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Yamaha Manuals
Motorcycle
YZ 2020 Series
Owner's service manual
Yamaha YZ 2020 Series Owner's Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety Information
For Safety, be Sure to Obey the Following
Location of Important Labels
Description
Identification
Vehicle Identification Number
Engine Serial Number
Power Tuner
Fuel Hose Joint Cover
Handlebar Protector
Nipple Wrench
Included Parts
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Basic Service Information
Electrical System
Special Tools
Instrument and Control Functions
Warning Lights
Engine Stop Switch
Start Switch
Mode Switch
Shift Pedal
Front Brake Lever
Sidestand
Rear Brake Pedal
Starter Knob
Fuel Tank Cap
Starting and Break-In
Fuel
Starting a Cold Engine
Starting a Warm Engine
Break-In Procedures
Engine Starting Precaution
Maintenance after Break-In
Major Maintenance
Air Filter Maintenance
Torque-Check Points
Motorcycle Care and Storage
Care
Storage
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
General Tightening Torque Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Cable Routing Diagram
Periodic Checks and Adjustments
Maintenance Intervals
General Inspection and Maintenance
Pre-Operation Inspection and Maintenance
Adjusting the Valve Clearance
Engine
Valve Clearance Shim Chart
Checking the Engine Idling Speed
Checking the Throttle Grip
Checking the Spark Plug
Changing the Engine Oil
Checking the Engine Oil Level
Adjusting the Clutch Lever Free Play
Adjusting the Clutch Lever Position
Cleaning the Air Filter Element
Checking the Fuel Line
Checking the Throttle Body Joint
Checking the Cylinder Head Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Changing the Coolant
Checking the Cooling System
Adjusting the Front Disc Brake
Adjusting the Rear Disc Brake
Chassis
Checking the Brake Fluid Level
Checking the Front Brake Hose
Checking the Front Brake Pads
Checking the Rear Brake Pads
Bleeding the Hydraulic Brake System
Checking the Brake Operation
Checking the Rear Brake Hose
Drive Chain Slack
Checking and Adjusting the Steering Head
Lubricating the Drive Chain
Checking the Front Fork Legs
Lubricating the Steering Head
Adjusting the Front Fork Legs
Checking the Rear Shock Absorber Assembly
Adjusting the Rear Shock Absorber Assembly
Checking and Tightening the Spokes
Checking the Connecting Arm and Relay Arm
Checking the Swingarm Operation
Checking the Tires
Lubricating the Swingarm Pivot
Chassis
General Chassis
Installing the Air Scoop
Removing the Number Plate
Removing the Seat
Installing the Side Cover
Removing the Side Cover
Front Wheel
Checking the Front Wheel
Disassembling the Front Wheel
Removing the Front Wheel
Assembling the Front Wheel
Installing the Front Wheel (Disc Brake)
Checking and Replacing the Rear Wheel Sprocket
Checking the Rear Wheel
Disassembling the Rear Wheel
Rear Wheel
Removing the Rear Wheel
Assembling the Rear Wheel
Installing the Rear Wheel (Disc Brake)
Front Brake
Checking the Front Brake Disc
Introduction
Replacing the Front Brake Pads
Disassembling the Front Brake Caliper
Removing the Front Brake Caliper
Assembling the Front Brake Caliper
Checking the Front Brake Caliper
Installing the Front Brake Caliper
Assembling the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Removing the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Checking the Rear Brake Disc
Introduction
Replacing the Rear Brake Pads
Assembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Removing the Rear Brake Caliper
Installing the Rear Brake Caliper
Assembling the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Removing the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Handlebar
Checking the Handlebar
Installing the Handlebar
Removing the Handlebar
Front Fork
Disassembling the Front Fork Legs
Removing the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Checking the Steering Head
Installing the Steering Head
Removing the Lower Bracket
Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Disposing of a Rear Shock Absorber
Handling the Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Installing the Rear Shock Absorber Assembly
Installing the Relay Arm
Swingarm
Checking the Swingarm
Installing the Swingarm
Removing the Swingarm
Chain Drive
Checking the Drive Chain
Removing the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Sprocket
Installing the Drive Chain
Engine
Engine Oil Lubrication Chart
Lubrication System Chart and Diagrams
Lubrication Diagrams
Engine Removal
Installing the Engine
Removing the Engine
Installing the Exhaust Pipe and Muffler
Camshaft
Removing the Camshaft
Checking the Camshaft
Checking the Decompression System
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Tensioners
Installing the Camshafts
Cylinder Head
Checking the Cylinder Head
Checking the Timing Chain Guide (Intake Side)
Removing the Cylinder Head
Installing the Cylinder Head
Removing the Valves
Valves and Valve Springs
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Lifters
Checking the Valve Springs
Installing the Valves
Cylinder and Piston
Checking the Cylinder and Piston
Removing the Piston
Checking the Piston Pin
Checking the Piston Rings
Installing the Piston and Cylinder
Generator
Checking the Generator
Checking the Woodruff Key
Installing the Generator
Removing the Generator
Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Removing the Starter Clutch
Electric Starter
Assembling the Starter Motor
Checking the Starter Motor
Clutch
Checking the Clutch Plates
Checking the Friction Plates
Removing the Clutch
Checking the Clutch Boss
Checking the Clutch Housing
Checking the Clutch Springs
Checking the Pressure Plate
Checking the Push Lever Shaft
Checking the Push Rods
Checking the Primary Drive Gear
Checking the Primary Driven Gear
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Removing the Segment
Oil Pump
Checking the Oil Pump
Removing the Oil Pump
Assembling the Oil Pump
Installing the Oil Pump
Crankcase
Checking the Crankcase
Checking the Timing Chain Guide (Exhaust Side)
Disassembling the Crankcase
Assembling the Crankcase
Crankshaft and Balancer Shaft
Checking the Crankshaft
Removing the Crankshaft
Installing the Crankshaft
Transmission
Checking the Shift Drum Assembly
Checking the Shift Forks
Removing the Transmission
Checking the Transmission
Cooling System
Cooling System Diagrams
Radiator
Checking the Radiator
Installing the Radiator
Water Pump
Assembling the Water Pump
Checking the Water Pump
Disassembling the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Installing the Fuel Pump
Removing the Fuel Pump
Removing the Fuel Tank
Installing the Fuel Tank
Throttle Body
Checking the Fuel Pressure
Checking the Injector
Checking the Throttle Body
Adjusting the Throttle Position Sensor
Electrical System
Circuit Diagram
Ignition System
Troubleshooting
Circuit Diagram
Electric Starting System
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Circuit Diagram
Signaling System
Troubleshooting
Circuit Diagram
Fuel Injection System
Ecu Self-Diagnostic Function
Troubleshooting Method
Connecting the Yamaha Diagnostic Tool
Yamaha Diagnostic Tool
Troubleshooting Details (Fault Code)
Circuit Diagram
Fuel Pump System
Troubleshooting
Electrical Components
Checking the Switches
Checking the Bulbs and Bulb Sockets
Checking the Fuses
Checking and Charging the Battery
Checking the Relay Unit (Diode)
Checking the Relays
Checking the Ignition Spark Gap
Checking the Spark Plug Cap
Checking the Crankshaft Position Sensor
Checking the Ignition Coil
Checking the Lean Angle Sensor
Checking the Rectifier/Regulator
Checking the Starter Motor Operation
Checking the Stator Coil
Checking the Fuel Sender
Checking the Resistor
Checking the Coolant Temperature Sensor
Checking the Throttle Position Sensor Input Voltage
Checking the Gear Position Switch
Checking the Intake Air Temperature Sensor
Checking the Injector
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2020
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXL1
LIT-11626-33-34
BAJ-28199-10
Table of
Contents
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3
4
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Chapters
Table of Contents
9
Specifications
45
Periodic Checks and Adjustments
75
Chassis
113
Engine
185
Cooling System
265
Fuel System
275
Electrical System
285
Troubleshooting
345
Tuning
361
Table of Contents
Troubleshooting
TROUBLESHOOTING
290
TROUBLESHOOTING
294
TROUBLESHOOTING
298
TROUBLESHOOTING
302
TROUBLESHOOTING METHOD
307
TROUBLESHOOTING DETAILS (FAULT CODE)
309
TROUBLESHOOTING
330
TROUBLESHOOTING
345
TROUBLESHOOTING
346
TROUBLESHOOTING OF CLUTCH
349
TROUBLESHOOTING OF TRANSMISSION
351
TROUBLESHOOTING OF COOLING SYSTEM
352
TROUBLESHOOTING OF BRAKE
353
TROUBLESHOOTING OF STEERING/HANDLING
355
TROUBLESHOOTING OF CHARGING SYSTEM
356
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This manual is also suitable for:
Yz250fx 2020
Yz250fxl 1 2020
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