAKE Disassembling the rear brake caliper (for YP250RA) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Brake caliper bracket Rear brake pad Brake pad shim...

  • Page 196: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 197: Replacing The Rear Brake Pads (For Yp250Ra)

    REAR BRAKE Always install new brake pads a new brake pad support and a new brake pad spring as a set. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

  • Page 198: Removing The Rear Brake Caliper

    REAR BRAKE • Brake pad shims (onto the brake pads) • Brake pads Always install new brake pads, brake pad shims, and brake pad supports as a set. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 199: Disassembling The Rear Brake Caliper (For Yp250R)

    REAR BRAKE EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER (for YP250R) 1. Remove: • Brake caliper piston “1” • Brake caliper piston dust seal “2” • Brake caliper piston seal “3” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 200: Checking The Rear Brake Caliper (For Yp250Ra)

    REAR BRAKE • Brake caliper cylinder “2” • Brake fluid delivery passages Scratches/wear → Replace the brake caliper (brake caliper body) Obstruction → Blow out with compressed air. assembly. • Brake caliper body “3” EWA2DM1001 WARNING Cracks/damage → Replace the brake caliper Whenever a brake caliper is disassembled, assembly.

  • Page 201: Installing The Rear Brake Caliper (For Yp250R)

    REAR BRAKE EAS2DM1014 INSTALLING THE REAR BRAKE CALIPER Specified brake fluid (for YP250R) DOT 4 1. Install: • Rear brake caliper “1” EWA13540 WARNING (temporarily) • Use only the designated brake fluid. Other • Copper washers “2” brake fluids may cause the rubber seals to •...

  • Page 202: Installing The Rear Brake Caliper (For Yp250Ra)

    REAR BRAKE 4. Fill: EAS2DM1015 INSTALLING THE REAR BRAKE CALIPER • Brake master cylinder reservoir (for YP250RA) (with the specified amount of the specified 1. Install: brake fluid) • Rear brake caliper “1” (temporarily) Specified brake fluid DOT 4 • Copper washers “2” •...

  • Page 203: Removing The Rear Brake Master Cylinder

    REAR BRAKE Refer to “BLEEDING THE HYDRAULIC EAS22730 ASSEMBLING THE REAR BRAKE MASTER BRAKE SYSTEM (ABS) (for YP250RA)” on CYLINDER page 3-11. EWA13520 WARNING EAS22700 REMOVING THE REAR BRAKE MASTER • Before installation, all internal brake com- CYLINDER ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 204 REAR BRAKE 4. Bleed: ECA14160 NOTICE • Brake system When installing the brake hose onto the Refer to “BLEEDING THE HYDRAULIC brake master cylinder, make sure the brake BRAKE SYSTEM (for YP250R)” on page pipe touches the projection “a” as shown. 3-10 and “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) (for YP250RA)”...

  • Page 205: Abs (Anti-Lock Brake System) (For Yp250Ra)

    ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 206: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS2DM1016 REMOVING THE HYDRAULIC UNIT Do not operate the brake levers while removing ASSEMBLY the brake hoses. ECA2DM1012 NOTICE ECA2DM1014 Unless necessary, avoid removing and in- NOTICE stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
  • Page 207 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. ECA2DM1015 NOTICE Do not remove the rubber plugs or bolts (M10 × 1.25) installed in the flare nut holes before installing the hydraulic unit assem- bly.

  • Page 208: Hydraulic Unit Operation Tests

    Securely support the vehicle so that there is no danger of it falling over. • For the brake line routing confirmation, use the 6. Start the Yamaha diagnostic tool and display diagnosis mode of the Yamaha diagnostic tool. the diagnosis mode screen.
  • Page 209 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.
  • Page 210 • The reaction-force pulsating action consists of quick pulses. • Be sure to continue operating the front brake 6. Start the Yamaha diagnostic tool and display lever and rear brake lever even after the pul- the diagnosis mode screen. sating action has stopped.

  • Page 211: Checking The Abs Warning Light

    12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool coupler from the ABS test coupler, and then install the protective cap. 14.Turn the main switch to “ON”.

  • Page 212: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 213 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 214: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR The upper handlebar holders should be installed 1. Stand the vehicle on a level surface. with the arrow marks “a” facing forward “A”. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
  • Page 215 HANDLEBAR EWA13700 WARNING • Be sure to position the washer between the Do not touch the handlebar grip until the rub- throttle grip and the right handlebar switch. ber adhesive has fully dried. • Lubricate the end of the throttle cables and the d.
  • Page 216 HANDLEBAR 9. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-23. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 4-73...

  • Page 217: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 40 Nm (4.0 m kgf, 29 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf)
  • Page 218 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod...

  • Page 219: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.

  • Page 220: Checking The Front Fork Legs

    FRONT FORK EAS23030 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13660 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.
  • Page 221 FRONT FORK While holding the damper rod with the damper rod holder “2” and T-handle “3”, tighten the damper rod bolt. Damper rod holder 90890-01294 Damping rod holder set YM-01300 T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 5. Install: •...

  • Page 222: Installing The Front Fork Legs

    FRONT FORK 10.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) Out of specification → Correct. Level 109.0 mm (4.29 in) 7. Fill: •...
  • Page 223 FRONT FORK Pull up the inner tube until it stops, and then tighten the lower bracket pinch bolts. Lower bracket pinch bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 2. Lower bracket 2. Install: • Cap bolt (along with the O-ring Cap bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) •...

  • Page 224: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 120 Nm (12 m kgf, 87 ft lbf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft lbf) • • 2nd 22 Nm (2.2 m kgf, 16 ft lbf)
  • Page 225 STEERING HEAD Removing the lower bracket 120 Nm (12 m kgf, 87 ft lbf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft lbf) • • 2nd 22 Nm (2.2 m kgf, 16 ft lbf) •...

  • Page 226: Removing The Lower Bracket

    STEERING HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS23110 REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1”...
  • Page 227 STEERING HEAD • Rubber washer • Center ring nut “2” • Lock washer “3” • Upper ring nut “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-15. 3. Install: • Woodruff key “1” • Lower handlebar holder “2” •...

  • Page 228: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS23160 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm (for YP250R) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 135 Nm (13.5 m kgf, 98 ft lbf) •...
  • Page 229 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm (for YP250RA) 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 135 Nm (13.5 m kgf, 98 ft lbf) •...

  • Page 230: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS23220 EAS23240 REMOVING THE REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ASSEMBLY 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Rear shock absorber rod WARNING Bends/damage → Replace the rear shock Securely support the vehicle so that there is absorber assembly.

  • Page 231: Installing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS28780 INSTALLING THE SWINGARM Rear wheel axle nut 1. Lubricate: 135 Nm (13.5 m·kgf, 98 ft·lbf) • Bearing Swingarm mounting bolt • Oil seal lips 28 Nm (2.8 m·kgf, 20 ft·lbf) Recommended lubricant Lithium-soap-based grease 2.
  • Page 232 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4-89...

  • Page 233: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-2 INSTALLING THE ENGINE............... 5-6 CYLINDER HEAD.................... 5-8 REMOVING THE CYLINDER HEAD............5-10 CHECKING THE CYLINDER HEAD ............5-10 CHECKING THE CAMSHAFT SPROCKET..........5-11 CHECKING THE TIMING CHAIN TENSIONER........5-11 INSTALLING THE CYLINDER HEAD .............5-12 CAMSHAFT ....................
  • Page 234 V-BELT AUTOMATIC TRANSMISSION ............5-30 REMOVING THE PRIMARY SHEAVE............5-34 REMOVING THE SECONDARY SHEAVE ..........5-34 DISASSEMBLING THE SECONDARY SHEAVE........5-35 CHECKING THE CLUTCH HOUSING ............5-35 CHECKING THE CLUTCH SHOES ............5-35 CHECKING THE V-BELT................5-35 CHECKING THE PRIMARY SHEAVE ............5-36 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-36 CHECKING THE PRIMARY SHEAVE SLIDERS ........

  • Page 236: Engine Inspection

    ENGINE INSPECTION EAS1SD1025 ENGINE INSPECTION Standard compression pressure (at sea level) EAS20710 1400 kPa/500 r/min (14.0 MEASURING THE COMPRESSION kgf/cm²/500 r/min, 199.1 psi/500 PRESSURE r/min) Minimum–maximum 1120–1570 kPa (11.2–15.7 Insufficient compression pressure will result in a kgf/cm², 159.3–223.3 psi) loss of performance. 1.

  • Page 237: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipe 65 Nm (6.5 m kgf, 47 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • •...
  • Page 238 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-18. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-20.
  • Page 239 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Ground lead Disconnect. For installation, reverse the removal proce- dure.
  • Page 240 ENGINE REMOVAL Removing the engine 59 Nm (5.9 m kgf, 43 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 64 Nm (6.4 m kgf, 46 ft Ibf) •...

  • Page 241: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine “1” • Engine bracket “2” • Engine bracket rods “3” • Spacer “4” • Engine mounting nut/washer/bolt “5” • Engine bracket rod bolts/washers/nuts “6” • Engine bracket nuts/bolts “7” • Rear shock absorber assemblies “8” •...
  • Page 242 ENGINE REMOVAL Tighten the muffler mounting bolts in the proper tightening sequence as shown. 7. Tighten: • Exhaust pipe nuts Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) 8. Tighten: • Muffler joint bolt Muffler joint bolt 14 Nm (1.4 m·kgf, 10 ft·lbf)

  • Page 243: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) •...
  • Page 244 CYLINDER HEAD Removing the cylinder head 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) •...

  • Page 245: Removing The Cylinder Head

    CYLINDER HEAD • Camshaft sprocket bolt “1” EAS24130 REMOVING THE CYLINDER HEAD • Camshaft sprocket plate “2” 1. Align: • Camshaft sprocket • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- To prevent the timing chain from falling into the tor cover) crankcase, fasten it with a wire “3”.

  • Page 246: Checking The Camshaft Sprocket

    CYLINDER HEAD To ensure an even surface, rotate the cylinder head several times. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS23870 CHECKING THE CAMSHAFT SPROCKET 1. Check: • Camshaft sprocket More than 1/4 tooth wear “a”...

  • Page 247: Installing The Cylinder Head

    CYLINDER HEAD EAS24230 INSTALLING THE CYLINDER HEAD 1. Tighten: • Cylinder head nuts “1” Cylinder head nut 22 Nm (2.2 m·kgf, 16 ft·lbf) • Cylinder head bolts “2” Cylinder head bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Lubricate the cylinder head nuts and washers with engine oil.
  • Page 248 CYLINDER HEAD c. Install the timing chain tensioner and gasket ECA2DL1003 NOTICE “5” onto the cylinder. Be sure to tighten the camshaft sprocket bolt Timing chain tensioner bolt to the specified torque to avoid the possibil- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ity of the bolt coming loose and damaging the engine.

  • Page 249: Camshaft

    CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft 14 Nm (1.4 m kgf, 10 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 250: Removing The Rocker Arms And Camshaft

    CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Straighten the lock plate tabs “a”. 2. Remove: • Lock plate “1” • Camshaft retainer “2” EAS23840 CHECKING THE CAMSHAFT 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Re- place the camshaft. 2.

  • Page 251: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT Rocker arm shaft outside diame- 11.981–11.991 mm (0.4717– 0.4721 in) Limit 11.950 mm (0.4705 in) 3. Check: • Camshaft oil passage Obstruction → Blow out with compressed air. EAS23880 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the 5.
  • Page 252 CAMSHAFT 3. Install: • Exhaust rocker arm • Exhaust rocker arm shaft Make sure the exhaust rocker arm shaft is com- pletely pushed into the cylinder head. 4. Install: • Intake rocker arm • Intake rocker arm shaft “1” Insert a guide stud (8 mm) “2” into the stud-bolt hole in the cylinder head and install the intake rocker arm shaft as shown.
  • Page 253 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-14. Valve cotter Upper spring seat Outer valve spring Inner valve spring...

  • Page 254: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 255 VALVES AND VALVE SPRINGS b. Install a new valve guide with the valve guide Valve-stem-to-valve-guide clear- installer “2” and valve guide remover “1”. ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 Limit 0.100 mm (0.0039 in) c.

  • Page 256: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • Valve stem runout Out of specification → Replace the valve. • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always re- place the valve stem seal. Valve stem runout ▼...

  • Page 257: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat contact width again. If the valve seat contact width is out of speci- fication, reface and lap the valve seat. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 258: Installing The Valves

    VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 76.50–88.30 N (7.80–9.00 kgf, 17.20–19.85 lbf) Installed compression spring force (exhaust) 76.50–88.30 N (7.80–9.00 kgf, 17.20–19.85 lbf) Installed length (intake) 30.10 mm (1.19 in) EAS24340 Installed length (exhaust) INSTALLING THE VALVES 30.10 mm (1.19 in) The following procedure applies to all of the Outer spring...
  • Page 259 VALVES AND VALVE SPRINGS • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 260: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Water pump outlet pipe Timing chain guide (exhaust side) Cylinder Cylinder gasket...

  • Page 261: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 262: Checking The Piston Rings

    CYLINDER AND PISTON EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 263: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter 17.004–17.015 mm (0.6694– The oil ring expander spacer end gap cannot be 0.6699 in) measured.
  • Page 264 CYLINDER AND PISTON 120˚ 120˚ 120˚ 2. Install: a. Top ring • Piston “1” b. Upper oil ring rail • Piston pin “2” c. Oil ring expander d. Lower oil ring rail • Piston pin clips “3” e. 2nd ring f.

  • Page 265: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • (11) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 266 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sheave and secondary sheave 22 Nm (2.2 m kgf, 16 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • •...
  • Page 267 • 3 Nm (0.3 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Spacer For installation, reverse the removal proce- dure. * Apply Shell BT grease 3® (Yamaha grease G 90793-40016). Yamaha grease G 90793-40016 5-32...
  • Page 268 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m kgf, 65 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch carrier nut Clutch carrier Clip Clutch carrier plate Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal...

  • Page 269: Removing The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS24620 REMOVING THE PRIMARY SHEAVE 1. Remove: • V-belt case Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 270: Disassembling The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS24640 EAS24660 DISASSEMBLING THE SECONDARY CHECKING THE CLUTCH SHOES SHEAVE The following procedure applies to all of the 1. Remove: clutch shoes. • Clutch carrier nut “1” 1. Check: • Clutch shoe Damage/wear → Replace the clutch shoes While compressing the compression spring with and springs as a set.

  • Page 271: Checking The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS24700 CHECKING THE PRIMARY SHEAVE V-belt width SLIDERS 23.0 mm (0.91 in) 1. Check: Limit 21.0 mm (0.83 in) • Primary sheave slider Cracks/damage/wear → Replace. EAS24710 CHECKING THE SECONDARY SHEAVE 1. Check: • Secondary fixed sheave •...

  • Page 272: Assembling The Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION • Primary sliding sheave • Spacer Install the secondary sliding sheave onto the • Primary sheave weights secondary fixed sheave “2” with the oil seal • Cam guide “3”. 2. Install: • Primary sheave weights “1” Oil seal guide (ø41) •...

  • Page 273: Installing The V-Belt

    V-BELT AUTOMATIC TRANSMISSION Clutch spring holder 90890-01337 Universal clutch compressor holder YM-33285 Clutch spring holder arm 90890-01464 Compressor holder adapter YM-33285-6 2. Tighten: • Clutch carrier nut “1” Clutch carrier nut 90 Nm (9.0 m·kgf, 65 ft·lbf) While holding the clutch carrier with the sheave holder “2”, tighten the clutch carrier nut with the locknut wrench “3”.
  • Page 274 V-BELT AUTOMATIC TRANSMISSION Sheave holder Rotor holding tool 90890-01701 90890-01235 Primary clutch holder Universal magneto and rotor YS-01880-A holder YU-01235 4. Install: 6. Install: • V-belt “1” • V-belt case • Primary fixed sheave “2” • Washer • Primary sheave nut “3” •...

  • Page 275: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EAS24480 STARTER CLUTCH AND GENERATOR Removing the generator cover and stator coil 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 276 STARTER CLUTCH AND GENERATOR Removing the generator rotor and starter clutch 30 Nm (3.0 m kgf, 22 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Circlip Washer Starter clutch idle gear shaft Starter clutch idle gear Generator rotor Woodruff key...

  • Page 277: Removing The Generator

    STARTER CLUTCH AND GENERATOR EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 278: Installing The Starter Clutch

    STARTER CLUTCH AND GENERATOR 2. Check: Sheave holder • Starter clutch idle gear 90890-01701 • Starter clutch gear Primary clutch holder Burrs/chips/roughness/wear → Replace the YS-01880-A defective part(s). 3. Check: • Starter clutch gear’s contact surfaces Damage/pitting/wear → Replace the starter clutch gear.
  • Page 279 Tighten the generator cover bolts in stages and in a crisscross pattern. 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 4. Install: • Oil seal “1” Installed depth “a”...

  • Page 280: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box/Air filter case 4-1. Starter motor lead Disconnect. Ground lead Disconnect.
  • Page 281 ELECTRIC STARTER Disassembling the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover O-ring Shim Lock washer Oil seal Bearing Starter motor yoke...

  • Page 282: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Digital circuit tester 1. Check: 90890-03174 • Commutator Model 88 Multimeter with ta- Dirt → Clean with 600 grit sandpaper. chometer YU-A1927 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter Armature coil motor.

  • Page 283: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing Damage/wear → Replace the bearing. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor rear cover “1” • Starter motor yoke “2” • Starter motor front cover “3” Align the match marks “a”...

  • Page 284: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “STARTER CLUTCH AND GENER- Starter clutch gear ATOR”...
  • Page 285 OIL PUMP Removing the oil pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump housing For installation, reverse the removal proce- dure.

  • Page 286: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump drive gear Less than 0.149 mm (0.0000– • Oil pump driven gear 0.0059 in) Limit • Oil pump housing 0.23 mm (0.0091 in) • Oil pump housing cover Outer-rotor-to-oil-pump-housing Cracks/damage/wear →...

  • Page 287: Installing The Oil Pump

    OIL PUMP When installing the oil pump shaft, align the pin in the oil pump shaft with the groove “a” in the in- ner rotor. 4. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-51. EAS25020 INSTALLING THE OIL PUMP 1.

  • Page 288: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission 16 Nm (1.6 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-27. Drain. Final transmission oil Refer to “CHANGING THE FINAL TRANS- MISSION OIL”...
  • Page 289 TRANSMISSION Removing the transmission 16 Nm (1.6 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Primary driven gear For installation, reverse the removal proce- dure. 5-54...

  • Page 290: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Transmission case cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS26300 CHECKING THE TRANSMISSION 1.

  • Page 291: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft 22 Nm (2.2 m kgf, 16 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 292 CRANKSHAFT Removing the crankshaft 22 Nm (2.2 m kgf, 16 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...

  • Page 293: Disassembling The Crankcase

    CRANKSHAFT EAS25560 DISASSEMBLING THE CRANKCASE • Before removing the crankshaft assembly, re- 1. Remove: move the timing chain from the crankshaft • Crankcase bolts sprocket. • The crankshaft assembly cannot be removed if Loosen each bolt 1/4 of a turn at a time, in stag- the timing chain is attached onto the crankshaft es and in a crisscross pattern.

  • Page 294: Checking The Timing Chain And Timing Chain Guide

    CRANKSHAFT EAS24180 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1. Check: • Timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 3. Measure: • Crankshaft width Out of specification → Replace the crank- shaft. Width A 59.75–59.80 mm (2.352–2.354 in) 2.

  • Page 295: Checking The Crankcase

    CRANKSHAFT a. Oil seal installed depth EAS25580 CHECKING THE CRANKCASE 3. Install: 1. Thoroughly wash the crankcase halves in a • Timing chain “1” mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Install the timing chain so it is not visible through 3.

  • Page 296: Assembling The Crankcase

    2. Apply: • Sealant 4. Install: (onto the crankcase mating surfaces) • Water pump assembly Yamaha bond No. 1215 • Crankcase bolts 90890-85505 (Three Bond No.1215®) Crankcase bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Do not allow any sealant to come into contact with the oil gallery.

  • Page 297: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-5 INSTALLING THE THERMOSTAT............6-5 WATER PUMP....................6-6 DISASSEMBLING THE WATER PUMP............ 6-8 CHECKING THE WATER PUMP .............. 6-8 ASSEMBLING THE WATER PUMP............6-8 INSTALLING THE WATER PUMP ............
  • Page 298 RADIATOR EAS26380 RADIATOR Removing the radiator 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Radiator cover/Leg shield 4-1.

  • Page 299: Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 300 RADIATOR 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 301: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1.

  • Page 302: Checking The Thermostat

    THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. Check: • Thermostat Does not open at 80.5–83.5 °C (176.9–182.3 °F) → Replace. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water.

  • Page 303: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 304 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 305: Disassembling The Water Pump

    • Install the water pump seal with the special tools. Remove the bearing and oil seal from the out- • Before installing the water pump seal, apply side of the water pump housing. Yamaha bond No.1215 (Three Bond No.1215®) “2” to the water pump housing “3”.

  • Page 306: Installing The Water Pump

    0.15 mm (0.0059 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller 5. Install: • Impeller shaft • Circlip After installation, check that the impeller shaft ro- tates smoothly.

  • Page 307: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-2 CHECKING THE FUEL PRESSURE ............7-3 THROTTLE BODY................... 7-4 REMOVING THE FUEL HOSE ..............7-6 CHECKING THE FUEL INJECTOR ............

  • Page 308: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 6 (6) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • •...

  • Page 309: Removing The Fuel Tank

    FUEL TANK • Do not touch the base section of the fuel EAS26630 REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. EAS26670 2. Disconnect: CHECKING THE FUEL PUMP BODY •...

  • Page 310: Checking The Fuel Pressure

    FUEL TANK • Wipe up any fuel remaining in the recess “a” in Before removing the hose, place a few rags in the fuel pump with a dry rag “1”. the area under where it will be removed. • After installing the fuel hose connector cover “2”, make sure that it is installed securely.

  • Page 311: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2 Nm (0.2 m kgf, 1.4 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3 Nm (0.3 m kgf, 2.2 ft Ibf) •...
  • Page 312 THROTTLE BODY Removing the throttle body 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2 Nm (0.2 m kgf, 1.4 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3 Nm (0.3 m kgf, 2.2 ft Ibf) •...

  • Page 313: Removing The Fuel Hose

    THROTTLE BODY b. Blow out all of the passages with compressed EAS2DL1001 REMOVING THE FUEL HOSE air. 1. Extract the fuel in the fuel tank through the ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 314: Installing The Throttle Body

    THROTTLE BODY ECA2DL1001 EAS2DL1005 CHECKING THE THROTTLE POSITION NOTICE SENSOR When installing the fuel hose, make sure that 1. Check: it is securely connected, and that the fuel • Throttle position sensor hose connector cover is in the correct posi- Refer to “CHECKING THE THROTTLE PO- tion, otherwise the fuel hose will not be prop- SITION SENSOR”...

  • Page 315: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM (for YP250R) ............8-5 CIRCUIT DIAGRAM (for YP250RA)............8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250R)..................... 8-9 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250RA) ..................
  • Page 316 IMMOBILIZER SYSTEM................8-79 CIRCUIT DIAGRAM ................8-79 GENERAL INFORMATION ..............8-81 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS...................8-81 TROUBLESHOOTING ................8-85 SELF-DIAGNOSIS FAULT CODE INDICATION........8-85 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA)........8-89 CIRCUIT DIAGRAM ................8-89 ABS COMPONENTS CHART ..............8-91 ABS COUPLER LOCATION CHART ............8-93 MAINTENANCE OF THE ABS ECU ............8-95 ABS TROUBLESHOOTING OUTLINE............8-95 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......
  • Page 317 ELECTRICAL COMPONENTS..............8-127 CHECKING THE SWITCHES ...............8-131 CHECKING THE BULBS AND BULB SOCKETS .........8-134 CHECKING THE FUSES ..............8-135 CHECKING AND CHARGING THE BATTERY........8-136 CHECKING THE RELAYS ..............8-139 CHECKING THE TURN SIGNAL/HAZARD RELAY......8-140 CHECKING THE DIODES..............8-141 CHECKING THE SPARK PLUG CAP ...........8-142 CHECKING THE IGNITION COIL ............8-142 CHECKING THE IGNITION SPARK GAP..........8-143 CHECKING THE CRANKSHAFT POSITION SENSOR......8-143...

  • Page 318: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 319 IGNITION SYSTEM 1. Crankshaft position sensor 5. Main switch 6. ECU fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 18.Sidestand switch 33.Lean angle sensor 35.ECU (engine control unit) 36.Ignition coil 37.Spark plug...

  • Page 320: Troubleshooting

    IGNITION SYSTEM EAS27120 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Storage box 2. Leg shield NG → 1. Check the fuses. (Main, ECU, and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 321 IGNITION SYSTEM NG → 9. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-131. OK ↓ NG → 10.Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor. ANGLE SENSOR”...

  • Page 322: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS2DM1095 CIRCUIT DIAGRAM (for YP250R)
  • Page 323 ELECTRIC STARTING SYSTEM 5. Main switch 9. Ignition fuse 11.Signaling system fuse 12.Battery 13.Main fuse 14.Starter relay 15.Starter motor 16.Diode 1 17.Frame ground 18.Sidestand switch 21.Starting circuit cut-off relay 22.Diode 2 24.Start switch 26.Front brake light switch 50.Rear brake light switch...

  • Page 324: Circuit Diagram (For Yp250Ra)

    ELECTRIC STARTING SYSTEM EAS2DM1096 CIRCUIT DIAGRAM (for YP250RA)
  • Page 325 ELECTRIC STARTING SYSTEM 5. Main switch 10.Ignition fuse 12.Signaling system fuse 13.Battery 14.Main fuse 15.Starter relay 16.Starter motor 17.Frame ground 18.Diode 1 19.Sidestand switch 24.Starting circuit cut-off relay 1 25.Diode 2 26.Starting circuit cut-off relay 2 28.Start switch 30.Front brake light switch 60.Rear brake light switch...

  • Page 326: Starting Circuit Cut-Off System Operation (For Yp250R)

    ELECTRIC STARTING SYSTEM EAS2DM1097 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250R) If the main switch is set to “ON” (switch circuit is closed), the starter motor can only operate if the fol- lowing conditions are met: • The brake lever is pulled to the handlebar (the brake switch is closed) and the sidestand is up (the sidestand switch is closed).
  • Page 327 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Diode 2 6. Starting circuit cut-off relay 7. Sidestand switch 8. Signaling system fuse 9. Front brake light switch 10. Rear brake light switch 11. Start switch 12.

  • Page 328: Starting Circuit Cut-Off System Operation (For Yp250Ra)

    ELECTRIC STARTING SYSTEM EAS2DM1098 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (for YP250RA) If the main switch is set to “ON” (switch circuit is closed), the starter motor can only operate if the fol- lowing conditions are met: • The brake lever is pulled to the handlebar (the brake switch is closed) and the sidestand is up (the sidestand switch is closed).
  • Page 329 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Signaling system fuse 6. Diode 2 7. Starting circuit cut-off relay 1 8. Rear brake light switch 9. Front brake light switch 10. Starting circuit cut-off relay 2 11.

  • Page 330: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Storage box 2. Meter assembly 3. Leg shield NG → 1. Check the fuses. (Main, ignition, and signaling sys- tem) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 331 ELECTRIC STARTING SYSTEM NG → 8. Check the diode 2. Refer to “CHECKING THE DI- Replace the diode 2. ODES” on page 8-141. OK ↓ NG → 9. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS”...

  • Page 332: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM B/L W/R Br/R Br/R OPEN LOCK Br/L Br/LBr/R Br/L Br/R Br/R B/W B Br/L Br/L R/G B Br/L R/WR/B L G/B R/L B/W 8-15...
  • Page 333 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 12.Battery 13.Main fuse 17.Frame ground 8-16...

  • Page 334: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling 3. Bottom cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 335 CHARGING SYSTEM 8-18...

  • Page 336: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-19...
  • Page 337 LIGHTING SYSTEM 5. Main switch 6. ECU fuse 9. Ignition fuse 10.Headlight fuse 11.Signaling system fuse 12.Battery 13.Main fuse 17.Frame ground 35.ECU (engine control unit) 44.Headlight relay 46.Dimmer switch 47.Pass switch 52.Tail/brake light 59.Auxiliary light 60.Headlight 61.License plate light 69.High beam indicator light 8-20...

  • Page 338: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillights, license plate light or aux- iliary lights. • Before troubleshooting, remove the following part(s): 1. Leg shield NG → 1. Check the condition of each bulb and bulb socket.
  • Page 339 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the ECU, meter assembly or tail/brake light assembly. 8-22...

  • Page 340: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS2DM1099 CIRCUIT DIAGRAM (for YP250R) 8-23...
  • Page 341 SIGNALING SYSTEM 1. Crankshaft position sensor 5. Main switch 6. ECU fuse 8. Turn signal/hazard fuse 9. Ignition fuse 11.Signaling system fuse 12.Battery 13.Main fuse 17.Frame ground 20.Fuel sender 25.Hazard switch 26.Front brake light switch 30.Coolant temperature sensor 34.Speed sensor 35.ECU (engine control unit) 42.Horn 43.Turn signal/hazard relay...

  • Page 342: Circuit Diagram (For Yp250Ra)

    SIGNALING SYSTEM EAS2DM1100 CIRCUIT DIAGRAM (for YP250RA) 8-25...
  • Page 343 SIGNALING SYSTEM 1. Crankshaft position sensor 5. Main switch 6. ABS ECU fuse 7. ECU fuse 9. Turn signal/hazard fuse 10.Ignition fuse 12.Signaling system fuse 13.Battery 14.Main fuse 17.Frame ground 21.Fuel sender 29.Hazard switch 30.Front brake light switch 35.Coolant temperature sensor 40.ECU (engine control unit) 46.Front wheel sensor 48.Wheel sensor lead shield...

  • Page 344: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal lights, brake lights, warning light or indicator lights. • The horn fails to sound. • The fuel meter fails to operate. • The coolant temperature meter fails to operate. •...
  • Page 345 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. The horn switch is faulty. Replace the left Refer to “CHECKING THE handlebar switch. SWITCHES” on page 8-131. OK ↓ NG → 2.
  • Page 346 SIGNALING SYSTEM NG → 3. Check the hazard switch. The hazard switch is faulty. Replace the Refer to “CHECKING THE right handlebar switch. SWITCHES” on page 8-131. OK ↓ NG → 4. Check the turn signal/hazard relay. Refer to “CHECKING THE TURN Replace the turn signal/hazard relay.
  • Page 347 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (for Properly connect or replace the wire har- YP250R)” on page 8-23 and “CIR- ness. CUIT DIAGRAM (for YP250RA)” on page 8-25. OK ↓ Replace the ECU or meter assembly. The speedometer fails to operate (for YP250R).
  • Page 348 SIGNALING SYSTEM • Between ECU coupler and meter assembly coupler. (yellow/blue–yellow/blue) The tachometer fails to operate. NG → 1. Check the crankshaft position sen- sor. Replace the crankshaft position sen- Refer to “CHECKING THE CRANK- sor/stator assembly. SHAFT POSITION SENSOR” on page 8-143.
  • Page 349 SIGNALING SYSTEM The engine oil change indicator fails to come on. NG → 1. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (for Properly connect or replace the wire har- YP250R)” on page 8-23 and “CIR- ness. CUIT DIAGRAM (for YP250RA)” on page 8-25.

  • Page 350: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-33...
  • Page 351 COOLING SYSTEM 5. Main switch 6. ECU fuse 7. Radiator fan motor fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 30.Coolant temperature sensor 35.ECU (engine control unit) 71.Radiator fan motor 72.Radiator fan motor relay 8-34...

  • Page 352: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING • The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Storage box 2. Leg shield NG → 1. Check the fuses. (Main, ignition, ECU, and radiator fan motor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 353 COOLING SYSTEM 8-36...

  • Page 354: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS2DM1101 CIRCUIT DIAGRAM (for YP250R) 8-37...
  • Page 355 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Backup fuse 5. Main switch 6. ECU fuse 7. Radiator fan motor fuse 9. Ignition fuse 10.Headlight fuse 12.Battery 13.Main fuse 17.Frame ground 18.Sidestand switch 19.Fuel pump 29.Throttle position sensor 30.Coolant temperature sensor 31.Intake air pressure sensor 32.Intake air temperature sensor 33.Lean angle sensor...

  • Page 356: Circuit Diagram (For Yp250Ra)

    FUEL INJECTION SYSTEM EAS2DM1102 CIRCUIT DIAGRAM (for YP250RA) 8-39...
  • Page 357 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Backup fuse 5. Main switch 6. ABS ECU fuse 7. ECU fuse 8. Radiator fan motor fuse 10.Ignition fuse 11.Headlight fuse 13.Battery 14.Main fuse 17.Frame ground 19.Sidestand switch 20.Fuel pump 22.Fuel pump relay 23.Diode 3 35.Coolant temperature sensor 36.Throttle position sensor...

  • Page 358: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 359: Troubleshooting Method

    FUEL INJECTION SYSTEM When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating, depending on the conditions. 3.
  • Page 360 FUEL INJECTION SYSTEM FI diagnostic tool 90890-03182 FI diagnostic tool YU-03182 Setting the diagnostic mode 1. Set the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Disconnect the self-diagnosis signal coupler, and then connect the FI diagnostic tool “1” as shown. 4.
  • Page 361 FUEL INJECTION SYSTEM 8. Set the main switch to “OFF” to cancel the diagnostic mode. 9. Disconnect the FI diagnostic tool and connect the self-diagnosis signal coupler. Information about each diagnostic code number is organized in this manual as follows: •...

  • Page 362: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the multi-function meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the multi-function meter according to the “Confirmation of service completion”.
  • Page 363 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Defective crankshaft posi- Check the crankshaft posi- Crank the engine. tion sensor. tion sensor. Fault code number is not dis- played →...
  • Page 364 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Installed condition of intake Improperly installed sensor Turn the main switch to “ON”. → Reinstall or replace the air pressure sensor. Fault code number is not dis- played →...
  • Page 365 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Condition of intake air pres- Clogged or detached hose Start the engine and let it idle →...
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of throttle posi- Turn the main switch to “ON”. tion sensor coupler.
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position Check throttle position sen- Turn the main switch to “ON”. sensor. sor signal. Fault code number is not dis- played → Service is finished. Execute the diagnostic mode.
  • Page 368 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected. Defective throttle position Check throttle position sen- Turn the main switch to “ON” sensor. sor signal. and then open and close the Execute the diagnostic throttle valve.
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow Item lead of the ECU is detected. Improperly connected → Connection of wire harness Turn the main switch to “ON”, ECU coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or replace the wire har-...
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
  • Page 371 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of wire harness Turn the main switch to “ON”. ECU coupler. Connect the coupler secure- Fault code number is not dis- played →...
  • Page 372 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — FI diagnostic tool display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job...
  • Page 373 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Defective O sensor. Check the O sensor. Start the engine, warm it up, and then race it, or execute Replace if defective. the diagnostic mode. (Code Refer to “ENGINE REMOV- No.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead Item of the ignition coil. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Actuates the ignition coil five times at one-second intervals. Actuation Illuminates the engine trouble warning light.
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is de- fective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is de- fective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). ISC valve is not moving cor- Replace the throttle body as- Start the engine and let it idle rectly.
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). Improperly connected → Connection of ISC (idle Execute the diagnostic speed control) unit coupler.
  • Page 378 FUEL INJECTION SYSTEM • If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number “46” first. • If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number “42”...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage FI diagnostic tool display • 0.4–1.4 (upright) •...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. 42 (For YP250R) Speed sensor: no normal signals are received from the speed Item sensor. Diagnostic code No. Front wheel speed pulse FI diagnostic tool display 0–999 Check that the number increases when the front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
  • Page 381 FUEL INJECTION SYSTEM Fault code No. 42 (For YP250RA) Front wheel sensor: no normal signals are received from the Item front wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Vehicle speed pulse FI diagnostic tool display 0–999 Check that the number increases when the front wheel is rotated.
  • Page 382 FUEL INJECTION SYSTEM Fault code No. 42 (For YP250RA) Front wheel sensor: no normal signals are received from the Item front wheel sensor. Open or short circuit → Re- Wire harness continuity or Execute the diagnostic defective front wheel sensor. place the wire harness.
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of wire harness Start the engine and let it idle ECU coupler.
  • Page 384 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. “01” is indicated in diagnostic Change the CO concentra- Turn the main switch to “ON”. mode (Code No. D60). EEP- tion, and rewrite in EE- Fault code number is not dis- played →...
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Faulty ECU memory. (When this malfunction is detected in the Item ECU, the fault code number might not appear on the multi- function meter.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 386 FUEL INJECTION SYSTEM Fault code No. Item ISC (idle speed control) unit: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU (engine control unit) internal malfunction (output signal Item error): signals cannot be transmitted between the ECU and the multi-function meter. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness.
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU (engine control unit) internal malfunction (output signal Item error): no signals are received from the ECU within the speci- fied duration. Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”. Fault code number is not dis- played →...
  • Page 389 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (engine control unit) internal malfunction (input signal er- Item ror): non-registered data has been received from the meter. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — FI diagnostic tool display —...

  • Page 390: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS2DM1103 CIRCUIT DIAGRAM (for YP250R) 8-73...
  • Page 391 FUEL PUMP SYSTEM 5. Main switch 6. ECU fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 19.Fuel pump 35.ECU (engine control unit) 8-74...

  • Page 392: Circuit Diagram (For Yp250Ra)

    FUEL PUMP SYSTEM EAS2DM1104 CIRCUIT DIAGRAM (for YP250RA) 8-75...
  • Page 393 FUEL PUMP SYSTEM 5. Main switch 7. ECU fuse 10.Ignition fuse 13.Battery 14.Main fuse 17.Frame ground 20.Fuel pump 22.Fuel pump relay 23.Diode 3 40.ECU (engine control unit) 8-76...

  • Page 394: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Storage box 2. Leg shield NG → 1. Check the fuses. (Main, ECU, and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 395 FUEL PUMP SYSTEM 8-78...

  • Page 396: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-79...
  • Page 397 IMMOBILIZER SYSTEM 4. Backup fuse 5. Main switch 6. ECU fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 35.ECU (engine control unit) 63.Multi-function meter 66.Immobilizer system indicator light 73.Self-diagnosis signal coupler 74.Immobilizer unit 8-80...

  • Page 398: General Information

    IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 399 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
  • Page 400 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
  • Page 401 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.

  • Page 402: Troubleshooting

    IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, ECU, and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 403 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo- UNIT key and immobilizer other transponder bilizer unit at unit do not match. (failed to recognize least 50 mm code after ten con- away from the secutive attempts).
  • Page 404 IMMOBILIZER SYSTEM a. Light on b. Light off 8-87...
  • Page 405 IMMOBILIZER SYSTEM 8-88...

  • Page 406: Abs (Anti-Lock Brake System) (For Yp250Ra)

    ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS2DM1122 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS27730 CIRCUIT DIAGRAM 8-89...
  • Page 407 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) 4. Backup fuse 5. Main switch 6. ABS ECU fuse 7. ECU fuse 10.Ignition fuse 12.Signaling system fuse 13.Battery 14.Main fuse 17.Frame ground 30.Front brake light switch 33.ABS motor fuse 34.ABS solenoid fuse 40.ECU (engine control unit) 46.Front wheel sensor 47.Rear wheel sensor 48.Wheel sensor lead shield...

  • Page 408: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS27740 ABS COMPONENTS CHART 1,2,3 1. ABS motor fuse 2. ABS ECU fuse 3. ABS solenoid fuse 4. ABS test coupler 5. ABS warning light 6. Hydraulic unit assembly 7. Front wheel sensor 8. Front wheel sensor rotor 9.
  • Page 409 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) 8-92...

  • Page 410: Abs Coupler Location Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) EAS27750 ABS COUPLER LOCATION CHART B Sb Dg B/L G/L W W W/R P/W W/R Br/W G/L G/W B/W (Gy) 8-93...
  • Page 411 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) 1. ABS test coupler 2. ABS ECU coupler 3. Meter assembly coupler 4. Front wheel sensor coupler 5. Rear wheel sensor coupler 8-94...

  • Page 412: Maintenance Of The Abs Ecu

    The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-99. For troubleshooting items other than the following items, follow the normal service method.

  • Page 413: Basic Instructions For Troubleshooting

    Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...

  • Page 414: Basic Process For Troubleshooting

    The main fuse is blown. • The meter assembly circuit is • defective. The connection with the Yamaha • [A-3] The ABS warning light comes diagnostic tool is defective. Cannot communicate Return to [A]. The ABS ECU fuse is blown.

  • Page 415: [A] Checking The Abs Warning Light

    EAS2DM1125 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler. If the Yamaha diagnostic tool cannot com- municate with the vehicle, perform the following steps. For information about connecting the Yamaha diagnostic tool, refer to “[B-2] DIAGNOSIS USING THE FAULT CODES” on page 8-99.

  • Page 416: [B-1] Malfunction Are Currently Detected

    5. The hydraulic unit assembly is defective. EAS2DM1127 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • Fault code number is displayed. [B-2] •...
  • Page 417 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation. 8-100...
  • Page 418 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Operation of the Yamaha diagnostic tool (Fault diagnosis mode) Malfunction results are displayed in the top part of the window area. Hydraulic unit assembly Detected Power is not supplied to the ABS motor. Rear wheel sensor Recovered Rear wheel sensor circuit is open or short-circuited.
  • Page 419 The diagnosis codes related to the detected malfunction are displayed. Fault code table The details of the fault codes displayed using the Yamaha diagnostic tool are shown in the following table. Refer to this table when checking the vehicle. Delete the fault codes when the service is finished. [B-3] •...
  • Page 420 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code Item Symptom Check point Rear wheel sensor (ab- Rear wheel sensor signal • Foreign material ad- normal pulse period) is not received properly. hered around the rear (The pulse period is ab- wheel sensor normal while the vehicle is •...
  • Page 421 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code Item Symptom Check point Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the rear (Missing pulses are de- wheel sensor tected in the signal while •...
  • Page 422 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code Item Symptom Check point Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse (abnormal ABS motor the motor circuit in the hy- • Defective coupler be- power supply) draulic unit assembly.
  • Page 423 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code Item Symptom Check point Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the rear (Missing pulses are de- wheel sensor tected in the signal while •...
  • Page 424 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code Item Symptom Check point Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly supply) the hydraulic unit assem- bly. Front wheel sensor power Power voltage supplied •...
  • Page 425 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are Symptom not received or are received intermittently while the vehicle is traveling.) Item/components and probable Order Check or maintenance job...
  • Page 426 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Foreign material adhered around the Check the surface of the sensor rotor and wheel...
  • Page 427 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
  • Page 428 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Item/components and probable Order Check or maintenance job cause Open or short circuit in the wire har- •...
  • Page 429 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Item/components and probable Order Check or maintenance job cause Defective coupler between the rear •...
  • Page 430 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Foreign material adhered around the...
  • Page 431 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Defective sensor rotor or incorrect in-...
  • Page 432 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Brake light switch or tail/brake light Brake light signal is not received properly while the vehicle is Symptom traveling (brake light circuit, or front or rear brake light switch circuit). Item/components and probable Order Check or maintenance job...
  • Page 433 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Hydraulic unit assembly (short circuit in ABS solenoid power Item supply circuit) Short circuit is detected in the solenoid power supply circuit Symptom in the hydraulic unit assembly. Item/components and probable Order Check or maintenance job cause...
  • Page 434 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Hydraulic unit assembly (short circuit in ABS motor power Item supply circuit) Short circuit is detected in the motor power supply circuit in Symptom the hydraulic unit assembly. Item/components and probable Order Check or maintenance job cause...
  • Page 435 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. (For fault code No. 42) Symptom •...
  • Page 436 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Defective sensor rotor or incorrect in-...
  • Page 437 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power supply is high) (for fault code No. 52) •...
  • Page 438 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS mo- Item tor power supply circuits) Abnormality is detected in the solenoid or motor power supply Symptom circuit in the hydraulic unit assembly. Item/components and probable Order Check or maintenance job...
  • Page 439 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Item Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hy- Symptom draulic unit assembly. Item/components and probable Order Check or maintenance job cause Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 440 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Front wheel sensor power supply (voltage of power supply is Item low) Power voltage supplied from the ABS ECU to the front wheel Symptom sensor is too low. Item/components and probable Order Check or maintenance job cause...
  • Page 441 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) Fault code No. Rear wheel sensor power supply (voltage of power supply is Item low) Power voltage supplied from the ABS ECU to the rear wheel Symptom sensor is too low. Item/components and probable Order Check or maintenance job cause...

  • Page 442: [B-3] Deleting The Fault Codes

    After the deletion procedure is finished, make sure that all of the fault codes displayed using the Yamaha diagnostic tool have been deleted. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the ABS test coupler (4P). EAS2DM1130 [C-1] FINAL CHECK Check the vehicle and finish the service according to the following procedures.
  • Page 443 ABS (ANTI-LOCK BRAKE SYSTEM) (for YP250RA) 8-126...

  • Page 444: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS YP250R 8-127...
  • Page 445 ELECTRICAL COMPONENTS 1. Battery 2. Diode 1 3. Fuse box 4. Front brake light switch 5. Rear brake light switch 6. Main switch/immobilizer unit 7. ECU (engine control unit) 8. Fuel pump 9. Ignition coil 10. Fuel injector 11. Intake air temperature sensor 12.
  • Page 446 ELECTRICAL COMPONENTS YP250RA 8-129...
  • Page 447 ELECTRICAL COMPONENTS 1. Battery 2. Diode 1 3. Fuse box 4. Front brake light switch 5. Rear brake light switch 6. Main switch/immobilizer unit 7. ECU (engine control unit) 8. Fuel pump 9. Ignition coil 10. Fuel injector 11. Intake air temperature sensor 12.

  • Page 448: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES L/W W/Y Br/W Ch Br/W Ch R Br/L Br/R Br/R OPEN LOCK Br/L Ch Br/W L/B G Y R/Y Y Br/W Ch 8-131...
  • Page 449 ELECTRICAL COMPONENTS 1. Start switch 2. Hazard switch 3. Front brake light switch 4. Trip switch 5. Information switch 6. Main switch 7. Dimmer switch 8. Pass switch 9. Turn signal switch 10. Horn switch 11. Rear brake light switch 12.
  • Page 450 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and, if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 451: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 EWA37P1018 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.

  • Page 452: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 453: Checking And Charging The Battery

    ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
  • Page 454 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
  • Page 455 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.

  • Page 456: Checking The Relays

    ELECTRICAL COMPONENTS • Upper panel 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay.

  • Page 457: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS Radiator fan motor relay 4. Negative tester probe Result Continuity (between “3” and “4”) Fuel pump (for YP250RA) 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity 1. Positive battery terminal (between “3”...

  • Page 458: Checking The Diodes

    ELECTRICAL COMPONENTS EAS28050 CHECKING THE DIODES Diode 2 1. Check: • Diode 2 Out of specification → Replace. Br/R Pocket tester 90890-03112 Analog pocket tester b. Turn the main switch to “ON”. YU-03112-C c. Measure the turn signal/hazard relay input voltage.

  • Page 459: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS28060 CHECKING THE SPARK PLUG CAP a. Disconnect the diode 2 from the wire har- 1. Check: ness. • Spark plug cap resistance b.

  • Page 460: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Refer to “TROUBLESHOOTING” on page 8-3. Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 461: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester yellow/green (wire harness color) 90890-03112 • Negative tester probe → Analog pocket tester black/blue (wire harness color) YU-03112-C • Positive tester probe → red “1” • Negative tester probe → white “2” c.

  • Page 462: Checking The Stator Coil

    ELECTRICAL COMPONENTS b. Check the starter motor operation. EAS28170 CHECKING THE RECTIFIER/REGULATOR ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1. Check: • Charging voltage EAS28150 CHECKING THE STATOR COIL Out of specification →...

  • Page 463: Checking The Speed Sensor (For Yp250R)

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 10) to the fuel Test harness– speed sensor (3P) 90890-03208 sender terminal as shown. Test harness–...

  • Page 464: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS c. Check the radiator fan motor movement. d. Heat the coolant or let it cool down to the specified temperatures. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ e.

  • Page 465: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to the test harness-TPS (3P). Test harness– TPS (3P) 90890-03204 Test harness– TPS (3P) YU-03204 Pocket tester 90890-03112 Analog pocket tester YU-03112-C c. Measure the throttle position sensor voltage. Out of specification → Replace the wire har- •...

  • Page 466: Checking The Air Temperature Sensor

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the in- a.

  • Page 467: Checking The Isc (Idle Speed Control) Unit

    ELECTRICAL COMPONENTS • Positive tester probe red/blue “1” • Negative tester probe orange/black “2” R/L O/B c. Measure the ISC unit resistance. Out of specification → Replace the throttle body. Resistance 27–33 Ω c. Measure the fuel injector resistance. ▲ ▲▲▲...
  • Page 468 ELECTRICAL COMPONENTS 8-151...

  • Page 469: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURE/HARD STARTING..........9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-3 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-5...

  • Page 470: Troubleshooting

    TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 471: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system Poor starting performance 1. Battery 1. V-belt • Discharged battery • Slipping V-belt • Faulty battery • Oil or grease on the V-belt 2. Spark plug 2. Primary sliding sheave • Incorrect spark plug gap • Faulty operation •...

  • Page 472: Overcooling

    TROUBLESHOOTING Fuel system • Bent or damaged damper rod 1. Throttle body • Incorrect oil viscosity • Damaged or loose throttle body joint • Incorrect oil level 2. Air filter EAS28670 • Clogged air filter element UNSTABLE HANDLING 1. Handlebar Chassis •...
  • Page 473 TROUBLESHOOTING Headlight bulb burnt out • Wrong headlight bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light LED • Too many electrical accessories •...
  • Page 474 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS1SD1039 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-diagnostic function table Fault Reference Item code No. pages Crankshaft position sensor: no normal signals are received from the 8-45 crankshaft position sensor. Intake air pressure sensor: open or short circuit detected. 8-46 Intake air pressure sensor: hose system malfunction (clogged or de- 8-47...

  • Page 475: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Reference Item code No. pages Immobilizer unit: Key code registration malfunction. 8-85 ECU: Unidentified code is received. 8-85 ISC (idle speed control) unit: open or short circuit detected. 8-68 Communication error with the meter Fault Reference Item...
  • Page 476 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Front wheel speed pulse Front wheel speed pulse Check that the number in- 0–999 creases when the front wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped.
  • Page 477 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Malfunction history code erasure • No history — • History exists • Displays the total num- To erase the history, push ber of malfunctions, in- the start switch “ ”. cluding the current malfunction, that have occurred since the histo-...
  • Page 478 EAS28740 58. Headlight assembly EAS28750 WIRING DIAGRAM COLOR CODE 59. Auxiliary light Black 60. Headlight YP250R 2014 Brown 61. License plate light 1. Crankshaft position sensor Chocolate 62. Meter assembly 2. AC magneto Dark green 63. Multi-function meter 3. Rectifier/regulator Green 64.
  • Page 479 EAS2DM1112 57. Pass switch EAS2DM1113 WIRING DIAGRAM COLOR CODE 58. Turn signal switch Black 59. Horn switch YP250RA 2014 Brown 60. Rear brake light switch 1. Crankshaft position sensor Chocolate 61. Right tail/brake light assembly 2. AC magneto Dark green 62.
  • Page 483 YP250R 2014 YP250R 2014 YP250R 2014 YP250R 2014 YP250R 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Y/G Br/W R/B B/W W/R L/Y L/W L/R Y Gy/G L Lg G/B B/L W/R G/R B/L 19 20 G/YL/W Sb B L B/L W/Y L/Y...
  • Page 484 YP250R 2014 YP250R 2014 YP250R 2014 YP250R 2014 YP250R 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO 19 20 OPEN LOCK (Gy)
  • Page 485 YP250RA 2014 YP250RA 2014 YP250RA 2014 YP250RA 2014 YP250RA 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO B/L W/R Y/G Br/W R/B B/W W/R L/Y L/W L/R Y Gy/G L Lg G/B Sb B G/R B/L L/B B L B/L R/L O/B B/L P/W L...
  • Page 486 YP250RA 2014 YP250RA 2014 YP250RA 2014 YP250RA 2014 YP250RA 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO OPEN LOCK (Gy)

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