Yamaha YZ250F 2024 Owner's Manual
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Yamaha YZ250F 2024 Owner's Manual

Yamaha YZ250F 2024 Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
USO E MANUTENZIONE
MANUAL DEL PROPIETARIO
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Leggere attentamente questo manuale prima di utilizzare questo veicolo.
Lea este manual atentamente antes de utilizar este vehículo.
2024
YZ250F
YZ250F
YZ250FR
BMF-28199-50

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  • Page 1 2024 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG USO E MANUTENZIONE MANUAL DEL PROPIETARIO YZ250F Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo.
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2024 OWNER’S MANUAL YZ250F Read this manual carefully before operating this vehicle. YZ250F YZ250FR BMF-28199-50-E0...
  • Page 4 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada in addition to notifying Yamaha Motor Canada Ltd, Canada. If Transport Canada receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 5 Declaration of Conformity: Hereby, YAMAHA MOTOR CO., LTD declares that the radio equipment type, Communication Control Unit, T722-A00 is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: https://global.yamaha-motor.com/eu_doc/...
  • Page 6 EAM20080 YZ250F YZ250FR OWNER’S MANUAL ©2024 by Yamaha Motor Co., Ltd. First edition, June 2023 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 7: Important Manual Information

    EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

  • Page 11: General Information

    GENERAL INFORMATION SAFETY INFORMATION..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING: ......1-1 ABOUT THE BATTERY ..................1-4 LITHIUM-ION BATTERY................1-4 LITHIUM-ION BATTERY DEGRADATION ..........1-4 RECYCLING THE BATTERY ..............1-4 LOCATION OF IMPORTANT LABELS ............1-5 DESCRIPTION ....................1-8 IDENTIFICATION .....................1-9 VEHICLE IDENTIFICATION NUMBER ............1-9 ENGINE SERIAL NUMBER.................1-9 INCLUDED PARTS..................1-10 SIDESTAND....................1-10...
  • Page 12 MAINTENANCE AFTER BREAK-IN ..............1-20 MAJOR MAINTENANCE ................1-20 AIR FILTER MAINTENANCE..............1-20 TORQUE-CHECK POINTS................1-21 MOTORCYCLE CARE AND STORAGE ............1-23 CARE ......................1-23 STORAGE....................1-24...

  • Page 13: Safety Information

    Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
  • Page 14 The use of offer other modifications for Yamaha vehicles. a safety helmet is the single most critical factor Yamaha is not in a position to test the products in the prevention or reduction of head injuries. that these aftermarket companies produce.
  • Page 15 SAFETY INFORMATION cause a dangerous loss of lights or engine power. Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance capabilities and to provide the best combina- tion of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate.

  • Page 16: About The Battery

    EAM30643 RECYCLING THE BATTERY Lithium-ion batteries can be recycled. If the ca- pacity decreases excessively due to degrada- tion, have a Yamaha dealer replace the battery. Always follow local regulations regarding the disposal of batteries. For EU countries: According...

  • Page 17: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1, 2, 3 4, 5, 6 7, 8 9, 10, 11 12, 13, 14...
  • Page 18 LOCATION OF IMPORTANT LABELS 4AA-22259-40...
  • Page 19 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF 4AA-22259-40...

  • Page 20: Description

    DESCRIPTION EAM20086 DESCRIPTION 10.Radiator 1. Clutch lever 11.Coolant drain bolt 2. Front brake lever 12.Oil level check window 3. Throttle grip 13.Rear brake pedal 4. Start switch 14.Air filter 5. Radiator cap 6. Fuel tank cap 15.Drive chain 16.Shift pedal 7.

  • Page 21: Identification

    There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.

  • Page 22: Included Parts

    INCLUDED PARTS EAM20088 INCLUDED PARTS EAM30372 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 • Never apply additional force to the sides- tand. • Remove this sidestand before starting out. EAM30007 FUEL HOSE JOINT COVER EAM30005 NIPPLE WRENCH...
  • Page 23 INCLUDED PARTS pression ratio, etc.) have been changed, the performance may not match to the ac- tual settings. COMMUN.CONT.UNIT ASSY. • Do not run the engine with the smartphone carried with you. Otherwise, the smart- phone could be damaged. P/N: S/N: •...
  • Page 24 INCLUDED PARTS If the CCU wireless network cannot be detect- ed, operate the start switch again. 1-12...

  • Page 25: Important Information

    YAMAHA genuine Refer to “CARE” on page 1-23. parts and recommended parts.

  • Page 26: Instrument And Control Functions

    • Indicator light on the handlebar switch (left) flashes orange  Check or replace any faulty electrical part(s). Have a Yamaha dealer check the electrical system. A. Drive mode 1 B. Drive mode 2 3.

  • Page 27: Lap Time Record Mode

     Check or replace any faulty light blinks in blue once every 4 seconds if the electrical part(s). ECU has been activated while the engine is Have a Yamaha dealer check the electrical sys- stopped even if the launch control system is tem. off.

  • Page 28: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS drive mode 2 is selected. 1 1 1 EAM30444 STARTER KNOB Starting a cold engine requires a larger amount EAM30185 SHIFT PEDAL of intake air, which is supplied by the starter The shift pedal “1” has adopted a method of 1 knob “1”.
  • Page 29 INSTRUMENT AND CONTROL FUNCTIONS tank cap “2”. • When installing the sub-seat, make sure that the plastic band is not twisted. • When installing the sub-seat, push down the quick fastener, rotate it, and then secure the sub-seat with the quick fastener. 1-17...

  • Page 30: Starting And Break-In

    10 %. Gaso- hol containing methanol is not recommended Since exhaust gas contains harmful ingredi- by Yamaha because it can cause damage to the ents, do not start or warm it up at an illventi- fuel system or vehicle performance problems.

  • Page 31: Starting A Warm Engine

    STARTING AND BREAK-IN check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour. •...

  • Page 32: Maintenance After Break-In

    Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other • Generator quality foam air filter oil to the element. (Excess Check for looseness in mounted areas of the oil in the element may adversely affect engine generator rotor and the stator coil assembly.

  • Page 33: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to rear fender Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
  • Page 34 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of shroud Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...

  • Page 35: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE especially on spoked wheels. If such prod- EAM20126 MOTORCYCLE CARE AND STOR- ucts are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thorough- ly rinse the area off with water, immediately EAM30200 CARE dry it, and then apply a corrosion protection...

  • Page 36: Storage

    Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
  • Page 37 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-23. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rust- ing and the fuel from deteriorating.
  • Page 38 MOTORCYCLE CARE AND STORAGE 1-26...

  • Page 39: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-4 ELECTRICAL SPECIFICATIONS..............2-7 TIGHTENING TORQUES .................2-8 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-8 ENGINE TIGHTENING TORQUES..............2-9 CHASSIS TIGHTENING TORQUES............2-12...

  • Page 40: General Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BMF1 (CAN) BMF2 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) BMF4 (AUS, NZL, ZAF) BMF6 (CAN) BMF7 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR)

  • Page 41: Engine Specifications

    ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm³ Number of cylinders Single cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 13.8 : 1 Starting system Electric starter Fuel...
  • Page 42 3.846 (50/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Idling condition Engine idling speed 1900–2100 r/min 70–80 C (158–176 F) Coolant temperature Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

  • Page 43: Chassis Specifications

    Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 486.0 cm³ (16.43 US oz, 17.14 Imp.oz) Quantity (right) 486.0 cm³ (16.43 US oz, 17.14 Imp.oz)
  • Page 44 CHASSIS SPECIFICATIONS Adjustment value from the start position 7 (CAN) (STD) 9 (AUS, AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, NZL, POL, PRT, SVK, SVN, SWE, TUR, ZAF) Adjustment value from the start position (Hard) Compression damping Adjusting system...
  • Page 45 CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position 10 (CAN) (STD) 11 (AUS, AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, NZL, POL, PRT, SVK, SVN, SWE, TUR, ZAF)

  • Page 46: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Battery Model BR98 Voltage, capacity 12 V, 2.4 Ah (5 HR) Fuse(s) Main fuse 15.0 A Spare fuse 15.0 A...

  • Page 47: Tightening Torques

    TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 48: Engine Tightening Torques

    TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Oil passage plug (cylinder head) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head bolt...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Intake air temperature sensor screw 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft)  Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft)

  • Page 51: Chassis Tightening Torques

    TIGHTENING TORQUES EAM30204 CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft)
  • Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Bolt (drive chain support) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Fuel tank bolt (front side) 8 N·m (0.8 kgf·m, 5.9 lb·ft) ...
  • Page 54 TIGHTENING TORQUES 2-15...
  • Page 55 PERIODIC CHECKS AND ADJUSTMENTS SERVICING PARTS..................3-1 MAINTENANCE INTERVALS ................3-2 MAINTENANCE INTERVALS ..............3-2 PRE-OPERATION INSPECTION AND MAINTENANCE.........3-6 GENERAL INSPECTION AND MAINTENANCE..........3-6 ENGINE ......................3-7 ADJUSTING THE VALVE CLEARANCE............3-7 CHECKING THE ENGINE IDLING SPEED..........3-8 CHECKING THE THROTTLE GRIP ............3-8 CHECKING THE SPARK PLUG..............3-9 CHECKING THE ENGINE OIL LEVEL............3-9 CHANGING THE ENGINE OIL..............3-10 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-11...
  • Page 56 CHECKING THE CHASSIS FASTENERS ..........3-31 CHECKING AND LUBRICATING THE CABLES ........3-31 LUBRICATING THE BRAKE LEVER ............3-31 LUBRICATING THE CLUTCH LEVER............3-31 LUBRICATING THE PEDAL..............3-31 ELECTRICAL SYSTEM..................3-32 CHECKING AND CHARGING THE BATTERY..........3-32 CHECKING THE FUSES................3-32...
  • Page 57 * For AUS, AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, NZL, POL, PRT, SVK, SVN, SWE, TUR, ZAF ** For CAN The part number is subject to change. In that case, order the part from a Yamaha dealer by stating the identification number of your vehicle.

  • Page 58: Maintenance Intervals

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 59 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check the coolant passages for corrosion. • Inspect carbon deposits and  11 * Cylinder head eliminate them.
  • Page 60 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   • Clean.   • Inspect and adjust.   • Replace oil. 30 * Front fork leg(s) ...
  • Page 61 MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours)   Brake pedal, footrest • Lubricate. Outside nuts and • Retighten.   44 * bolts •...

  • Page 62: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 63: Engine

    “b” on the crankcase cover. • This section is intended for those who have basic knowledge and skill concerning the ser- vicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning ser-...

  • Page 64: Checking The Engine Idling Speed

    1. Start the engine, and warm this up until the oil has reached the specified temperature. 2. Measure the coolant temperature using the Yamaha diagnostic tool. EAM30475 Yamaha diagnostic tool USB CHECKING THE THROTTLE GRIP 90890-03274 Yamaha diagnostic tool (A/I) Prior to adjusting throttle grip free play, the en- 90890-03273 gine idling speed should be adjusted.

  • Page 65: Checking The Spark Plug

    ENGINE 4. Check: • Electrode “1” Damage/wear  Replace the spark plug. • Insulator “2” Abnormal color  Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or a wire brush) 6.

  • Page 66: Changing The Engine Oil

    ENGINE minimum level mark “a” and maximum level 2. Place an oil pan under the drain bolt. mark “b”. 3. Remove: Below the minimum level mark  Add the • Oil filler cap “1” recommended engine oil to the proper level. •...

  • Page 67: Adjusting The Clutch Lever Free Play

    ENGINE c. Replace the new O-ring “2”. EWA19120 When the engine is started with the check bolt removed, oil will spout; therefore, al- ways loosen it before the checkup. 1 1 1 d. Install the oil strainer. Oil strainer bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) b.

  • Page 68: Adjusting The Clutch Lever Position

    ENGINE EAM30370 ADJUSTING THE CLUTCH LEVER POSITION 1. Adjust: • Clutch lever position “a” Loosen the locknut “1” and use the adjuster “2” to adjust the clutch lever position “a” as desired. 2. Adjust: • Clutch lever free play Handlebar side a.
  • Page 69 • Seal “3” Damage  Replace. (from the air filter element) 5. Apply: • Yamaha foam air filter oil or other quality To remove the air filter element: foam air filter oil • Release the band “a” from the projection “b”, a.

  • Page 70: Checking The Throttle Body Joint

    ENGINE (to the air filter case cover) • To install the air filter case cover: • Insert the projection “a” on air filter case cov- er to the hole “b” in the air filter case “3”. • Push the rear side of the air filter case cover to hook the ribs “c”...

  • Page 71: Checking The Fuel Line

    ENGINE EAM30222 EAM30221 CHECKING THE FUEL LINE CHECKING THE EXHAUST SYSTEM 1. Remove: 1. Remove: • Seat • Exhaust pipe 1 • Side cover (left/right) • Exhaust pipe 2 • Shroud (left/right) Refer to “EXHAUST SYSTEM” on page 5-1. • Fuel tank 2.
  • Page 72 ENGINE f. Install the silencer body “8” and bolts “9”. Silencer body bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® Apply heat-resistant sealant to the areas “d” shown, making sure that there are no gaps in the beads of sealant. b.

  • Page 73: Checking The Coolant Level

    ENGINE 7. Check: • Tightening torques Exhaust pipe nut “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe clamp bolt “2” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Exhaust pipe clamp bolt “3” 12 N·m (1.2 kgf·m, 8.9 lb·ft) Silencer bolt (rear) “4” 30 N·m (3.0 kgf·m, 22 lb·ft) j.

  • Page 74: Checking The Cooling System

    ENGINE ator cap and turn it counterclockwise to re- • Side cover (left/right) move. • Shroud (left/right) 2. Check: 1. Stand the vehicle upright on a level surface. • Radiator 2. Remove: • Radiator hose • Radiator cap “1” Crack/damage  Replace. 3.
  • Page 75 ENGINE 5. Install: • Copper washer • Coolant drain bolt Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti- freeze containing anti-corrosion for aluminum engine Radiator (including all routes) 0.94 L (0.99 US qt, 0.83 Imp.qt) Coolant mixing ratio 1:1 (Coolant:Water) EWA13040...

  • Page 76: Chassis

    CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.

  • Page 77: Checking The Front Brake Pads

    CHASSIS Add. Specified brake fluid DOT 4 EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. A. Front brake 2. Check: B. Rear brake • Rear brake pad Wear indicator grooves “1” almost touch the EWA13090 brake disc ...

  • Page 78: Checking The Rear Brake Hose

    CHASSIS the reservoir to overflow. • Make sure that there is enough brake fluid be- fore applying the brake. Ignoring this precau- tion could allow air to enter the brake system, considerably lengthening the bleeding proce- dure. a a a •...

  • Page 79: Drive Chain Slack

    CHASSIS h. Repeat steps (d) to (g) until all of the air bubbles have disappeared from the brake Measure drive chain slack between the drive fluid in the plastic hose. chain guide and the bottom of the chain as shown. During the procedure, keep adding brake fluid to the reservoir.

  • Page 80: Checking And Adjusting The Steering Head

    CHASSIS Drive chain puller locknut 21 N·m (2.1 kgf·m, 15 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front wheel off the ground. EWA13120 Securely support the vehicle so that there is no danger of it falling over.

  • Page 81: Lubricating The Steering Head

    Unsmooth operation  Correct or replace. Refer to “FRONT FORK” on page 4-15. If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 5. Check: • Protector guide “1”...

  • Page 82: Adjusting The Front Fork Legs

    CHASSIS EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 • Always adjust the left and right front forks evenly. If this is not done, the vehicle may have poor stability. • Securely support the vehicle so that there is no danger of it falling over. Rebound damping ECA24340 Compression damping...

  • Page 83: Checking The Rear Shock Absorber Assembly

    CHASSIS 3. Check: • Rear shock absorber assembly smooth ac- tion • Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly. Unsmooth operation ...
  • Page 84 CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 30 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 10 click(s) in direction “b”* (CAN) Standard 9 click(s) in direction “b”* (AUS, Position in which the spring is AUT, BEL, CHE, CYP, CZE, DEU, turned in 5.0 mm (0.20 in) from...

  • Page 85: Checking The Swingarm Operation

    CHASSIS Direction “a” Direction “a” Compression damping is increased Compression damping is increased (suspension is harder). (suspension is harder). Direction “b” Direction “b” Compression damping is decreased Compression damping is decreased (suspension is softer). (suspension is softer). Fast compression damping Slow compression damping Minimum (soft) Minimum (soft)

  • Page 86: Checking The Tires

    CHASSIS • Collar Recommended lubricant Lithium-soap-based grease EAM30243 CHECKING THE TIRES 1. Measure: • Tire pressure Out of specification  Regulate. Tire air pressure (measured on cold tires) A tight spoke will emit a clear, ringing tone; a Front loose spoke will sound flat. 100 kPa (1.00 kgf/cm², 15 psi) Rear 2.

  • Page 87: Lubricating The Pedal

    CHASSIS wheel. EAM30250 LUBRICATING THE PEDAL 1. Lubricate the pivoting point and metal-to- EAM30253 metal moving parts of the pedal. CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are Recommended lubricant properly tightened. Lithium-soap-based grease Refer to “CHASSIS TIGHTENING TORQUES” on page 2-12.

  • Page 88: Electrical System

    ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-1. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 7-1. 3-32...
  • Page 89 CHASSIS GENERAL CHASSIS ..................4-1 REMOVING THE SEAT................4-1 REMOVING THE NUMBER PLATE ............4-1 INSTALLING THE SHROUD ...............4-1 REMOVING THE SIDE COVER..............4-2 INSTALLING THE SIDE COVER ..............4-2 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL ..............4-3 INSTALLING THE FRONT WHEEL .............4-3 REAR WHEEL ....................4-4 REMOVING THE REAR WHEEL ..............4-4 CHECKING AND REPLACING THE REAR WHEEL SPROCKET....4-4 INSTALLING THE REAR WHEEL ...............4-4...
  • Page 90 CHAIN DRIVE....................4-30 REMOVING THE DRIVE CHAIN ...............4-30 CHECKING THE DRIVE CHAIN..............4-30 CHECKING THE DRIVE SPROCKET............4-31 CHECKING THE REAR WHEEL SPROCKET ...........4-31 INSTALLING THE DRIVE CHAIN..............4-31...

  • Page 91: General Chassis

    GENERAL CHASSIS EAM20094 GENERAL CHASSIS 2 2 2 EAM30016 REMOVING THE SEAT The sub-seat and the seat are coupled with each other with a plastic band. When removing the seat, always remove the a a a sub-seat beforehand. 1. Remove: •...

  • Page 92: Removing The Side Cover

    GENERAL CHASSIS EAM30459 REMOVING THE SIDE COVER 1. Remove: • Side cover (right) “1” Remove the side cover (right) from the vehicle by removing the bolts and sliding it as shown. 1 1 1 a. Projection b. Slot EAM30460 INSTALLING THE SIDE COVER 1.

  • Page 93: Front Wheel

    FRONT WHEEL EAM20095 ECA24430 FRONT WHEEL Before tightening the front wheel axle nut, EAM30017 push down hard on the handlebar(s) several REMOVING THE FRONT WHEEL times and check if the front fork rebounds 1. Use a maintenance stand to raise the front smoothly.

  • Page 94: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL EAM30022 REMOVING THE REAR WHEEL 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Remove: b.
  • Page 95 REAR WHEEL drive chain. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-23. 3. Install: • Drive chain puller (left) “1” • Rear wheel axle “2” • Install the drive chain puller (left), and insert the 6.

  • Page 96: Front Brake

    FRONT BRAKE EAM20097 FRONT BRAKE EAM30519 REPLACING THE FRONT BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1. Remove: • Brake pad 3. Install: a. Remove the pad pin plug “1”. •...
  • Page 97 FRONT BRAKE Front brake caliper bolt 28 N·m (2.8 kgf·m, 21 lb·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) f. Install the pad pin plug “6”. Pad pin plug 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 98: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Brake pad lining thickness limit 1.0 mm (0.04 in) EAM30523 REPLACING THE REAR BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1.
  • Page 99 REAR BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. e. Install the brake caliper “5” and the rear wheel “6”. f. Tighten the pad pin “7”. Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) g. Install the pad pin plug “8” and the protector “9”.

  • Page 100: Handlebar

    HANDLEBAR EAM20099 EAM30054 HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. EAM30052 EWA13120 REMOVING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over. 2.
  • Page 101 HANDLEBAR A. Routing when installing the damper and lower handlebar in the rear holes B. Routing when installing the damper and lower handlebar in the front holes 3. Tighten: • Lower handlebar holder nut Lower handlebar holder nut 40 N·m (4.0 kgf·m, 30 lb·ft) 4.
  • Page 102 HANDLEBAR a a a 168 mm (6.61 in) 5. Install: 7. Install: • Handlebar switch (left) “1” • Clutch cable “1” • Clamp “2” Before installation, apply the lithium-soap- Handlebar switch (left) based grease to the clutch cable end. 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) •...
  • Page 103 HANDLEBAR 12.Install: • Throttle cable housing “1” • Screw (throttle cable housing) “2” Screw (throttle cable housing) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) EWA19310 After tightening the throttle cable housing screws, check that the throttle grip “3” 10.Install: moves smoothly. If it does not, retighten the •...
  • Page 104 HANDLEBAR Refer to “CHECKING THE THROTTLE GRIP” on page 3-8. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 14.Install: • Start switch “1” • Front brake master cylinder assembly “2” • Front brake master cylinder holder “3” • Front brake master cylinder holder bolt “4” •...

  • Page 105: Front Fork

    FRONT FORK cap bolt ring wrench “4” between the inner EAM20100 FRONT FORK tube and locknut “3”. • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS ECA24520 1. Use a maintenance stand to raise the front wheel off the ground.

  • Page 106: Checking The Front Fork Legs

    FRONT FORK Inner tube bending limit 0.2 mm (0.01 in) The bending value is shown by one half of the dial gauge reading. EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 5. Remove: 2.

  • Page 107: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil 6. Check: Yamaha Suspension Oil S1 • Upper spring seat “1” Standard oil amount 216 cm³ (7.30 US oz, 7.62 (contacting surface “a”) Imp.oz) Wear/damage ...
  • Page 108 FRONT FORK case, repeat the steps (1) to (3). 6. Install: • Base valve “1” 4. Measure: (to the damper assembly “2”) • Oil level (left and right) “a” Out of specification  Regulate. First bring the damper rod pressure to a maxi- mum.
  • Page 109 FRONT FORK 9. After filling, pump the damper assembly “1” 12.Check: slowly up and down more than 10 times to • Damper assembly smooth movement Tightness/binding/rough spots  Repeat distribute the fork oil. the steps (1) to (12). 10.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- 13.Install: cessive oil to overflow on the base valve...
  • Page 110 FRONT FORK 14.Install: • Piston metal “1” Install the piston metal onto the slot on inner tube. 17.Install: • Oil seal “1” Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. 15.Install: Fork seal driver •...
  • Page 111 FRONT FORK 19.Install: 22.Install: • Dust seal “1” • Upper spring seat “1” • Fork spring “2” (to the damper assembly “3”) Apply lithium-soap-based grease on the inner tube. Install the upper spring seat with its larger dia. end “a” facing the fork spring. 20.Check: •...
  • Page 112 FRONT FORK • Unless the damping force adjuster is fully correct damping force cannot be obtained. loosened, correct damping characteristic can- not be obtained after installation. 27.Tighten: • Adjuster (damper assembly) “1” 25.Install: Adjuster (damper assembly) • Damper adjusting rod “1” 29 N·m (2.9 kgf·m, 21 lb·ft) •...

  • Page 113: Installing The Front Fork Legs

    FRONT FORK Recommended oil Yamaha Suspension Oil S1 Standard oil amount 280 cm³ (9.47 US oz, 9.88 Imp.oz) Extent of adjustment 260–365 cm³ (8.79–12.34 US oz, 9.17–12.87 Imp.oz) ECA24570 • Be sure to use the recommended oil. Other EAM30059 INSTALLING THE FRONT FORK LEGS oils may have an adverse effect on front 1.
  • Page 114 FRONT FORK • Front fork protector bolt “2” Front fork protector bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3. Adjust: • Front fork top end “a” Front fork top end (standard) “a” 5 mm (0.2 in) 6. Adjust: • Rebound damping force Turn in the damping adjuster “1”...

  • Page 115: Steering Head

    STEERING HEAD c. Install a new bearing race. EAM20101 STEERING HEAD ECA14270 EAM30060 If the bearing race is not installed properly, REMOVING THE LOWER BRACKET the steering head pipe could be damaged. 1. Use a maintenance stand to raise the front wheel off the ground.
  • Page 116 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 117 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...

  • Page 118: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Gas leaks/oil leaks  Replace the rear shock EAM20102 REAR SHOCK ABSORBER AS- absorber assembly. SEMBLY • Spring Damage/wear  Replace. • Spring guide EAM30065 REMOVING THE REAR SHOCK ABSORBER Damage/wear  Replace. ASSEMBLY • Bearing 1.

  • Page 119: Swingarm

    SWINGARM EAM20103 SWINGARM EAM30071 REMOVING THE SWINGARM 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...

  • Page 120: Chain Drive

    CHAIN DRIVE (length “a” between pin inner sides + EAM20104 CHAIN DRIVE length “b” between pin outer sides)/2 EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 Securely support the vehicle so that there is no danger of it falling over.

  • Page 121: Checking The Drive Sprocket

    CHAIN DRIVE Damage/wear  Replace the drive chain. G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a”  Replace the drive sprocket and the rear wheel sprocket G089070 as a set.
  • Page 122 CHAIN DRIVE Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) ECA24590 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its.
  • Page 123 ENGINE EXHAUST SYSTEM ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER ........5-1 CLUTCH ......................5-3 REMOVING THE CLUTCH .................5-3 CHECKING THE FRICTION PLATES ............5-3 CHECKING THE CLUTCH PLATES ............5-3 CHECKING THE CLUTCH SPRINGS ............5-3 CHECKING THE CLUTCH HOUSING ............5-3 CHECKING THE CLUTCH BOSS...............5-4 CHECKING THE PRESSURE PLATE ............5-4 CHECKING THE PUSH LEVER SHAFT............5-4 CHECKING THE PUSH RODS ..............5-4...

  • Page 124: Exhaust System

    EXHAUST SYSTEM EAM20199 EXHAUST SYSTEM 2 mm (0.08 in) EAM30167 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket • Exhaust pipe 1 “1” • Nut (exhaust pipe 1) “2” 3. Install: Nut (exhaust pipe 1) • Clamp 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
  • Page 125 EXHAUST SYSTEM joints are inserted in position. • Make sure that the exhaust pipe clamp “1” does not ride on the projection “a” on the ex- haust pipe “2” or silencer “3”. Be sure to insert the projection “b” into the slot in the exhaust pipe (or silencer).

  • Page 126: Clutch

    CLUTCH EAM20111 CLUTCH Friction plate thickness 2.70–2.90 mm (0.106–0.114 in) Wear limit EAM30108 REMOVING THE CLUTCH 2.60 mm (0.102 in) 1. Straighten the clutch boss nut rib “a”. EAM30110 CHECKING THE CLUTCH PLATES 1. Check: • Clutch plate Damage  Replace the clutch plates as a set.

  • Page 127: Checking The Clutch Boss

    CLUTCH EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. EAM30113 CHECKING THE CLUTCH BOSS 1 1 1 1. Check: • Clutch boss splines Damage/pitting/wear ...
  • Page 128 CLUTCH • Washer “4” Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 5. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
  • Page 129 CLUTCH a a a 1 1 1 7. Install: • Bearing “1” • Washer “2” • Circlip “3” (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 6. Install: • Friction plate “1” •...
  • Page 130 CLUTCH a a a 10.Install: • Clutch spring • Clutch spring bolt Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 11.Install: • Gasket “1” 12.Install: • Clutch cover • Clutch cover bolt Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross...

  • Page 131: Fuel System

    FUEL SYSTEM FUEL TANK ......................6-1 REMOVING THE FUEL TANK ..............6-1 INSTALLING THE FUEL TANK ..............6-1...

  • Page 132: Removing The Fuel Tank

    FUEL TANK EAM20140 FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Seat • Side cover (left/right) • Shroud (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 3.
  • Page 133 FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Shroud (left/right) • Side cover (left/right) • Seat Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 134 FUEL TANK...
  • Page 135 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ................7-1 CHECKING THE FUSES................7-1 CHECKING AND CHARGING THE BATTERY..........7-1...

  • Page 136: Electrical Components

    If the fuse immediately blows again, have battery. Otherwise, the battery or charger a Yamaha dealer check the electrical sys- could be damaged. tem. • Be careful not to drop the battery or subject Amperage it to strong impacts.
  • Page 137 • Seat When replacing the battery, be sure to use a Refer to “GENERAL CHASSIS” on page 4-1. Yamaha genuine lithium-ion battery. 2. Disconnect: • Battery lead (from the battery terminals) Do not check the battery at high temperature of 65 C (149 F) or more or low temperatures be-...
  • Page 138 ELECTRICAL COMPONENTS d. If the battery is hot, wait until the battery has cooled down to the ambient temper- ature. e. Measure the voltage between the battery terminals. 13.25 V or more  The battery is normal. Checking is finished. 10 V or more and less than 13.25 V ...

  • Page 139: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION .................8-1 TROUBLESHOOTING OF ENGINE (fault code not detected) ....8-1 TROUBLESHOOTING OF CLUTCH ............8-4 TROUBLESHOOTING OF TRANSMISSION..........8-6 TROUBLESHOOTING OF COOLING SYSTEM..........8-7 TROUBLESHOOTING OF BRAKE..............8-8 TROUBLESHOOTING OF SUSPENSION...........8-8 TROUBLESHOOTING OF STEERING/HANDLING........8-10 TROUBLESHOOTING OF CHARGING SYSTEM ........8-11...

  • Page 140: Troubleshooting

    • The following guide for troubleshooting represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the mo- torcycle properly.
  • Page 141 Low fuel pressure Clogged fuel pump Clean or replace the fuel pump. Cracks or damage in fuel pump Replace the fuel pump. Have a Yamaha dealer check the Fuel pump malfunction electrical system. Failed or clogged fuel injector Replace the fuel injector.
  • Page 142 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.

  • Page 143: Troubleshooting Of Clutch

    TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
  • Page 144 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 145: Troubleshooting Of Transmission

    TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.

  • Page 146: Troubleshooting Of Cooling System

    TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head Clean the piston head and com- and combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Adjust the oil level to the specified Incorrect oil level level.

  • Page 147: Troubleshooting Of Brake

    TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
  • Page 148 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...

  • Page 149: Troubleshooting Of Steering/Handling

    TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.

  • Page 150: Troubleshooting Of Charging System

    Replace the swingarm bearing. Damaged or worn swingarm bear- Replace the swingarm bearing or ing or bushing bushing. EAM30516 TROUBLESHOOTING OF CHARGING SYSTEM Symptom Possible cause Actions Battery is not charged Have a Yamaha dealer check the electrical system. 8-11...

  • Page 151: Tuning

    TUNING CHASSIS ......................9-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ..9-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ......9-1 TIRE PRESSURE ..................9-1 FRONT FORK SETTING ................9-2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ....9-2 SETTING OF SPRING AFTER REPLACEMENT .........9-2 FRONT FORK SETTING PARTS..............9-3 REAR SUSPENSION SETTING ..............9-3 CHOOSING SET LENGTH................9-3...

  • Page 152: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) B2W-25449-00 Secondary reduction ratio = Number of (STD) B2W-25450-00 rear wheel sprocket teeth/Number of B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.846 (50/13)

  • Page 153: Front Fork Setting

    (in position etc.) Recommended oil when setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.

  • Page 154: Front Fork Setting Parts

    CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring STD Spring rate N/mm 2.

  • Page 155: Setting Of Spring After Replacement

    CHASSIS EAM30177 EAM30178 SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS REPLACEMENT • Rear shock spring “1” After replacement, be sure to adjust the spring STD Spring rate to the set length [sunken length 90–100 mm N/mm (3.5–3.9 in)] and set it. Spring 1.

  • Page 156: Suspension Setting (Front Fork)

    CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 157: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend- ing to lower front ...
  • Page 158 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.

  • Page 159: Wiring Diagram

    EAM20149 EAM30323 WIRING DIAGRAM COLOR CODE Black YZ250F/YZ250FR 2024 Brown 1. Crankshaft position sensor Dark blue 2. AC magneto Green 3. Rectifier/regulator Gray 4. Engine ground Blue 5. Frame ground Pink 6. Battery 7. Fuse Sky blue 8. Starter relay White 9.
  • Page 160 PRINTED IN JAPAN...
  • Page 162 Original instructions Notice originale Originalbetriebsanleitung Istruzioni originali Manual original PRINTED IN JAPAN 2023.07-0.9×1 ! (E, F, G, H, S)
  • Page 163 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
  • Page 164 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 YZ250F/YZ250FR 2024 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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