Yamaha YZ250FXH 2017 Manuals

Manuals and User Guides for Yamaha YZ250FXH 2017. We have 3 Yamaha YZ250FXH 2017 manuals available for free PDF download: Owner's Service Manual, User Manual

Yamaha YZ250FXH 2017 User Manual

Yamaha YZ250FX 2017, YZ250FXH 2017 Manual

Brand: Yamaha | Category: Motorcycle | Size: 2 MB

Table of Contents

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Yamaha YZ250FXH 2017 Owner's Service Manual

Yamaha YZ250FXH 2017 Owner's Service Manual (414 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13 MB

Table of Contents

Table of Contens

11
- Important Manual Information
  6
- Safety Information
  7
- How to Use this Manual
  8
- Table of Contents
  11
- General Information
  13
- Location of Important Labels
  15
- Description
  18
- Identification
  19
- Vehicle Identification Number
  19
- Engine Serial Number
  19
- Handlebar Protector
  20
- Fuel Hose Joint Cover
  20
- Coupler for Connecting Optional Part
  20
- Nipple Wrench
  20
- Spark Plug Wrench
  20
- Included Parts
  20
- Important Information
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Gaskets, Oil Seals and O-Rings
  22
- Lock Washers/Plates and Cotter Pins
  22
- Bearings and Oil Seals
  22
- Circlips
  22
- Basic Service Information
  23
- Electrical System
  23
- Special Tools
  27
- Start Switch
  33
- Clutch Lever
  33
- Control Functions
  33
- Warning Lights
  33
- Engine Stop Switch
  33
- Shift Pedal
  34
- Throttle Grip
  34
- Front Brake Lever
  34
- Rear Brake Pedal
  34
- Sidestand
  34
- Starter Knob/Idle Adjusting Screw
  34
- Fuel Tank Cap
  35
- Air Filter Maintenance
  36
- Starting a Cold Engine
  36
- Fuel
  36
- Handling Note
  36
- Starting and Break-In
  36
- Starting a Warm Engine
  37
- Break-In Procedures
  37
- Maintenance after Break-In
  38
- Major Maintenance
  38
- Torque-Check Points
  39
- Motorcycle Care and Storage
  41
- Care
  41
- Storage
  42
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  52
- Electrical Specifications
  55
- General Tightening Torque Specifications
  57
- Tightening Torques
  57
- Engine Tightening Torques
  58
- Chassis Tightening Torques
  61
- Engine
  64
- Lubrication Points and Lubricant Types
  64
- Chassis
  65
- Lubrication Diagrams
  68
- Lubrication System Chart and Diagrams
  68
- Cable Routing Diagram
  76
Periodic Checks and Adjustments

91
- Maintenance Intervals
  93
- General Inspection and Maintenance
  99
- Pre-Operation Inspection and Maintenance
  99
- Changing the Coolant
  100
- Checking the Coolant Level
  100
- Checking the Cooling System
  100
- Engine
  100
- Checking the Radiator Cap
  101
- Checking the Radiator Cap Valve Opening Pressure
  101
- Adjusting the Clutch Lever Free Play
  102
- Checking the Coolant Circulatory System for Leaks
  102
- Adjusting the Throttle Grip Free Play
  103
- Lubricating the Throttle Cable
  103
- Cleaning the Air Filter Element
  104
- Checking the Breather Hoses
  105
- Checking the Exhaust System
  105
- Checking the Throttle Body Joint
  105
- Checking the Engine Oil Level
  106
- Checking the Fuel Line
  106
- Changing the Engine Oil
  107
- Adjusting the Engine Idling Speed
  108
- Adjusting the Valve Clearance
  109
- Bleeding the Brake System
  114
- Chassis
  114
- Adjusting the Front Brake
  115
- Checking the Brake Hose
  115
- Adjusting the Rear Brake
  116
- Checking the Front Brake Pads
  116
- Checking the Rear Brake Pads
  118
- Checking the Brake Fluid Level
  119
- Checking the Rear Brake Pad Insulator
  119
- Adjusting the Drive Chain Slack
  120
- Air Bleeding from Front Fork
  121
- Checking the Front Fork Legs
  121
- Checking the Front Fork Protector Guide
  121
- Cleaning the Front Fork Oil Seal and Dust Seal
  121
- Adjusting the Front Fork Legs
  122
- Adjusting the Rear Shock Absorber Assembly
  123
- Checking the Rear Suspension
  123
- Checking the Swingarm Operation
  123
- Checking and Tightening the Spokes
  125
- Checking the Tires
  125
- Checking and Adjusting the Steering Head
  126
- Checking the Wheel Bearings
  126
- Checking the Wheels
  126
- Checking and Lubricating the Cables
  127
- Lubricating the Drive Chain
  127
- Lubricating the Levers
  127
- Lubricating the Pedal
  127
- Checking the Chassis Fasteners
  128
- Lubricating the Sidestand
  128
- Checking the Ignition Timing
  129
- Checking the Spark Plug
  129
- Electrical System
  129
- Checking and Charging the Battery
  130
Chassis

131
- General Chassis
  133
- Removing the Left Side Cover
  134
- Removing the Number Plate
  134
- Removing the Seat
  134
- Front Wheel
  135
- Checking the Front Wheel
  136
- Removing the Front Wheel
  136
- Assembling the Front Wheel
  137
- Disassembling the Front Wheel
  137
- Installing the Front Wheel
  138
- Rear Wheel
  139
- Checking and Replacing the Rear Wheel Sprocket
  140
- Checking the Rear Wheel
  140
- Disassembling the Rear Wheel
  140
- Removing the Rear Wheel
  140
- Assembling the Rear Wheel
  141
- Installing the Rear Wheel
  141
- Front Brake
  143
- Checking the Front Brake Disc
  147
- Disassembling the Front Brake Caliper
  147
- Introduction
  147
- Removing the Front Brake Caliper
  147
- Assembling the Front Brake Caliper
  148
- Checking the Front Brake Caliper
  148
- Installing the Brake Caliper Piston
  148
- Installing the Front Brake Caliper
  149
- Assembling the Front Brake Master Cylinder
  150
- Checking the Front Brake Master Cylinder
  150
- Removing the Front Brake Master Cylinder
  150
- Installing the Front Brake Master Cylinder
  151
- Rear Brake
  153
- Checking the Rear Brake Disc
  157
- Introduction
  157
- Assembling the Rear Brake Caliper
  158
- Checking the Rear Brake Caliper
  158
- Disassembling the Rear Brake Caliper
  158
- Removing the Rear Brake Caliper
  158
- Installing the Brake Caliper Piston
  159
- Installing the Rear Brake Caliper
  159
- Checking the Rear Brake Master Cylinder
  160
- Removing the Rear Brake Master Cylinder
  160
- Assembling the Rear Brake Master Cylinder
  161
- Installing the Rear Brake Master Cylinder
  161
- Checking the Handlebar
  165
- Handlebar
  165
- Installing the Handlebar
  165
- Removing the Handlebar
  165
- Front Fork
  170
- Disassembling the Front Fork Legs
  172
- Removing the Front Fork Legs
  172
- Checking the Front Fork Legs
  173
- Assembling the Front Fork Legs
  174
- Installing the Front Fork Legs
  181
- Steering Head
  183
- Checking the Steering Head
  185
- Installing the Steering Head
  185
- Removing the Lower Bracket
  185
- Rear Shock Absorber Assembly
  188
- Disposing of a Rear Shock Absorber
  191
- Handling the Rear Shock Absorber
  191
- Removing the Bearing
  191
- Removing the Rear Shock Absorber Assembly
  191
- Checking the Connecting Arm and Relay Arm
  192
- Checking the Rear Shock Absorber Assembly
  192
- Installing the Relay Arm
  192
- Installing the Rear Shock Absorber Assembly
  193
- Swingarm
  195
- Checking the Swingarm
  196
- Removing the Bearing
  196
- Removing the Swingarm
  196
- Installing the Swingarm
  197
- Chain Drive
  198
- Checking the Drive Chain
  199
- Removing the Drive Chain
  199
- Checking the Drive Sprocket
  200
- Checking the Rear Wheel Sprocket
  200
- Installing the Drive Chain
  200
Engine

203
- Engine Removal
  206
- Removing the Drive Sprocket
  211
- Removing the Exhaust Pipe 2
  211
- Removing the Silencer
  211
- Changing the Silencer Fiber
  212
- Checking the Silencer and Exhaust Pipe
  212
- Removing the Engine
  212
- Installing the Engine
  213
- Installing the Brake Pedal
  214
- Installing the Drive Sprocket
  214
- Installing the Exhaust Pipe and Muffler
  215
- Camshaft
  217
- Removing the Camshaft
  219
- Checking the Camshaft
  220
- Checking the Timing Chain and Camshaft Sprocket
  221
- Checking the Timing Chain Tensioners
  221
- Checking the Decompression System
  222
- Installing the Camshafts
  222
- Cylinder Head
  224
- Checking the Cylinder Head
  226
- Checking the Timing Chain Guide (Intake Side)
  226
- Removing the Cylinder Head
  226
- Installing the Cylinder Head
  227
- Valves and Valve Springs
  228
- Removing the Valves
  229
- Checking the Valves and Valve Guides
  230
- Checking the Valve Seats
  231
- Checking the Valve Springs
  233
- Checking the Valve Lifters
  234
- Installing the Valves
  234
- Cylinder and Piston
  236
- Checking the Cylinder and Piston
  237
- Removing the Piston
  237
- Checking the Piston Rings
  238
- Checking the Piston Pin
  239
- Installing the Piston and Cylinder
  239
- Electric Starter
  241
- Checking the Starter Motor
  243
- Assembling the Starter Motor
  244
- Checking the Clutch Plates
  249
- Checking the Clutch Springs
  249
- Checking the Friction Plates
  249
- Clutch
  249
- Removing the Clutch
  249
- Checking the Clutch Boss
  250
- Checking the Clutch Housing
  250
- Checking the Clutch Push Rods
  250
- Checking the Pressure Plate
  250
- Checking the Primary Drive Gear
  250
- Checking the Push Lever Shaft
  250
- Checking the Primary Driven Gear
  251
- Installing the Oil Seal
  251
- Installing the Right Crankcase Cover
  251
- Installing the Clutch
  252
- Shift Shaft
  255
- Checking the Shift Guide and Shift Lever Assembly
  257
- Checking the Shift Shaft
  257
- Checking the Stopper Lever
  257
- Removing the Segment
  257
- Removing the Shift Guide and Shift Lever Assembly
  257
- Installing the Segment
  258
- Installing the Shift Guide and Shift Lever Assembly
  258
- Installing the Stopper Lever
  258
- Installing the Shift Pedal
  259
- Installing the Shift Shaft
  259
- Oil Pump and Balancer Gear
  260
- Checking the Balancer
  262
- Checking the Oil Pump
  262
- Checking the Primary Drive Gear, Balancer Drive Gear, and Balancer Weight Gear
  262
- Removing the Balancer
  262
- Assembling the Oil Pump
  263
- Installing the Oil Pump and Balancer Gear
  264
- Generator and Starter Clutch
  266
- Checking the Starter Clutch
  268
- Removing the Generator
  268
- Installing the Generator
  269
- Installing the Starter Clutch
  269
- Crankcase
  273
- Checking the Crankcase
  275
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  275
- Disassembling the Crankcase
  275
- Removing the Crankcase Bearing
  275
- Assembling the Crankcase
  276
- Installing the Oil Seal
  276
- Crankshaft Assembly and Balancer Shaft
  278
- Checking the Crankshaft Assembly
  279
- Removing the Crankshaft Assembly
  279
- Installing the Balancer Shaft
  280
- Installing the Crankshaft Assembly
  280
- Checking the Shift Forks
  282
- Removing the Transmission
  282
- Transmission
  282
- Checking the Shift Drum Assembly
  283
- Checking the Transmission
  283
- Installing the Transmission
  283
- Cooling System
  287
  - Water Pump
    291
Fuel System

295
- Fuel Tank
  296
- Checking the Fuel Pump Body
  298
- Installing the Fuel Pump
  298
- Removing the Fuel Pump
  298
- Removing the Fuel Tank
  298
- Checking the Fuel Sender
  299
- Installing the Fuel Sender
  299
- Installing the Fuel Tank
  299
- Removing the Fuel Sender
  299
- Checking the Damper
  300
- Checking the Fuel Pressure
  300
- Checking and Replacing the Protector
  301
- Throttle Body
  302
- Checking the Injector
  305
- Checking the Throttle Body
  305
- Checking the Throttle Body Joint
  305
- Adjusting the Throttle Position Sensor
  306
Electrical System

307
- Circuit Diagram
  310
- Ignition System
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Electric Starting System
  314
- Starting Circuit Cut-Off System Operation
  316
- Troubleshooting
  318
- Charging System
  320
- Circuit Diagram
  320
- Troubleshooting
  322
- Circuit Diagram
  324
- Signaling System
  324
- Troubleshooting
  326
- Circuit Diagram
  328
- COOLING SYSTEM (for JPN)
  328
- Troubleshooting
  330
- Circuit Diagram
  332
- Fuel Injection System
  332
- Ecu Self-Diagnostic Function
  334
- Troubleshooting Method
  335
- Yamaha Diagnostic Tool
  336
- Troubleshooting Details
  339
- Circuit Diagram
  360
- Fuel Pump System
  360
- Troubleshooting
  362
- Electrical Components
  364
- Checking the Switches
  368
- Checking the Bulbs and Bulb Sockets
  371
- Checking the Fuses
  371
- Checking and Charging the Battery
  372
- Checking the Relays
  375
- Checking the Diode
  376
- Checking the Ignition Coil
  377
- Checking the Ignition Spark Gap
  377
- Checking the Spark Plug Cap
  377
- Checking the Crankshaft Position Sensor
  378
- Checking the Lean Angle Sensor
  378
- Checking the Starter Motor Operation
  379
- Checking the Stator Coil
  379
- Checking the Fuel Sender
  380
- Checking the Rectifier/Regulator
  380
- Checking the Coolant Temperature Sensor
  381
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  381
- Checking the Resister
  381
- Checking the Throttle Position Sensor
  382
- Checking the Intake Air Pressure Sensor
  383
- Checking the Intake Air Temperature Sensor
  383
- Checking the Throttle Position Sensor Input Voltage
  383
- Checking the Fuel Injector
  384
Troubleshooting

385
- General Information
  386
- Incorrect Engine Idling Speed
  386
- Starting Failures
  386
- Troubleshooting
  386
- Clutch Drags
  387
- Clutch Slips
  387
- Jumps out of Gear
  387
- Overheating
  387
- Poor Medium-And-High-Speed Performance
  387
- Shift Pedal Does Not Move
  387
- Shifting Is Difficult
  387
- Faulty Front Fork Legs
  388
- Front Fork Oil Leaking
  388
- Overcooling
  388
- Poor Braking Performance
  388
- Unstable Handling
  388
- List of Self-Diagnostic and Fail-Safe Actions
  390
Tuning

393
- Chassis
  394
- Drive and Rear Wheel Sprockets Setting Parts
  394
- Selection of the Secondary Reduction Ratio (Sprocket)
  394
- Tire Pressure
  394
- Change in Amount and Characteristics of Fork Oil
  395
- Front Fork Setting
  395
- Setting of Spring after Replacement
  395
- Choosing Set Length
  396
- Front Fork Setting Parts
  396
- Rear Suspension Setting
  396
- Rear Shock Absorber Setting Parts
  397
- Setting of Spring after Replacement
  397
- Suspension Setting (Front Fork)
  399
- Suspension Setting (Rear Shock Absorber)
  400
- Kick Starter Kit (Optional Parts)
  402
- Parts Location
  402
- Setup Procedures
  404
- Starting the Engine
  407
- Maintenance
  408
  - Wiring Diagram
    410
  - Color Code
    410

Yamaha YZ250FXH 2017 Owner's Service Manual

Yamaha YZ250FXH 2017 Owner's Service Manual (410 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13 MB

Table of Contents

Table of Contents

9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Included Parts
  16
- Spark Plug Wrench
  16
- Nipple Wrench
  16
- Handlebar Protector
  16
- Fuel Hose Joint Cover
  16
- Coupler for Connecting Optional Part
  16
- Replacement Parts
  17
- Important Information
  17
- Preparation for Removal and Disassembly
  17
- Gaskets, Oil Seals and O-Rings
  18
- Lock Washers/Plates and Cotter Pins
  18
- Bearings and Oil Seals
  18
- Circlips
  18
- Basic Service Information
  19
- Electrical System
  19
- Special Tools
  23
- Clutch Lever
  29
- Start Switch
  29
- Engine Stop Switch
  29
- Warning Lights
  29
- Control Functions
  29
- Shift Pedal
  30
- Throttle Grip
  30
- Front Brake Lever
  30
- Rear Brake Pedal
  30
- Sidestand
  30
- Starter Knob/Idle Adjusting Screw
  30
- Fuel Tank Cap
  31
- Starting a Cold Engine
  32
- Air Filter Maintenance
  32
- Handling Note
  32
- Fuel
  32
- Starting and Break-In
  32
- Starting a Warm Engine
  33
- Break-In Procedures
  33
- Maintenance after Break-In
  35
- Major Maintenance
  35
- Torque-Check Points
  36
- Motorcycle Care and Storage
  38
- Care
  38
- Storage
  39
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  52
- General Tightening Torque Specifications
  53
- Tightening Torques
  53
- Engine Tightening Torques
  54
- Chassis Tightening Torques
  57
- Engine
  60
- Lubrication Points and Lubricant Types
  60
- Chassis
  61
- Lubrication Diagrams
  64
- Lubrication System Chart and Diagrams
  64
- Cable Routing Diagram
  72
Periodic Checks and Adjustments

87
- Maintenance Intervals
  89
- General Inspection and Maintenance
  95
- Pre-Operation Inspection and Maintenance
  95
- Changing the Coolant
  96
- Checking the Coolant Level
  96
- Checking the Cooling System
  96
- Engine
  96
- Checking the Radiator Cap
  97
- Checking the Radiator Cap Valve Opening Pressure
  97
- Adjusting the Clutch Lever Free Play
  98
- Checking the Coolant Circulatory System for Leaks
  98
- Adjusting the Throttle Grip Free Play
  99
- Lubricating the Throttle Cable
  99
- Cleaning the Air Filter Element
  100
- Checking the Breather Hoses
  101
- Checking the Exhaust System
  101
- Checking the Throttle Body Joint
  101
- Checking the Engine Oil Level
  102
- Checking the Fuel Line
  102
- Changing the Engine Oil
  103
- Adjusting the Engine Idling Speed
  104
- Adjusting the Valve Clearance
  105
- Bleeding the Brake System
  110
- Chassis
  110
- Adjusting the Front Brake
  111
- Checking the Brake Hose
  111
- Adjusting the Rear Brake
  112
- Checking the Front Brake Pads
  112
- Checking the Rear Brake Pads
  114
- Checking the Brake Fluid Level
  115
- Checking the Rear Brake Pad Insulator
  115
- Adjusting the Drive Chain Slack
  116
- Air Bleeding from Front Fork
  117
- Checking the Front Fork Legs
  117
- Checking the Front Fork Protector Guide
  117
- Cleaning the Front Fork Oil Seal and Dust Seal
  117
- Adjusting the Front Fork Legs
  118
- Adjusting the Rear Shock Absorber Assembly
  119
- Checking the Rear Suspension
  119
- Checking the Swingarm Operation
  119
- Checking and Tightening the Spokes
  121
- Checking the Tires
  121
- Checking and Adjusting the Steering Head
  122
- Checking the Wheel Bearings
  122
- Checking the Wheels
  122
- Checking and Lubricating the Cables
  123
- Lubricating the Drive Chain
  123
- Lubricating the Levers
  123
- Lubricating the Pedal
  123
- Checking the Chassis Fasteners
  124
- Lubricating the Sidestand
  124
- Checking the Ignition Timing
  125
- Checking the Spark Plug
  125
- Electrical System
  125
- Checking and Charging the Battery
  126
Chassis

127
- General Chassis
  129
- Removing the Left Side Cover
  130
- Removing the Number Plate
  130
- Removing the Seat
  130
- Front Wheel
  131
- Checking the Front Wheel
  132
- Removing the Front Wheel
  132
- Assembling the Front Wheel
  133
- Disassembling the Front Wheel
  133
- Installing the Front Wheel
  134
- Rear Wheel
  135
- Checking and Replacing the Rear Wheel Sprocket
  136
- Checking the Rear Wheel
  136
- Disassembling the Rear Wheel
  136
- Removing the Rear Wheel
  136
- Assembling the Rear Wheel
  137
- Installing the Rear Wheel
  137
- Front Brake
  139
- Checking the Front Brake Disc
  143
- Disassembling the Front Brake Caliper
  143
- Introduction
  143
- Removing the Front Brake Caliper
  143
- Assembling the Front Brake Caliper
  144
- Checking the Front Brake Caliper
  144
- Installing the Brake Caliper Piston
  144
- Installing the Front Brake Caliper
  145
- Assembling the Front Brake Master Cylinder
  146
- Checking the Front Brake Master Cylinder
  146
- Removing the Front Brake Master Cylinder
  146
- Installing the Front Brake Master Cylinder
  147
- Rear Brake
  149
- Checking the Rear Brake Disc
  153
- Introduction
  153
- Assembling the Rear Brake Caliper
  154
- Checking the Rear Brake Caliper
  154
- Disassembling the Rear Brake Caliper
  154
- Removing the Rear Brake Caliper
  154
- Installing the Brake Caliper Piston
  155
- Installing the Rear Brake Caliper
  155
- Checking the Rear Brake Master Cylinder
  156
- Removing the Rear Brake Master Cylinder
  156
- Assembling the Rear Brake Master Cylinder
  157
- Installing the Rear Brake Master Cylinder
  157
- Checking the Handlebar
  161
- Handlebar
  161
- Installing the Handlebar
  161
- Removing the Handlebar
  161
- Front Fork
  166
- Disassembling the Front Fork Legs
  168
- Removing the Front Fork Legs
  168
- Checking the Front Fork Legs
  169
- Assembling the Front Fork Legs
  170
- Installing the Front Fork Legs
  177
- Steering Head
  179
- Checking the Steering Head
  181
- Installing the Steering Head
  181
- Removing the Lower Bracket
  181
- Rear Shock Absorber Assembly
  184
- Disposing of a Rear Shock Absorber
  187
- Handling the Rear Shock Absorber
  187
- Removing the Bearing
  187
- Removing the Rear Shock Absorber Assembly
  187
- Checking the Connecting Arm and Relay Arm
  188
- Checking the Rear Shock Absorber Assembly
  188
- Installing the Relay Arm
  188
- Installing the Rear Shock Absorber Assembly
  189
- Swingarm
  191
- Checking the Swingarm
  192
- Removing the Bearing
  192
- Removing the Swingarm
  192
- Installing the Swingarm
  193
- Chain Drive
  194
- Checking the Drive Chain
  195
- Removing the Drive Chain
  195
- Checking the Drive Sprocket
  196
- Checking the Rear Wheel Sprocket
  196
- Installing the Drive Chain
  196
Engine

199
- Engine Removal
  202
- Removing the Drive Sprocket
  207
- Removing the Exhaust Pipe 2
  207
- Removing the Silencer
  207
- Changing the Silencer Fiber
  208
- Checking the Silencer and Exhaust Pipe
  208
- Removing the Engine
  208
- Installing the Engine
  209
- Installing the Brake Pedal
  210
- Installing the Drive Sprocket
  210
- Installing the Exhaust Pipe and Muffler
  211
- Camshaft
  213
- Removing the Camshaft
  215
- Checking the Camshaft
  216
- Checking the Timing Chain and Camshaft Sprocket
  217
- Checking the Timing Chain Tensioners
  217
- Checking the Decompression System
  218
- Installing the Camshafts
  218
- Cylinder Head
  220
- Checking the Cylinder Head
  222
- Checking the Timing Chain Guide (Intake Side)
  222
- Removing the Cylinder Head
  222
- Installing the Cylinder Head
  223
- Removing the Valves
  225
- Valves and Valve Springs
  225
- Checking the Valves and Valve Guides
  226
- Checking the Valve Seats
  228
- Checking the Valve Springs
  229
- Checking the Valve Lifters
  230
- Installing the Valves
  230
- Checking the Cylinder and Piston
  233
- Cylinder and Piston
  233
- Removing the Piston
  233
- Checking the Piston Rings
  234
- Checking the Piston Pin
  235
- Installing the Piston and Cylinder
  235
- Electric Starter
  237
- Checking the Starter Motor
  239
- Assembling the Starter Motor
  240
- Checking the Clutch Plates
  245
- Checking the Clutch Springs
  245
- Checking the Friction Plates
  245
- Clutch
  245
- Removing the Clutch
  245
- Checking the Clutch Boss
  246
- Checking the Clutch Housing
  246
- Checking the Clutch Push Rods
  246
- Checking the Pressure Plate
  246
- Checking the Primary Drive Gear
  246
- Checking the Push Lever Shaft
  246
- Checking the Primary Driven Gear
  247
- Installing the Oil Seal
  247
- Installing the Right Crankcase Cover
  247
- Installing the Clutch
  248
- Shift Shaft
  251
- Checking the Shift Guide and Shift Lever Assembly
  253
- Checking the Shift Shaft
  253
- Checking the Stopper Lever
  253
- Removing the Segment
  253
- Removing the Shift Guide and Shift Lever Assembly
  253
- Installing the Segment
  254
- Installing the Shift Guide and Shift Lever Assembly
  254
- Installing the Stopper Lever
  254
- Installing the Shift Pedal
  255
- Installing the Shift Shaft
  255
- Oil Pump and Balancer Gear
  257
- Checking the Balancer
  259
- Checking the Oil Pump
  259
- Checking the Primary Drive Gear, Balancer Drive Gear, and Balancer Weight Gear
  259
- Removing the Balancer
  259
- Assembling the Oil Pump
  260
- Installing the Oil Pump and Balancer Gear
  261
- Checking the Starter Clutch
  265
- Generator and Starter Clutch
  265
- Removing the Generator
  265
- Installing the Generator
  266
- Installing the Starter Clutch
  266
- Checking the Crankcase
  272
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  272
- Crankcase
  272
- Disassembling the Crankcase
  272
- Removing the Crankcase Bearing
  272
- Assembling the Crankcase
  273
- Installing the Oil Seal
  273
- Crankshaft Assembly and Balancer Shaft
  275
- Checking the Crankshaft Assembly
  276
- Removing the Crankshaft Assembly
  276
- Installing the Balancer Shaft
  277
- Installing the Crankshaft Assembly
  277
- Transmission
  278
- Checking the Shift Forks
  279
- Removing the Transmission
  279
- Checking the Shift Drum Assembly
  280
- Checking the Transmission
  280
- Installing the Transmission
  280
- Cooling System
  283
Fuel System

291
- Fuel Tank
  292
- Checking the Fuel Pump Body
  294
- Installing the Fuel Pump
  294
- Removing the Fuel Pump
  294
- Removing the Fuel Tank
  294
- Checking the Fuel Sender
  295
- Installing the Fuel Sender
  295
- Installing the Fuel Tank
  295
- Removing the Fuel Sender
  295
- Checking the Damper
  296
- Checking the Fuel Pressure
  296
- Checking and Replacing the Protector
  297
- Throttle Body
  298
- Checking the Injector
  301
- Checking the Throttle Body
  301
- Checking the Throttle Body Joint
  301
- Adjusting the Throttle Position Sensor
  302
Electrical System

303
- Circuit Diagram
  306
- Ignition System
  306
- Troubleshooting
  308
- Circuit Diagram
  310
- Electric Starting System
  310
- Starting Circuit Cut-Off System Operation
  312
- Troubleshooting
  314
- Charging System
  316
- Circuit Diagram
  316
- Troubleshooting
  318
- Circuit Diagram
  320
- Signaling System
  320
- Troubleshooting
  322
- Circuit Diagram
  324
- COOLING SYSTEM (for JPN)
  324
- Troubleshooting
  326
- Circuit Diagram
  328
- Fuel Injection System
  328
- Ecu Self-Diagnostic Function
  330
- Troubleshooting Method
  331
- Yamaha Diagnostic Tool
  332
- Troubleshooting Details
  335
- Circuit Diagram
  356
- Fuel Pump System
  356
- Troubleshooting
  358
- Electrical Components
  360
- Checking the Switches
  364
- Checking the Bulbs and Bulb Sockets
  367
- Checking the Fuses
  367
- Checking and Charging the Battery
  368
- Checking the Relays
  371
- Checking the Diode
  372
- Checking the Ignition Spark Gap
  372
- Checking the Ignition Coil
  373
- Checking the Spark Plug Cap
  373
- Checking the Crankshaft Position Sensor
  374
- Checking the Lean Angle Sensor
  374
- Checking the Starter Motor Operation
  375
- Checking the Stator Coil
  375
- Checking the Fuel Sender
  376
- Checking the Rectifier/Regulator
  376
- Checking the Resister
  376
- Checking the Coolant Temperature Sensor
  377
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  377
- Checking the Throttle Position Sensor
  378
- Checking the Throttle Position Sensor Input Voltage
  378
- Checking the Intake Air Pressure Sensor
  379
- Checking the Intake Air Temperature Sensor
  379
- Checking the Fuel Injector
  380
Troubleshooting

381
- General Information
  382
- Incorrect Engine Idling Speed
  382
- Starting Failures
  382
- Troubleshooting
  382
- Clutch Drags
  383
- Clutch Slips
  383
- Jumps out of Gear
  383
- Overheating
  383
- Poor Medium-And-High-Speed Performance
  383
- Shift Pedal Does Not Move
  383
- Shifting Is Difficult
  383
- Faulty Front Fork Legs
  384
- Front Fork Oil Leaking
  384
- Overcooling
  384
- Poor Braking Performance
  384
- Unstable Handling
  384
- List of Self-Diagnostic and Fail-Safe Actions
  387
Tuning

389
- Chassis
  390
- Drive and Rear Wheel Sprockets Setting Parts
  390
- Selection of the Secondary Reduction Ratio (Sprocket)
  390
- Tire Pressure
  390
- Change in Amount and Characteristics of Fork Oil
  391
- Front Fork Setting
  391
- Setting of Spring after Replacement
  391
- Choosing Set Length
  392
- Front Fork Setting Parts
  392
- Rear Suspension Setting
  392
- Setting of Spring after Replacement
  393
- Suspension Setting (Front Fork)
  395
- Suspension Setting (Rear Shock Absorber)
  396
- Kickstarter Kit (Optional Parts)
  398
- Parts Location
  398
- Setup Procedures
  400
- Starting the Engine
  403
- Maintenance
  404

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