Yamaha YZ250FXK 2019 Manuals

Manuals and User Guides for Yamaha YZ250FXK 2019. We have 1 Yamaha YZ250FXK 2019 manual available for free PDF download: Owner's Service Manual

Yamaha YZ250FXK 2019 Owner's Service Manual

Yamaha YZ250FXK 2019 Owner's Service Manual (398 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18.95 MB

Table of Contents

Table of Contents

9
- Location of Important Labels
  13
- Description
  14
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Identification
  15
- Included Parts
  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
- Control Functions
  29
- Warning Lights
  29
- Engine Stop Switch
  29
- Start Switch
  29
- Clutch Lever
  29
- Shift Pedal
  29
- Starter Knob/Idle Screw
  30
- Sidestand
  30
- Rear Brake Pedal
  30
- Front Brake Lever
  30
- Throttle Grip
  30
- Fuel Tank Cap
  31
- Starting and Break-In
  32
- Fuel
  32
- Handling Note
  32
- Air Filter Maintenance
  32
- Starting a Cold Engine
  32
- Break-In Procedures
  33
- Starting a Warm Engine
  33
- Maintenance after Break-In
  34
- Major Maintenance
  34
- Torque-Check Points
  35
- Motorcycle Care and Storage
  37
- Care
  37
- Storage
  38
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  50
- General Tightening Torque Specifications
  52
- Tightening Torques
  52
- Engine Tightening Torques
  53
- Chassis Tightening Torques
  56
- 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
  93
- Pre-Operation Inspection and Maintenance
  93
- Changing the Coolant
  95
- Checking the Coolant Level
  95
- Checking the Cooling System
  95
- Engine
  95
- Checking the Radiator Cap
  96
- Checking the Radiator Cap Valve Opening Pressure
  96
- Adjusting the Clutch Lever Free Play
  97
- Checking the Coolant Circulatory System for Leaks
  97
- Adjusting the Throttle Grip Free Play
  98
- Lubricating the Throttle Cable
  98
- Cleaning the Air Filter Element
  99
- Checking the Breather Hoses
  100
- Checking the Exhaust System
  100
- Checking the Throttle Body Joint
  100
- Checking the Engine Oil Level
  101
- Checking the Fuel Line
  101
- Changing the Engine Oil
  102
- Adjusting the Engine Idling Speed
  103
- Adjusting the Valve Clearance
  104
- Valve Clearance Shim Chart
  107
- Bleeding the Brake System
  109
- Chassis
  109
- Adjusting the Front Brake
  110
- Checking the Brake Hose
  110
- Adjusting the Rear Brake
  111
- Checking the Front Brake Pads
  111
- Checking the Rear Brake Pads
  113
- Checking the Brake Fluid Level
  114
- Checking the Rear Brake Pad Insulator
  114
- Adjusting the Drive Chain Slack
  115
- Checking the Front Fork Legs
  116
- Checking the Front Fork Protector Guide
  116
- Cleaning the Front Fork Oil Seal and Dust Seal
  116
- Adjusting the Front Fork Legs
  117
- Air Bleeding from Front Fork
  117
- Adjusting the Rear Shock Absorber Assembly
  118
- Checking the Rear Suspension
  118
- Checking the Swingarm Operation
  118
- Checking and Tightening the Spokes
  120
- Checking the Tires
  120
- Checking and Adjusting the Steering Head
  121
- Checking the Wheel Bearings
  121
- Checking the Wheels
  121
- Checking and Lubricating the Cables
  122
- Lubricating the Levers
  122
- Lubricating the Pedal
  122
- Checking the Chassis Fasteners
  123
- Lubricating the Drive Chain
  123
- Lubricating the Sidestand
  123
- Checking the Ignition Timing
  124
- Checking the Spark Plug
  124
- Electrical System
  124
- Checking and Charging the Battery
  125
Chassis

127
- General Chassis
  130
- 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
- Handlebar
  159
- Checking the Handlebar
  160
- Installing the Handlebar
  160
- Removing the Handlebar
  160
- Front Fork
  165
- Disassembling the Front Fork Legs
  167
- Removing the Front Fork Legs
  167
- Checking the Front Fork Legs
  168
- Assembling the Front Fork Legs
  169
- Installing the Front Fork Legs
  175
- Steering Head
  178
- Checking the Steering Head
  179
- Installing the Steering Head
  179
- Removing the Lower Bracket
  179
- Rear Shock Absorber Assembly
  182
- Disposing of a Rear Shock Absorber
  185
- Handling the Rear Shock Absorber
  185
- Removing the Bearing
  185
- Removing the Rear Shock Absorber Assembly
  185
- Checking the Connecting Arm and Relay Arm
  186
- Checking the Rear Shock Absorber Assembly
  186
- Installing the Relay Arm
  186
- Installing the Rear Shock Absorber Assembly
  187
- Swingarm
  189
- Checking the Swingarm
  190
- Removing the Bearing
  190
- Removing the Swingarm
  190
- Installing the Swingarm
  191
- Chain Drive
  192
- Checking the Drive Chain
  193
- Removing the Drive Chain
  193
- Checking the Drive Sprocket
  194
- Checking the Rear Wheel Sprocket
  194
- Installing the Drive Chain
  194
- Engine
  197
- Cooling System
  277
Fuel System

285
- Checking the Fuel Pump Body
  287
- Installing the Fuel Pump
  287
- Removing the Fuel Pump
  287
- Removing the Fuel Tank
  287
- Checking the Fuel Sender
  288
- Installing the Fuel Sender
  288
- Installing the Fuel Tank
  288
- Removing the Fuel Sender
  288
- Checking and Replacing the Protector
  289
- Checking the Damper
  289
- Checking the Fuel Pressure
  289
- Throttle Body
  291
- Checking the Injector
  294
- Checking the Throttle Body
  294
- Checking the Throttle Body Joint
  294
- Adjusting the Throttle Position Sensor
  295
Electrical System

297
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Electric Starting System
  304
- Starting Circuit Cut-Off System Operation
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Signaling System
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- Fuel Injection System
  318
- Ecu Self-Diagnostic Function
  320
- Troubleshooting Method
  321
- Connecting the Yamaha Diagnostic Tool
  322
- Features of the Yamaha Diagnostic Tool
  322
- Functions of the Yamaha Diagnostic Tool
  322
- Yamaha Diagnostic Tool
  322
- Troubleshooting Details
  324
- Circuit Diagram
  344
- Fuel Pump System
  344
- Troubleshooting
  346
- Electrical Components
  348
- Checking the Switches
  352
- Checking the Bulbs and Bulb Sockets
  355
- Checking the Fuses
  355
- Checking the Relays
  359
- Checking the Diode
  360
- Checking the Ignition Spark Gap
  360
- Checking the Ignition Coil
  361
- Checking the Spark Plug Cap
  361
- Checking the Crankshaft Position Sensor
  362
- Checking the Lean Angle Sensor
  362
- Checking the Rectifier/Regulator
  363
- Checking the Starter Motor Operation
  363
- Checking the Stator Coil
  363
- Checking the Fuel Sender
  364
- Checking the Resistor
  364
- Checking the Coolant Temperature Sensor
  365
- Checking the Throttle Position Sensor Input Voltage
  365
- Checking the Fuel Injector
  366
- Checking the Intake Air Temperature Sensor
  366
Troubleshooting

369
- General Information
  370
- Incorrect Engine Idling Speed
  370
- Starting Failures
  370
- Troubleshooting
  370
- Clutch Drags
  371
- Clutch Slips
  371
- Jumps out of Gear
  371
- Overheating
  371
- Poor Medium-And-High-Speed Performance
  371
- Shift Pedal Does Not Move
  371
- Shifting Is Difficult
  371
- Faulty Front Fork Legs
  372
- Front Fork Oil Leaking
  372
- Overcooling
  372
- Poor Braking Performance
  372
- Unstable Handling
  372
- Communication Error with Yamaha Diagnostic Tool
  373
- Sensor Operation Table
  374
- Actuator Operation Table
  375
Tuning

377
- Chassis
  378
- Drive and Rear Wheel Sprockets Setting Parts
  378
- Selection of the Secondary Reduction Ratio (Sprocket)
  378
- Tire Pressure
  378
- Change in Amount and Characteristics of Fork Oil
  379
- Front Fork Setting Parts
  379
- Setting of Spring after Replacement
  379
- Choosing Set Length
  380
- Rear Suspension Setting
  380
- Rear Shock Absorber Setting Parts
  381
- Setting of Spring after Replacement
  381
- Suspension Setting (Front Fork)
  383
- Suspension Setting (Rear Shock Absorber)
  384
- Kickstarter Kit (Optional Parts)
  386
- Parts Location
  386
- Setup Procedures
  388
- Installing the Kick Shaft
  389
- Setup Procedure (Kickstarter Lever)
  390
- Installing the Kickstarter Lever
  391
- Maintenance
  391
- Starting the Engine
  391

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