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Yamaha XMAX 125 Service Manual

Other manuals for XMAX 125: Owner's Manual

Summary of XMAX 125

  • Page 1

    Service manual 2010 37p-f8197-e0 yp125r/yp250r.

  • Page 2

    Eas20060 yp125r/yp250r 2010 service manual ©2009 by yamaha motor españa, s.A. First edition, november 2009 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor españa, s.A. Is expressly prohibited..

  • Page 3: Important

    Eas20071 important this manual was produced by yamaha motor españa, s.A. Primarily for use by yamaha and mbk deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs o...

  • Page 4: How to Use This Manual

    Eas20090 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5: Symbols

    Eas20101 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...

  • Page 7: Table of Contents

    Eas20110 table of contents general information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 electrical system 8 troubleshooting 9.

  • Page 9: General Information

    1 general information identification ............................................................................................ 1-1 vehicle identification number ..................................................... 1-1 model label......................................................................

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the frame. Eas20150 model label the model label “1” is affixed to the location shown. This information will be needed to order spare parts. 1 1.

  • Page 11: Features

    Features 1-2 eas20170 features eas37p1140 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor s...

  • Page 12: Features

    Features 1-3 eas37p1141 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kpa (2.50 kgf/cm², 36.3 psi). Accordingly, when the energizing signal from the ecu energizes the...

  • Page 13: Instrument Functions

    Instrument functions 1-4 eas37p1080 instrument functions multi-function display warning ewa37p1016 be sure to stop the vehicle before making any setting changes to the multi-function display. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-fun...

  • Page 14: Instrument Functions

    Instrument functions 1-5 to reset a tripmeter, select it by pushing the “se- lect” button until “trip” or “trip f” begins flash- ing (“trip” or “trip f” will only flash for five seconds). While “trip” or “trip f” is flashing, push the “reset” button for at least one sec- ond. If you do not reset the...

  • Page 15: Instrument Functions

    Instrument functions 1-6 3. Release the “oil change” button, and the oil change indicator will go off. The electrical circuit of the indicator can be checked according to the following procedure. 1. Turn the key to “on”. 2. Check that the indicator comes on for a few seconds and then goes off. 3. If...

  • Page 16: Instrument Functions

    Instrument functions 1-7 immobilizer system keys may cause signal inter- ference, which may prevent the engine from starting. 2. If the engine starts, turn it off, and try starting the engine with the standard keys. 3. If one or both of the standard keys do not start the engine, re-register the stan...

  • Page 17: Important Information

    Important information 1-8 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-11. 3. When disassem...

  • Page 18: Important Information

    Important information 1-9 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if ...

  • Page 19: Checking The Connections

    Checking the connections 1-10 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 20: Special Tools

    Special tools 1-11 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 21: Special Tools

    Special tools 1-12 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-38, 4-59 damper rod holder 90890-01294 damping rod holder set ym-01300 4-52, 4-54 t-handle 90890-01326 t-handle 3/8" drive 60 cm long ym-01326 4-52, 4-54 fork seal driver weight 90890-01367 replacement hammer ym-...

  • Page 22: Special Tools

    Special tools 1-13 valve spring compressor 90890-04019 ym-04019 5-19, 5-24, 5-78, 5-83 valve spring compressor attachment 90890-04108 valve spring compressor adapter 22 mm ym-04108 5-19, 5-24, 5-78, 5-83 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-20 valve guide in...

  • Page 23: Special Tools

    Special tools 1-14 locknut wrench 90890-01348 ym-01348 5-33, 5-37, 5-93, 5-97 clutch spring holder 90890-01337 5-34, 5-37, 5-94, 5-97 clutch spring holder arm 90890-01464 5-34, 5-37, 5-94, 5-97 oil seal guide (ø41) 90890-01396 5-36, 5-96 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-41,...

  • Page 24: Special Tools

    Special tools 1-15 crankcase separating tool 90890-01135 crankcase separator yu-01135-b 5-56, 5-117 crankshaft installer pot 90890-01274 installing pot yu-90058 5-58, 5-59, 5-119, 5-120 crankshaft installer bolt 90890-01275 bolt yu-90060 5-58, 5-59, 5-119, 5-120 adapter (m14) 90890-01478 adapter #6 ...

  • Page 25: Special Tools

    Special tools 1-16 weight 90890-01084 yu-01083-3 5-74 valve guide remover (ø6) 90890-04064 valve guide remover (6.0 mm) ym-04064-a 5-79 valve guide installer (ø6) 90890-04065 valve guide installer (6.0 mm) ym-04065-a 5-79 valve guide reamer (ø6) 90890-04066 valve guide reamer (6.0 mm) ym-04066 5-79 ...

  • Page 26: Special Tools

    Special tools 1-17 adapter (m16) 90890-01280 adapter #7 ym-90067 5-120 spacer 90890-01288 5-120 mechanical seal installer 90890-04145 6-6 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-6, 6-15 mechanical seal installer 90890-04132 water pump seal installer ym-33221-a ...

  • Page 27: Special Tools

    Special tools 1-18 test harness-lean angle sensor (6p) 90890-03209 8-84 test harness 90890-03204 8-89 tool name/tool no. Illustration reference pages.

  • Page 28: Special Tools

    Special tools 1-19.

  • Page 29: Specifications

    2 specifications general specifications (yp125r)........................................................ 2-1 engine specifications (yp125r) ........................................................... 2-2 chassis specifications (yp125r) ......................................................... 2-9 el...

  • Page 30

    Cooling system diagrams (yp250r) ................................................. 2-73 cable routing (yp250r) ........................................................................ 2-75.

  • Page 32: 2-1

    General specifications (yp125r) 2-1 eas37p1117 general specifications (yp125r) model model 39d1 (yamaha) 39d3 (mbk) dimensions overall length 2201 mm (86.7 in) overall width 776 mm (30.6 in) overall height 1337 mm (52.6 in) seat height 792 mm (31.2 in) wheelbase 1545 mm (60.8 in) ground clearance 13...

  • Page 33: 2-2

    Engine specifications (yp125r) 2-2 eas37p1118 engine specifications (yp125r) engine engine type liquid cooled 4-stroke, sohc displacement 124 cm³ cylinder arrangement forward-inclined single cylinder bore × stroke 52.0 × 58.6 mm (2.05 × 2.31 in) compression ratio 11.20 :1 standard compression pressu...

  • Page 34: 2-3

    Engine specifications (yp125r) 2-3 radiator cap opening pressure 100.0–120.0 kpa (1.00–1.20 kgf/cm², 14.5–17.4 psi) thermostat valve opening temperature 70.5–73.5 °c (158.9–164.3 °f) valve full open temperature 85.0 °c (185.0 °f) valve lift (full open) 3.0 mm (0.12 in) radiator core width 244.0 mm (...

  • Page 35: 2-4

    Engine specifications (yp125r) 2-4 camshaft runout limit 0.030 mm (0.0012 in) timing chain tensioning system automatic rocker arm/rocker arm shaft rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in) limit 10.015 mm (0.3943 in) rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928...

  • Page 36: 2-5

    Engine specifications (yp125r) 2-5 limit 0.5 mm (0.02 in) valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) limit 4.445 mm (0.1750 in) valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) limit 4.430 mm (0.1744 in) valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0...

  • Page 37: 2-6

    Engine specifications (yp125r) 2-6 winding direction (intake) clockwise winding direction (exhaust) clockwise cylinder bore 52.000–52.010 mm (2.0472–2.0476 in) wear limit 52.110 mm (2.0516 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.005 mm (0.0002 in) warp limit 0.05 mm (0.0020 in) pis...

  • Page 38: 2-7

    Engine specifications (yp125r) 2-7 limit 0.60 mm (0.0236 in) ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) limit 0.120 mm (0.0047 in) oil ring dimensions (b × t) 1.50 × 1.95 mm (0.06 × 0.08 in) end gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) ring side clearance 0.060–0.150 mm (0.0024–0.0...

  • Page 39: 2-8

    Engine specifications (yp125r) 2-8 secondary reduction ratio 44/13 (3.385) operation centrifugal automatic type gear ratio 2.645–0.824 :1 decompression device device type auto decomp air filter air filter element oil-coated paper element fuel pump pump type electrical output pressure 250.0 kpa (2.50...

  • Page 40: 2-9

    Chassis specifications (yp125r) 2-9 eas37p1119 chassis specifications (yp125r) chassis frame type steel tube underbone caster angle 28.00° trail 100.0 mm (3.94 in) front wheel wheel type cast wheel rim size 15 × mt3.5 rim material aluminum wheel travel 110.0 mm (4.33 in) radial wheel runout limit 1....

  • Page 41: 2-10

    Chassis specifications (yp125r) 2-10 front disc brake disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in) brake disc thickness limit 4.5 mm (0.18 in) brake disc deflection limit 0.15 mm (0.0059 in) brake pad lining thickness (inner) 5.0 mm (0.20 in) limit 1.5 mm (0.06 in) brake pad li...

  • Page 42: 2-11

    Chassis specifications (yp125r) 2-11 rear suspension type unit swing spring/shock absorber type coil spring/oil damper rear shock absorber assembly travel 95.0 mm (3.74 in) spring free length 274.0 mm (10.79 in) installed length 241.3 mm (9.50 in) spring rate k1 8.00 n/mm (0.82 kgf/mm, 45.68 lb/in) ...

  • Page 43: 2-12

    Electrical specifications (yp125r) 2-12 eas37p1120 electrical specifications (yp125r) voltage system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 8.0°/1700 r/min engine control unit model/manufacturer 39d0/yamaha ignition coil minimum ig...

  • Page 44: 2-13

    Electrical specifications (yp125r) 2-13 indicator lights turn signal indicator light 12 v, 1.4 w × 2 high beam indicator light 12 v, 1.4 w × 1 engine trouble warning light 12 v, 1.4 w × 1 immobilizer system indicator light led electric starting system system type constant mesh starter motor power ou...

  • Page 45: 2-14

    Electrical specifications (yp125r) 2-14 spare fuse 15.0 a spare fuse 10.0 a spare fuse 5.0 a spare fuse 7.5 a.

  • Page 46: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-15 eas37p1121 tightening torques (yp125r) eas37p1123 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are p...

  • Page 47: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-16 eas37p1122 engine tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 2 20 nm (2.0 m·kgf, 14 ft·lbf) muffler bolt m10 3 53 nm (5.3 m·kgf, 38 ft·lbf) muffler joint bolt m8 1 14 nm (1.4 m·kgf, 10 ft·lbf) o 2 sensor m18 1 45 nm (4.5 m·...

  • Page 48: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-17 cylinder head tightening sequence: muffler tightening sequence: engine oil drain bolt m12 1 20 nm (2.0 m·kgf, 14 ft·lbf) final transmission oil drain bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) crankcase bolt m6 10 10 nm (1.0 m·kgf, 7.2 ft·lbf) timing chain guide bolt (in...

  • Page 49: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-18 eas37p1124 chassis tightening torques item thread size q’ty tightening torque remarks engine bracket nut m12 2 59 nm (5.9 m·kgf, 43 ft·lbf) engine bracket rod nut m10 2 64 nm (6.4 m·kgf, 46 ft·lbf) engine mounting nut m10 1 43 nm (4.3 m·kgf, 31 ft·lbf) radiator bolt ...

  • Page 50: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-19 front brake hose holder bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) front brake caliper bleed screw m7 1 6 nm (0.6 m·kgf, 4.3 ft·lbf) front brake pad pin cap m8 1 3 nm (0.3 m·kgf, 2.2 ft·lbf) front brake pad pin m8 1 18 nm (1.8 m·kgf, 13 ft·lbf) front brake caliper retain...

  • Page 51: Tightening Torques (Yp125R)

    Tightening torques (yp125r) 2-20 tip lower ring nut 1. Tighten the lower ring nut 38 nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower ring nut 22 nm (2.2 m·kgf, 16 ft·lbf) with a torque wrench and the steering nut wren...

  • Page 52: 2-21

    Lubrication points and lubricant types (yp125r) 2-21 eas37p1125 lubrication points and lubricant types (yp125r) eas37p1126 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head nut mounting surface crankshaft pin connecting rod big end thrust surface oil pump drive gear inn...

  • Page 53: 2-22

    Lubrication points and lubricant types (yp125r) 2-22 timing chain tensioner bolt yamaha bond no.1215® lubrication point lubricant.

  • Page 54: 2-23

    Lubrication points and lubricant types (yp125r) 2-23 eas37p1127 chassis lubrication point lubricant drive axle swingarm oil seal lips steering bearings (upper and lower) seat hinge pin front wheel oil seal lip and front wheel axle speed sensor oil seal lip brake lever pivoting point and metal-to-met...

  • Page 55: 2-24

    Lubrication points and lubricant types (yp125r) 2-24.

  • Page 56: 2-25

    Lubrication system diagrams (yp125r) 2-25 eas37p1139 lubrication system diagrams (yp125r) 1 2 3 4 5 3.

  • Page 57: 2-26

    Lubrication system diagrams (yp125r) 2-26 1. Camshaft 2. Crankshaft 3. Oil pump 4. Oil filter 5. Oil strainer.

  • Page 58: 2-27

    Cooling system diagrams (yp125r) 2-27 eas37p1128 cooling system diagrams (yp125r) b a b a 4 3 3 2 2 1 3 4 5 2 6 7 6.

  • Page 59: 2-28

    Cooling system diagrams (yp125r) 2-28 1. Coolant reservoir 2. Coolant reservoir hose 3. Radiator cap 4. Radiator filler hose 5. Radiator 6. Radiator inlet hose 7. Radiator outlet hose.

  • Page 60: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-29 eas37p1129 cable routing (yp125r) battery (front view) a b c d e f g h 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 11 11 15 12 15 14 13 17 16 13.

  • Page 61: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-30 1. Positive battery lead 2. Meter assembly lead 3. Self-diagnosis signal lead 4. Fuse box 1 5. Air temperature sensor lead 6. Fuse box 2 7. Starter relay lead 8. Negative battery lead 9. Headlight lead 10. Wire harness 11. Lean angle sensor lead 12. Speed sensor coupler 1...

  • Page 62: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-31 front fork (front view) a 1 1 1 1 2 2 2 3 4 5 6 7.

  • Page 63: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-32 1. Speed sensor lead 2. Front brake hose 3. Rectifier/regulator 4. Left front turn signal light coupler 5. Wire harness 6. Horn 7. Right front turn signal light coupler a. Point the end of the plastic locking tie forward, and then cut off the excess end of the tie to 0 – ...

  • Page 64: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-33 front brake hose (right side view) b 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 8 9 10 11 11 11 12 13 13 14 a c.

  • Page 65: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-34 1. Front brake hose 2. Radiator fan motor relay 3. Starting circuit cut-off relay 4. Speed sensor lead 5. Right front turn signal light 6. Radiator fan motor 7. Radiator fan motor lead 8. Wire harness 9. Rear brake pipe 10. Horn leads 11. Starter motor lead 12. Headlight ...

  • Page 66: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-35 engine (right side view) a 7 3 2 2 2 1 3 4 5 6 7.

  • Page 67: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-36 1. Seat lock cable 2. Wire harness 3. Ignition coil lead 4. Spark plug cap 5. O 2 sensor 6. Starter motor lead 7. Rear brake hose a. Point the end of the plastic locking tie to the right, and then cut off the excess end of the tie to 0 – 5 mm (0 – 0.20 in)..

  • Page 68: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-37 throttle cables (left side view) a b c i j 1 2 3 3 3 4 5 5 5 6 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 d d e f h h g.

  • Page 69: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-38 1. Meter assembly 2. Ecu (engine control unit) 3. Seat lock cable 4. Immobilizer unit coupler 5. Throttle cables 6. Wire harness 7. Sidestand switch lead 8. Rear brake hose 9. Front brake hose 10. Left front turn signal light lead 11. Rectifier/regulator 12. Starter motor...

  • Page 70: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-39 engine (left side view) 2 1 3 4 a 3.

  • Page 71: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-40 1. Wire harness 2. Intake air temperature sensor 3. Seat lock cable 4. Left tail/brake light assembly a. Point the end of the plastic locking tie to the left, and then cut off the excess end of the tie to 0 – 5 mm (0 – 0.20 in)..

  • Page 72: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-41 handlebar (top view) a 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17.

  • Page 73: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-42 1. Radiator fan motor relay 2. Starting circuit cut-off relay 3. Headlight relay 4. Right handlebar switch lead 5. Front brake hose 6. Fuel pump coupler 7. Fuel sender coupler 8. Fuel hose 9. Left handlebar switch lead 10. Rear brake hose 11. Ecu (engine control unit) 12....

  • Page 74: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-43 throttle body (top view) 3 1 3 4 6 10 11 9 2 2 2 3 3 c b a 18 17 13 15 16 12 11 14 3 5 7 8 10 11 12 16 15 7 19 4.

  • Page 75: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-44 1. Rear brake pipe 2. Crankshaft position sensor/stator assembly lead 3. Wire harness 4. Isc (idle speed control) unit coupler 5. Ground lead 6. Intake air temperature sensor coupler 7. Intake air pressure sensor coupler 8. Seat lock cable 9. Fuel injector assembly 10. Ra...

  • Page 76: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-45 tail/brake light (top view) 2 1 3 4 b a 1 5 6.

  • Page 77: Cable Routing (Yp125R)

    Cable routing (yp125r) 2-46 1. Wire harness 2. Rear brake hose 3. License plate light lead 4. Right tail/brake light assembly coupler 5. Left tail/brake light assembly coupler 6. Seat lock cable a. Point the end of the plastic locking tie to the right, and then cut off the excess end of the tie to 0...

  • Page 78: 2-47

    General specifications (yp250r) 2-47 eas20280 general specifications (yp250r) model model 37p1 (yamaha) dimensions overall length 2201 mm (86.7 in) overall width 776 mm (30.6 in) overall height 1337 mm (52.6 in) seat height 792 mm (31.2 in) wheelbase 1545 mm (60.8 in) ground clearance 134 mm (5.30 i...

  • Page 79: 2-48

    Engine specifications (yp250r) 2-48 eas20290 engine specifications (yp250r) engine engine type liquid cooled 4-stroke, sohc displacement 249 cm³ cylinder arrangement forward-inclined single cylinder bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) compression ratio 10.00 :1 standard compression pressur...

  • Page 80: 2-49

    Engine specifications (yp250r) 2-49 thermostat valve opening temperature 80.5–83.5 °c (176.9–182.3 °f) valve full open temperature 93.0–97.0 °c (199.4–206.6 °f) valve lift (full open) 3.0 mm (0.12 in) radiator core width 244.0 mm (9.61 in) height 128.9 mm (5.07 in) depth 22.0 mm (0.87 in) water pump...

  • Page 81: 2-50

    Engine specifications (yp250r) 2-50 timing chain tensioning system automatic rocker arm/rocker arm shaft rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) limit 12.030 mm (0.4736 in) rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) limit 11.950 mm (0.4705 in) rocker...

  • Page 82: 2-51

    Engine specifications (yp250r) 2-51 valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) limit 6.050 mm (0.2382 in) valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) limit 6.050 mm (0.2382 in) valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004...

  • Page 83: 2-52

    Engine specifications (yp250r) 2-52 spring rate k1 (intake) 23.18 n/mm (2.36 kgf/mm, 132.36 lb/in) spring rate k2 (intake) 31.66 n/mm (3.23 kgf/mm, 180.78 lb/in) spring rate k1 (exhaust) 23.18 n/mm (2.36 kgf/mm, 132.36 lb/in) spring rate k2 (exhaust) 31.66 n/mm (3.23 kgf/mm, 180.78 lb/in) installed ...

  • Page 84: 2-53

    Engine specifications (yp250r) 2-53 dimensions (b × t) 1.00 × 2.60 mm (0.04 × 0.10 in) end gap (installed) 0.15–0.30 mm (0.0059–0.0118 in) limit 0.55 mm (0.0217 in) ring side clearance 0.040–0.080 mm (0.0016–0.0031 in) limit 0.130 mm (0.0051 in) 2nd ring ring type taper dimensions (b × t) 1.00 × 2.9...

  • Page 85: 2-54

    Engine specifications (yp250r) 2-54 clutch shoe spring free length 40.5 mm (1.59 in) clutch housing inside diameter 145.0 mm (5.71 in) limit 145.5 mm (5.73 in) compression spring free length 102.4 mm (4.03 in) limit 90.0 mm (3.54 in) weight outside diameter 20.0 mm (0.79 in) limit 19.5 mm (0.77 in) ...

  • Page 86: 2-55

    Engine specifications (yp250r) 2-55 water temperature 85.0–95.0 °c (185.00–203.00 °f) oil temperature 75.0–85.0 °c (167.00–185.00 °f) throttle cable free play 3.0–5.0 mm (0.12–0.20 in).

  • Page 87: 2-56

    Chassis specifications (yp250r) 2-56 eas20300 chassis specifications (yp250r) chassis frame type steel tube underbone caster angle 28.00° trail 100.0 mm (3.94 in) front wheel wheel type cast wheel rim size 15 × mt3.5 rim material aluminum wheel travel 110.0 mm (4.33 in) radial wheel runout limit 1.0...

  • Page 88: 2-57

    Chassis specifications (yp250r) 2-57 front disc brake disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in) brake disc thickness limit 4.5 mm (0.18 in) brake disc deflection limit 0.15 mm (0.0059 in) brake pad lining thickness (inner) 5.0 mm (0.20 in) limit 1.5 mm (0.06 in) brake pad li...

  • Page 89: 2-58

    Chassis specifications (yp250r) 2-58 rear suspension type unit swing spring/shock absorber type coil spring/oil damper rear shock absorber assembly travel 95.0 mm (3.74 in) spring free length 274.0 mm (10.79 in) installed length 241.3 mm (9.50 in) spring rate k1 8.00 n/mm (0.82 kgf/mm, 45.68 lb/in) ...

  • Page 90: 2-59

    Electrical specifications (yp250r) 2-59 eas20310 electrical specifications (yp250r) voltage system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 10.0°/1550 r/min engine control unit model/manufacturer 37p0/yamaha ignition coil minimum ign...

  • Page 91: 2-60

    Electrical specifications (yp250r) 2-60 indicator lights turn signal indicator light 12 v, 1.4 w × 2 high beam indicator light 12 v, 1.4 w × 1 engine trouble warning light 12 v, 1.4 w × 1 immobilizer system indicator light led electric starting system system type constant mesh starter motor power ou...

  • Page 92: 2-61

    Electrical specifications (yp250r) 2-61 spare fuse 15.0 a spare fuse 10.0 a spare fuse 5.0 a spare fuse 7.5 a.

  • Page 93: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-62 eas20320 tightening torques (yp250r) eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provi...

  • Page 94: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-63 eas20340 engine tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 2 20 nm (2.0 m·kgf, 14 ft·lbf) muffler bolt m10 3 53 nm (5.3 m·kgf, 38 ft·lbf) muffler joint bolt m8 1 14 nm (1.4 m·kgf, 10 ft·lbf) o 2 sensor m18 1 45 nm (4.5 m·kg...

  • Page 95: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-64 oil pump assembly bolt m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) transmission case cover bolt m8 6 16 nm (1.6 m·kgf, 11 ft·lbf) oil strainer cover m35 1 32 nm (3.2 m·kgf, 23 ft·lbf) engine oil drain bolt m12 1 20 nm (2.0 m·kgf, 14 ft·lbf) final transmission oil drain bolt m8...

  • Page 96: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-65 cylinder head tightening sequence: muffler tightening sequence: 2 3 1.

  • Page 97: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-66 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine bracket nut m12 2 59 nm (5.9 m·kgf, 43 ft·lbf) engine bracket rod nut m10 2 64 nm (6.4 m·kgf, 46 ft·lbf) engine mounting nut m10 1 43 nm (4.3 m·kgf, 31 ft·lbf) radiator bolt m6...

  • Page 98: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-67 front brake hose holder bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) front brake caliper bleed screw m7 1 6 nm (0.6 m·kgf, 4.3 ft·lbf) front brake pad pin cap m8 1 3 nm (0.3 m·kgf, 2.2 ft·lbf) front brake pad pin m8 1 18 nm (1.8 m·kgf, 13 ft·lbf) front brake caliper retain...

  • Page 99: Tightening Torques (Yp250R)

    Tightening torques (yp250r) 2-68 tip lower ring nut 1. Tighten the lower ring nut 38 nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower ring nut 22 nm (2.2 m·kgf, 16 ft·lbf) with a torque wrench and the steering nut wren...

  • Page 100: 2-69

    Lubrication points and lubricant types (yp250r) 2-69 eas20360 lubrication points and lubricant types (yp250r) eas20370 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head nut mounting surface crankshaft pin connecting rod big end thrust surface rotary filter inner surface...

  • Page 101: 2-70

    Lubrication points and lubricant types (yp250r) 2-70 crankshaft position sensor/stator assembly lead grommet yamaha bond no. 1215 lubrication point lubricant.

  • Page 102: 2-71

    Lubrication points and lubricant types (yp250r) 2-71 eas20380 chassis lubrication point lubricant drive axle swingarm oil seal lips steering bearings (upper and lower) seat hinge pin front wheel oil seal lip and front wheel axle speed sensor oil seal lip brake lever pivoting point and metal-to-metal...

  • Page 103: 2-72

    Lubrication points and lubricant types (yp250r) 2-72.

  • Page 104: 2-73

    Cooling system diagrams (yp250r) 2-73 eas20420 cooling system diagrams (yp250r) a a 4 3 3 2 2 1 3 4 5 2 6 7.

  • Page 105: 2-74

    Cooling system diagrams (yp250r) 2-74 1. Coolant reservoir 2. Coolant reservoir hose 3. Radiator cap 4. Radiator filler hose 5. Radiator 6. Radiator inlet hose 7. Radiator outlet hose.

  • Page 106: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-75 eas20430 cable routing (yp250r) battery (front view) a b c d e f g h 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 12 13 14 15 15 11 11 13 16 17.

  • Page 107: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-76 1. Positive battery lead 2. Meter assembly lead 3. Self-diagnosis signal lead 4. Fuse box 1 5. Air temperature sensor lead 6. Fuse box 2 7. Starter relay lead 8. Negative battery lead 9. Headlight lead 10. Wire harness 11. Lean angle sensor lead 12. Speed sensor coupler 1...

  • Page 108: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-77 front fork (front view) 1 1 2 3 4 5 6 7 1 2 a 1 2.

  • Page 109: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-78 1. Speed sensor lead 2. Front brake hose 3. Rectifier/regulator 4. Left front turn signal light coupler 5. Wire harness 6. Horn 7. Right front turn signal light coupler a. Point the end of the plastic locking tie forward, and then cut off the excess end of the tie to 0 – ...

  • Page 110: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-79 front brake hose (right side view) 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 9 10 11 11 11 11 12 13 13 14 15 8 a b.

  • Page 111: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-80 1. Front brake hose 2. Radiator fan motor relay 3. Starting circuit cut-off relay 4. Speed sensor lead 5. Right front turn signal light 6. Radiator fan motor 7. Radiator fan motor lead 8. Wire harness 9. Rear brake pipe 10. Horn leads 11. Starter motor lead 12. Headlight ...

  • Page 112: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-81 engine (right side view) a 7 3 2 2 2 1 3 4 5 6 7 8 b.

  • Page 113: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-82 1. Seat lock cable 2. Wire harness 3. Ignition coil lead 4. Spark plug cap 5. Coolant temperature sensor lead 6. O 2 sensor 7. Starter motor lead 8. Rear brake hose a. Fasten the wire harness, starter motor lead, crankshaft position sensor/stator assembly lead, and o 2 se...

  • Page 114: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-83 throttle cables (left side view) a b c i j 1 2 3 3 3 4 5 5 5 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 d d e f h h g 6.

  • Page 115: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-84 1. Meter assembly 2. Ecu (engine control unit) 3. Seat lock cable 4. Immobilizer unit coupler 5. Throttle cables 6. Wire harness 7. Sidestand switch lead 8. Rear brake hose 9. Front brake hose 10. Left front turn signal light lead 11. Rectifier/regulator 12. Starter motor...

  • Page 116: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-85 engine (left side view) 2 1 3 4 5 6 b a 3 7.

  • Page 117: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-86 1. Wire harness 2. Intake air temperature sensor 3. Seat lock cable 4. Left tail/brake light assembly 5. Safety protector 6. O 2 sensor 7. Spark plug cap a. Route the left tail/brake light assembly lead and right tail/brake light assembly lead over the safety protector. B...

  • Page 118: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-87 handlebar (top view) a 1 2 3 4 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17.

  • Page 119: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-88 1. Radiator fan motor relay 2. Starting circuit cut-off relay 3. Headlight relay 4. Right handlebar switch lead 5. Front brake hose 6. Fuel pump coupler 7. Fuel sender coupler 8. Fuel hose 9. Left handlebar switch lead 10. Rear brake hose 11. Ecu (engine control unit) 12....

  • Page 120: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-89 throttle body (top view) 3 3 1 2 3 a 6 7 8 8 9 13 c b d 11 10 10 11 4 5 4 4 4 4 4 12 12 12.

  • Page 121: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-90 1. Rear brake pipe 2. Intake air pressure sensor coupler 3. Wire harness 4. Starter motor lead 5. Ground lead 6. Breather hose (air filter case to throttle body) 7. Intake air temperature sensor coupler 8. Fuel injector lead 9. Seat lock cable 10. Cylinder head breather h...

  • Page 122: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-91 tail/brake light (top view) 2 1 3 4 b a 1 5 6 8 7.

  • Page 123: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-92 1. Wire harness 2. Rear brake hose 3. License plate light lead 4. Right tail/brake light assembly coupler 5. Left tail/brake light assembly coupler 6. Seat lock cable 7. Cylinder head breather hose 8. Intake air temperature sensor coupler a. Point the end of the plastic l...

  • Page 124: Cable Routing (Yp250R)

    Cable routing (yp250r) 2-93.

  • Page 125

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance chart for the emission control system ...

  • Page 126

    Chassis ....................................................................................................... 3-35 checking the brake fluid level................................................. 3-35 checking the front brake pads ................................................ 3-35 checking the r...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-2 5 * brake hoses • check for cracks or damage. √ √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for damage. √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. √ √ √ √ √ 8 * wheel bearings...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-3 eas37p1070 tip • engine air filter and v-belt air filter • this model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the engine air filter element needs to be replaced and the ...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-4 3 * front brake • check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √ • replace brake pads. Whenever worn to the limit 4 * rear brake • check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √ • replace brake pads. Whenever worn to the limi...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-5 eau38262 tip • engine air filter and v-belt air filters • this model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the engine air filter element needs to be replaced and the v...

  • Page 133: Engine (Yp125R)

    Engine (yp125r) 3-6 eas37p1087 engine (yp125r) eas37p1088 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston mu...

  • Page 134: Engine (Yp125R)

    Engine (yp125r) 3-7 c. Check that the cam lobes are positioned as shown in the illustration. D. Measure the valve clearance with a thickness gauge “1”. Out of specification → adjust. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 135: Engine (Yp125R)

    Engine (yp125r) 3-8 8. Install: • v-belt case air filter element • v-belt case air duct • v-belt case cover 9. Install: • storage box refer to “general chassis” on page 4-1. Eas37p1089 adjusting the exhaust gas volume tip be sure to set the co density level to standard, and then adjust the exhaust g...

  • Page 136: Engine (Yp125R)

    Engine (yp125r) 3-9 15.Install: • upper panel refer to “general chassis” on page 4-1. Eas37p1090 adjusting the throttle cable free play 1. Check: • throttle cable free play “a” out of specification → adjust. 2. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. S...

  • Page 137: Engine (Yp125R)

    Engine (yp125r) 3-10 7. Install: • spark plug tip before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug cap eas37p1092 checking the ignition timing tip prior to checking the ignition timing, check the wiring connections of the entire ignition system. Mak...

  • Page 138: Engine (Yp125R)

    Engine (yp125r) 3-11 eas37p1093 measuring the compression pressure tip insufficient compression pressure will result in a loss of performance. 1. Remove: • storage box refer to “general chassis” on page 4-1. 2. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve c...

  • Page 139: Engine (Yp125R)

    Engine (yp125r) 3-12 eas37p1134 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • dipstick “1” 4. Check: • en...

  • Page 140: Engine (Yp125R)

    Engine (yp125r) 3-13 5. If the oil filter element is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the oil filter element cover “1” and oil filter element “2”. B. Install a new o-ring “3”. Tip be sure to face the “ ” mark “a” on the...

  • Page 141: Engine (Yp125R)

    Engine (yp125r) 3-14 b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. C. Check the engine oil passages and the oil pump for damage or leakage. Refer to “oil pump...

  • Page 142: Engine (Yp125R)

    Engine (yp125r) 3-15 9. Start the engine, warm it up for several min- utes, turn it off, and then check for oil leak- age. Eas37p1096 replacing the air filter element tip check hoses are located on the bottom of the air filter case. If dust or water or both collects in a hose, remove the clamp from ...

  • Page 143: Engine (Yp125R)

    Engine (yp125r) 3-16 3. Check: • v-belt case air filter element damage → replace. 4. Apply the recommended oil to the entire sur- face of the v-belt case air filter element and squeeze out the excess oil. The v-belt case air filter element should be wet but not drip- ping. 5. Install: • v-belt case ...

  • Page 144: Engine (Yp125R)

    Engine (yp125r) 3-17 3. Install: • storage box refer to “general chassis” on page 4-1. Eas37p1101 checking the exhaust system 1. Check: • exhaust pipe “1” • muffler “2” cracks/damage → replace. • exhaust system connection exhaust gas leaks → replace the gaskets “3”. 2. Check: • tightening torque eas...

  • Page 145: Engine (Yp125R)

    Engine (yp125r) 3-18 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: • coolant level tip before checking the coolant level, wait a few minutes until it settles. Eas37p1103 checking the cooling system 1. Remove: • storage box • bottom cover • footrest board refe...

  • Page 146: Engine (Yp125R)

    Engine (yp125r) 3-19 6. Remove: • coolant drain bolt (from the cylinder) “1” (along with the copper washer) 7. Drain: • coolant (from the engine and radiator) 8. Install: • coolant drain bolt (to the cylinder) (along with the copper washer ) 9. Connect: • coolant reservoir hose 10.Fill: • cooling sy...

  • Page 147: Engine (Yp125R)

    Engine (yp125r) 3-20 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then turn it off. 15.Check: • coolant level refer to “checking the coolant lev- el” on page 3-17. Tip before checking the coolant level, wait a few minutes until the coolant has settle...

  • Page 148: Engine (Yp250R)

    Engine (yp250r) 3-21 eas20470 engine (yp250r) eas20520 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must ...

  • Page 149: Engine (Yp250R)

    Engine (yp250r) 3-22 d. Measure the valve clearance with a thickness gauge “1”. Out of specification → adjust. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1”. B. Insert a thickness gauge “2” b...

  • Page 150: Engine (Yp250R)

    Engine (yp250r) 3-23 eas20600 adjusting the exhaust gas volume tip be sure to set the co density level to standard, and then adjust the exhaust gas volume. 1. Remove: • upper panel refer to “general chassis” on page 4-1. 2. Set the main switch to “off”. 3. Disconnect: • self-diagnosis signal coupler...

  • Page 151: Engine (Yp250R)

    Engine (yp250r) 3-24 2. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slide back the rubber cover “1”. B. Loosen the locknut “2”. C. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle cable free play is obtained. D. Tighten the l...

  • Page 152: Engine (Yp250R)

    Engine (yp250r) 3-25 tip before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug cap eas20700 checking the ignition timing tip prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections...

  • Page 153: Engine (Yp250R)

    Engine (yp250r) 3-26 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Disconnect: • spark plug cap 5. Remove: • spark plug notice eca37p1016 before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug well to prevent it fr...

  • Page 154: Engine (Yp250R)

    Engine (yp250r) 3-27 tip • before checking the engine oil level, wait a few minutes until the oil has settled. • do not screw the dipstick in when inspecting the oil level. Notice ewa37p1003 do not allow foreign materials to enter the crankcase. 5. Start the engine, warm it up for several min- utes,...

  • Page 155: Engine (Yp250R)

    Engine (yp250r) 3-28 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • engine oil drain bolt (along with the gasket ) 7. Fill: • crankcase (with the specified amount of the recom- mended engine oil) 8. Install: • engine oil filler cap 9. Start the engine, warm it up for several min- ut...

  • Page 156: Engine (Yp250R)

    Engine (yp250r) 3-29 5. Remove: • final transmission oil drain bolt “1” completely drain the final transmission oil. 6. Install: • final transmission oil drain bolt (along with the gasket ) 7. Fill: • final transmission oil (specified amount of the recommended final transmission oil) 8. Install: • o...

  • Page 157: Engine (Yp250R)

    Engine (yp250r) 3-30 eas20980 cleaning the v-belt case air filter element 1. Remove: • v-belt case air filter cover “1” • v-belt case air filter element 2. Clean: • v-belt case air filter element “1” blow compressed air onto the outer surface of the v-belt case air filter element. 3. Check: • v-belt...

  • Page 158: Engine (Yp250R)

    Engine (yp250r) 3-31 3. Install: • storage box refer to “general chassis” on page 4-1. Eas21080 checking the exhaust system 1. Check: • exhaust pipe “1” • muffler “2” cracks/damage → replace. • exhaust system connection exhaust gas leaks → replace the gasket “3”. 2. Check: • tightening torque eas211...

  • Page 159: Engine (Yp250R)

    Engine (yp250r) 3-32 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: • coolant level tip before checking the coolant level, wait a few minutes until it settles. Eas21120 checking the cooling system 1. Remove: • storage box • bottom cover • footrest board refer ...

  • Page 160: Engine (Yp250R)

    Engine (yp250r) 3-33 6. Remove: • coolant drain bolt (water pump) “1” (along with the copper washer) 7. Drain: • coolant (from the engine and radiator) 8. Install: • coolant drain bolt (water pump) (along with the copper washer ) 9. Connect: • coolant reservoir hose 10.Fill: • cooling system (with t...

  • Page 161: Engine (Yp250R)

    Engine (yp250r) 3-34 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then turn it off. 15.Check: • coolant level refer to “checking the coolant lev- el” on page 3-31. Tip before checking the coolant level, wait a few minutes until the coolant has settle...

  • Page 162: Chassis

    Chassis 3-35 eas21140 chassis eas21240 checking the brake fluid level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle is upright. 2. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the prope...

  • Page 163: Chassis

    Chassis 3-36 eas21260 checking the rear brake pads (yp250r) the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake pad wear indicator groove “a” has almost disap- peared → replace the brake pads as a set. Refer to “rear brake” on page 4-29. Eas21270 ch...

  • Page 164: Chassis

    Chassis 3-37 • when bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. • if bleeding is difficult, it may be nece...

  • Page 165: Chassis

    Chassis 3-38 binding/looseness → adjust the steering head. 3. Remove: • lower handlebar holder refer to “steering head” on page 4-57. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the upper ring nut “1”, the lock wash- er “2”, the center ring nut “3” and the ...

  • Page 166: Chassis

    Chassis 3-39 5. Install: • lower handlebar holder refer to “steering head” on page 4-57. Eas21530 checking the front fork 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Check: • inner tubes damage/scratches → r...

  • Page 167: Chassis

    Chassis 3-40 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the ant...

  • Page 168: Chassis

    Chassis 3-41 warning ewa37p1007 after extensive tests, the tires listed below have been approved by yamaha motor es- paña, s.A. For this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given i...

  • Page 169: Chassis

    Chassis 3-42 eas21730 lubricating the centerstand lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant lithium-soap-based grease.

  • Page 170: Electrical System

    Electrical system 3-43 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-71. Eas21770 checking the fuses refer to “electrical components” on page 8-71. Eas21780 replacing a headlight bulb to replace a high beam headlight bulb 1. Remove: ...

  • Page 171: Electrical System

    Electrical system 3-44 6. Install: • headlight bulb notice eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoro...

  • Page 172: Electrical System

    Electrical system 3-45.

  • Page 173: Chassis

    4 chassis general chassis....................................................................................... 4-1 removing the storage box............................................................ 4-2 installing the seat .............................................................................

  • Page 174

    Handlebar ................................................................................................ 4-46 removing the handlebar.............................................................. 4-48 checking the handlebar .............................................................. 4-48 install...

  • Page 176: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and storage box order job/parts to remove q’ty remarks 1 seat 1 2 grab bar 2 3 rear cover 1 4 tail/brake light assembly coupler 2 disconnect. 5 tail/brake light assembly 2 6 center panel 2 7 rear panel 2 8 license plate light coupler 1 d...

  • Page 177: General Chassis

    General chassis 4-2 eas37p1079 removing the storage box 1. Remove: • storage box bolts “1” tip be sure not to let the storage box bolts fall inside the vehicle when removing them. 2. Remove: • storage box “1” tip • unhook the tabs “a” from the storage box. • remove the storage box by moving the seat...

  • Page 178: General Chassis

    General chassis 4-3 tip when tightening the mudguard bolts, tighten the center bolt “a” first, and then tighten the side bolts “b”. 3. Install: • seat tip tighten the seat nuts in the proper tightening se- quence as shown. T r . . Seat nut 10 nm (1.0 m·kgf, 7.2 ft·lbf) b b a 3 2 1 4.

  • Page 179: General Chassis

    General chassis 4-4 removing the headlight assembly order job/parts to remove q’ty remarks 1 logo plate 1 2 upper panel 1 3 windshield 1 4 windshield bracket 1 5 headlight assembly coupler 1 disconnect. 6 front cowling assembly 1 7 headlight assembly 1 for installation, reverse the removal proce- du...

  • Page 180: General Chassis

    General chassis 4-5 removing the meter assembly order job/parts to remove q’ty remarks windshield refer to “removing the headlight assembly”. 1 rearview mirror 2 2 center handlebar cover 1 3 upper handlebar cover 1 4 lower handlebar cover 1 5 storage compartment molding 1 6 meter assembly coupler 1 ...

  • Page 181: General Chassis

    General chassis 4-6 removing the radiator cover order job/parts to remove q’ty remarks storage box refer to “removing the seat and storage box”. Front cowling assembly refer to “removing the headlight assembly”. 1 front turn signal light coupler 2 disconnect. 2 front upper panel 2 3 front turn signa...

  • Page 182: General Chassis

    General chassis 4-7 removing the storage compartment order job/parts to remove q’ty remarks radiator cover refer to “removing the radiator cover”. 1 radiator air duct 1 2 bottom cover 1 3 auxiliary dc jack coupler (option) 1 disconnect. 4 storage compartment 1 5 footrest board 1 for installation, re...

  • Page 183: General Chassis

    General chassis 4-8 removing the air filter case assembly order job/parts to remove q’ty remarks storage box refer to “removing the seat and storage box”. 1 air filter case cover 1 2 air filter element 1 3 intake air temperature sensor coupler 1 disconnect. 4 intake air temperature sensor 1 5 cylind...

  • Page 184: Front Wheel

    Front wheel 4-9 eas21870 front wheel removing the front wheel and brake disc order job/parts to remove q’ty remarks 1 front wheel axle pinch bolt 1 loosen. 2 front wheel axle 1 3 front wheel 1 4 speed sensor 1 5 spacer 1 6 front brake disc 1 for installation, reverse the removal proce- dure. 5 1 2 3...

  • Page 185: Front Wheel

    Front wheel 4-10 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 1 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure. 1 2 2 3 ls new.

  • Page 186: Front Wheel

    Front wheel 4-11 eas21890 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • front wheel tip do not ...

  • Page 187: Front Wheel

    Front wheel 4-12 eas21960 assembling the front wheel 1. Install: • wheel bearings ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearing (right side). Notice eca37p1029 do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only with the oute...

  • Page 188: Front Wheel

    Front wheel 4-13 f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. G. The spot where all the marks come to rest is the front wheel’s heavy spot “x”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • front wheel static balance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 189: Front Wheel

    Front wheel 4-14 2. Check: • front brake disc refer to “checking the front brake disc” on page 4-22. 3. Lubricate: • oil seal lips • speed sensor oil seal lip 4. Install: • spacer • speed sensor • front wheel tip • make sure that the speed sensor and the wheel hub are installed with the projection “...

  • Page 190: Rear Wheel

    Rear wheel 4-15 eas22020 rear wheel removing the rear wheel and brake disc order job/parts to remove q’ty remarks muffler refer to “engine removal (yp125r)” on page 5-1 and “engine removal (yp250r)” on page 5-61. Swingarm refer to “rear shock absorber as- semblies and swingarm” on page 4-61. 1 air f...

  • Page 191: Rear Wheel

    Rear wheel 4-16 eas28760 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on the centerstand so that the rear wheel is elevated. Also, place a suitable stand under the e...

  • Page 192: Front Brake

    Front brake 4-17 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks 1 front brake caliper bolt 2 2 speed sensor lead guide 1 3 front brake caliper 1 4 brake pad pin cap 1 5 brake pad pin 1 6 front brake pad 2 7 brake pad spring 1 8 brake pad support 1 for insta...

  • Page 193: Front Brake

    Front brake 4-18 removing the front brake master cylinder order job/parts to remove q’ty remarks lower handlebar cover refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-36. 1 brake master cylinder reservoir cap 1 2 brake master cylind...

  • Page 194: Front Brake

    Front brake 4-19 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 1 2 new s s bf.

  • Page 195: Front Brake

    Front brake 4-20 removing the front brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-36. 1 brake hose union bolt 1 2 copper washer 2 3 front brake hose 1 4 front brake caliper bolt 2 5 speed sensor lead guide 1 6 front b...

  • Page 196: Front Brake

    Front brake 4-21 disassembling the front brake caliper order job/parts to remove q’ty remarks 1 brake pad pin cap 1 2 brake pad pin 1 3 front brake pad 2 4 brake pad spring 1 5 brake pad support 1 6 brake caliper bracket 1 7 brake caliper piston 2 8 brake caliper piston dust seal 2 9 brake caliper p...

  • Page 197: Front Brake

    Front brake 4-22 eas22220 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 198: Front Brake

    Front brake 4-23 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 199: Front Brake

    Front brake 4-24 5. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-36. Eas22290 removing the front brake caliper tip before removing the brake caliper, drain the brake fluid from the entire brake system. 1. R...

  • Page 200: Front Brake

    Front brake 4-25 2. Check: • brake caliper bracket cracks/damage → replace. Eas22400 assembling the front brake caliper warning ewa37p1011 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com...

  • Page 201: Front Brake

    Front brake 4-26 • when refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. Notice eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, alway...

  • Page 202: Front Brake

    Front brake 4-27 eas22530 installing the front brake master cylinder 1. Install: • brake master cylinder “1” • brake master cylinder holder tip • align the projection “a” on the brake master cyl- inder with the hole “b” in the handlebar. • first, tighten the front bolt, then the rear bolt. 2. Instal...

  • Page 203: Front Brake

    Front brake 4-28 6. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-36. A.

  • Page 204: Rear Brake

    Rear brake 4-29 eas22550 rear brake removing the rear brake pads (yp125r) order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 rear brake caliper 1 3 brake pad clip 1 4 brake pad pin 1 5 rear brake pad 2 6 brake pad spring 1 for installation, reverse the removal proce- dure. S 1 3 4 ...

  • Page 205: Rear Brake

    Rear brake 4-30 removing the rear brake pads (yp250r) order job/parts to remove q’ty remarks 1 rear brake caliper retaining bolt 2 2 rear brake caliper 1 3 rear brake pad 2 4 brake pad shim 4 5 brake pad support 2 for installation, reverse the removal proce- dure. 2 5 5 4 3 1 4 s s 6 nm (0.6 m • kgf...

  • Page 206: Rear Brake

    Rear brake 4-31 removing the rear brake master cylinder order job/parts to remove q’ty remarks lower handlebar cover refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-36. 1 brake master cylinder reservoir cap 1 2 brake master cylinder...

  • Page 207: Rear Brake

    Rear brake 4-32 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. Bf s s 1 2 new.

  • Page 208: Rear Brake

    Rear brake 4-33 removing the rear brake caliper (yp125r) order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-36. 1 brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 rear brake caliper bolt 2 5 rear brake caliper 1 for insta...

  • Page 209: Rear Brake

    Rear brake 4-34 removing the rear brake caliper (yp250r) order job/parts to remove q’ty remarks muffler refer to “engine removal (yp250r)” on page 5-61. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-36. 1 brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 r...

  • Page 210: Rear Brake

    Rear brake 4-35 disassembling the rear brake caliper (yp125r) order job/parts to remove q’ty remarks 1 brake pad clip 1 2 brake pad pin 1 3 rear brake pad 2 4 brake pad spring 1 5 bleed screw/cap 1/1 for assembly, reverse the disassembly pro- cedure. New 1 2 3 4 5 14 nm (1.4 m • kgf, 10 ft • ibf) t....

  • Page 211: Rear Brake

    Rear brake 4-36 disassembling the rear brake caliper (yp250r) order job/parts to remove q’ty remarks 1 rear brake caliper retaining bolt 2 2 brake caliper bracket 1 3 rear brake pad 2 4 brake pad shim 4 5 brake pad support 2 6 brake caliper piston 2 7 brake caliper piston dust seal 2 8 brake caliper...

  • Page 212: Rear Brake

    Rear brake 4-37 eas22560 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 213: Rear Brake

    Rear brake 4-38 tip always install new brake pads and a new brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the br...

  • Page 214: Rear Brake

    Rear brake 4-39 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. D. Install new brake pad shims onto each new brake pad. E. Install new brake pad supports and new brake pads. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 215: Rear Brake

    Rear brake 4-40 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pistons from the brake caliper. Warning ewa13550 • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled fr...

  • Page 216: Rear Brake

    Rear brake 4-41 2. Check: • brake caliper bracket cracks/damage → replace. Eas22650 assembling the rear brake caliper warning ewa37p1015 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ...

  • Page 217: Rear Brake

    Rear brake 4-42 notice eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • brake system refer to “bleeding the hydraulic brake system” on page 3-36. 6. Check: • brake fluid level below the minimum level mark “a...

  • Page 218: Rear Brake

    Rear brake 4-43 warning ewa13540 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...

  • Page 219: Rear Brake

    Rear brake 4-44 eas22730 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents. Eas22750 installing the rear brake master cy...

  • Page 220: Rear Brake

    Rear brake 4-45 5. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-35. 6. Check: • brake lever operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hy...

  • Page 221: Handlebar

    Handlebar 4-46 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks lower handlebar cover refer to “general chassis” on page 4-1. 1 grip end 2 2 front brake light switch connector 2 disconnect. 3 front brake master cylinder holder 1 4 front brake master cylinder 1 5 right...

  • Page 222: Handlebar

    Handlebar 4-47 14 handlebar 1 for installation, reverse the removal proce- dure. Removing the handlebar order job/parts to remove q’ty remarks 7 5 5 3 13 9 11 6 6 1 14 12 4 2 10 8 1 ls ls 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 23 nm (2.3 m • kgf, 17 ft • ibf) t.R...

  • Page 223: Handlebar

    Handlebar 4-48 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” tip blow compressed air between the handlebar and the handlebar grip, and gradually pus...

  • Page 224: Handlebar

    Handlebar 4-49 tip • align the projection “a” on the brake master cyl- inder with the hole “b” in the handlebar. • first, tighten the front bolt, then the rear bolt. 6. Install: • throttle grip “1” • throttle cables “2” • right handlebar switch “3” tip • be sure to position the washer between the th...

  • Page 225: Front Fork

    Front fork 4-50 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front cowling assembly refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-9. 1 front brake caliper...

  • Page 226: Front Fork

    Front fork 4-51 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 fork spring 1 2 dust seal 1 3 oil seal clip 1 4 damper rod bolt 1 5 copper washer 1 6 damper rod 1 7 inner tube 1 8 oil flow stopper 1 9 oil seal...

  • Page 227: Front Fork

    Front fork 4-52 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • cap bolt “1” notice eca37p1027 when...

  • Page 228: Front Fork

    Front fork 4-53 eas23010 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube bends/damage/scratches → replace. Warning ewa13650 do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: •...

  • Page 229: Front Fork

    Front fork 4-54 tip while holding the damper rod with the damper rod holder “2” and t-handle “3”, tighten the damper rod bolt. 4. Install: • oil seal “1” (with the fork seal driver weight “2” and fork seal driver attachment “3”) notice eca14220 make sure the numbered side of the oil seal faces up. T...

  • Page 230: Front Fork

    Front fork 4-55 7. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) notice eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling the front fork leg, do not allow any for...

  • Page 231: Front Fork

    Front fork 4-56 2. Install: • cap bolt (along with the o-ring ) notice eca37p1028 when installing the cap bolt, take care not to damage the rectifier/regulator with the tools. Tip • before installing the cap bolt, lubricate its o- ring with grease. • if the cap bolt is difficult to install, slightly...

  • Page 232: Steering Head

    Steering head 4-57 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. Meter assembly cover refer to “general chassis” on page 4-1. Front fork legs refer to “front fork” on page 4-50. 1 speed sensor l...

  • Page 233: Steering Head

    Steering head 4-58 13 upper bearing 1 14 lower bearing 1 15 lower bearing inner race 1 16 dust seal 1 17 lower bearing outer race 1 18 upper bearing outer race 1 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks 4 5 6 7 8 9 11 12 13 ...

  • Page 234: Steering Head

    Steering head 4-59 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut “1” • lock washer • center ring nut • rubber washer • lower ring nut “2” • lower br...

  • Page 235: Steering Head

    Steering head 4-60 • rubber washer • center ring nut “2” • lock washer “3” • upper ring nut “4” refer to “checking and adjusting the steering head” on page 3-37. 3. Install: • woodruff key “1” • lower handlebar holder “2” • steering stem nut tip align the woodruff key with the groove “a” in the lowe...

  • Page 236: 4-61

    Rear shock absorber assemblies and swingarm 4-61 eas23160 rear shock absorber assemblies and swingarm removing the rear shock absorber assemblies and swingarm (yp125r) order job/parts to remove q’ty remarks muffler refer to “engine removal (yp125r)” on page 5-1. 1 rear wheel axle nut 1 2 brake hose ...

  • Page 237: 4-62

    Rear shock absorber assemblies and swingarm 4-62 removing the rear shock absorber assemblies and swingarm (yp250r) order job/parts to remove q’ty remarks muffler refer to “engine removal (yp250r)” on page 5-61. 1 rear wheel axle nut 1 2 brake hose holder 1 3 rear brake caliper 1 4 rear shock absorbe...

  • Page 238: 4-63

    Rear shock absorber assemblies and swingarm 4-63 eas23220 removing the rear shock absorber assemblies 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on the centerstand so that the rear wheel ...

  • Page 239: 4-64

    Rear shock absorber assemblies and swingarm 4-64 t r . . Rear wheel axle nut 135 nm (13.5 m·kgf, 98 ft·lbf) swingarm mounting bolt (upper side) 28 nm (2.8 m·kgf, 20 ft·lbf) (yp125r) 59 nm (5.9 m·kgf, 43 ft·lbf) (yp250r) swingarm mounting bolt (lower side) 28 nm (2.8 m·kgf, 20 ft·lbf) (yp125r) 59 nm ...

  • Page 240: 4-65

    Rear shock absorber assemblies and swingarm 4-65.

  • Page 241: Engine

    5 engine engine removal (yp125r)........................................................................ 5-1 installing the engine....................................................................... 5-5 cylinder head (yp125r)...........................................................................

  • Page 242

    Starter clutch and generator (yp125r)..................................... 5-39 removing the generator ............................................................. 5-41 removing the starter clutch ................................................... 5-41 checking the starter clutch ....................

  • Page 243

    Valves and valve springs (yp250r) ................................................. 5-77 removing the valves...................................................................... 5-78 checking the valves and valve guides .................................. 5-78 checking the valve seats .................

  • Page 244

    Crankshaft (yp250r) ........................................................................... 5-115 disassembling the crankcase.................................................. 5-117 removing the crankshaft assembly ..................................... 5-117 checking the timing chain and timing ...

  • Page 246: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-1 eas37p1135 engine removal (yp125r) removing the muffler and exhaust pipe order job/parts to remove q’ty remarks 1 o 2 sensor coupler 1 disconnect. 2 o 2 sensor 1 3 muffler 1 4 gasket 1 5 exhaust pipe 1 6 gasket 1 for installation, reverse the removal proce- dure. 1 2 3 4 ...

  • Page 247: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-2 disconnecting the leads and hoses order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-12. Coolant drain. Refer to “changing the coolant” on page 3-18. Air filter case refer to “general chassis” on page 4-1. V-belt case air...

  • Page 248: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-3 8 ground lead 1 disconnect. For installation, reverse the removal proce- dure. Disconnecting the leads and hoses order job/parts to remove q’ty remarks 3 5 1 2 4 8 7 6 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R..

  • Page 249: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-4 removing the engine order job/parts to remove q’ty remarks rear brake caliper refer to “rear shock absorber as- semblies and swingarm” on page 4-61. Tip place a suitable stand under the engine. 1 mudguard 1 2 rear shock absorber 2 3 engine mounting nut/washer/bolt 1/1/1 4...

  • Page 250: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-5 eas37p1136 installing the engine 1. Install: • engine “1” • engine bracket “2” • engine bracket rods “3” • spacer “4” • engine mounting nut/washer/bolt “5” • engine bracket rod bolts/washers/nuts “6” • engine bracket nuts/bolts “7” • rear shock absorber assemblies “8” tip...

  • Page 251: Engine Removal (Yp125R)

    Engine removal (yp125r) 5-6 tip tighten the muffler mounting bolts in the proper tightening sequence as shown. 7. Tighten: • exhaust pipe nuts 8. Tighten: • muffler joint bolt • o 2 sensor t r . . Exhaust pipe nut 20 nm (2.0 m·kgf, 14 ft·lbf) t r . . Muffler joint bolt 14 nm (1.4 m·kgf, 10 ft·lbf) o...

  • Page 252: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-7 eas37p1001 cylinder head (yp125r) removing the cylinder head order job/parts to remove q’ty remarks thermostat refer to “thermostat (yp125r)” on page 6-3. Water pump refer to “water pump (yp125r)” on page 6-5. Engine refer to “engine removal (yp125r)” on page 5-1. 1 timing...

  • Page 253: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-8 12 cylinder head 1 13 cylinder head gasket 1 14 dowel pin 2 for installation, reverse the removal proce- dure. Removing the cylinder head order job/parts to remove q’ty remarks 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf...

  • Page 254: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-9 eas37p1002 removing the cylinder head 1. Align: • “i” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the primary sheave nut on the left side of the crankshaft counterclock...

  • Page 255: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-10 tip do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head damage/scratches → replace. • cylinder head water jacket mineral deposits/rust → eliminate. 3. Measure: • cylinder head warpage out of sp...

  • Page 256: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-11 d. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner hous- ing smoothly. If there is rough movement, re- place the timing chain tensioner. E. Install the timing chain tensioner plug. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas...

  • Page 257: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-12 e. While holding the primary sheave nut with a wrench, temporarily tighten the camshaft sprocket bolt. F. Remove the wire from the timing chain. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • timing chain tensioner gasket • timing chain tensioner ▼▼▼ ▼ ▼ ...

  • Page 258: Cylinder Head (Yp125R)

    Cylinder head (yp125r) 5-13 6. Tighten: • camshaft sprocket bolt notice eca37p1002 be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil- ity of the bolt coming loose and damaging the engine. 7. Measure: • valve clearance out of specification → adjust. Refer to ...

  • Page 259: Camshaft (Yp125R)

    Camshaft (yp125r) 5-14 eas37p1007 camshaft (yp125r) removing the rocker arms and camshaft order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp125r)” on page 5-7. 1 locknut 4 2 adjusting screw 4 3 decompression cam 1 4 camshaft retainer 1 5 camshaft 1 6 rocker arm shaft 2 ...

  • Page 260: Camshaft (Yp125R)

    Camshaft (yp125r) 5-15 eas37p1008 removing the camshaft 1. Remove: • camshaft “1” tip screw an m8 bolt “2” into the threaded end of the camshaft, and then pull out the camshaft. Eas37p1009 checking the camshaft 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft....

  • Page 261: Camshaft (Yp125R)

    Camshaft (yp125r) 5-16 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas37p1011 checking the rocker arms and rocker arm shafts the following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm • rocker arm roller “1” damage/wear → replace. 2. Check: • rocker...

  • Page 262: Camshaft (Yp125R)

    Camshaft (yp125r) 5-17 eas37p1012 installing the camshaft and rocker arms 1. Lubricate: • camshaft 2. Lubricate: • rocker arms • rocker arm shafts 3. Install: • rocker arms • rocker arm shafts “1” tip • make sure that the cutout “a” in each rocker arm shaft is facing downward as shown in the illustr...

  • Page 263: 5-18

    Valves and valve springs (yp125r) 5-18 eas37p1013 valves and valve springs (yp125r) removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp125r)” on page 5-7. Rocker arms/camshaft refer to “camshaft (yp125r)” on page 5-14. 1 valve cotter...

  • Page 264: 5-19

    Valves and valve springs (yp125r) 5-19 eas37p1014 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • v...

  • Page 265: 5-20

    Valves and valve springs (yp125r) 5-20 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide r...

  • Page 266: 5-21

    Valves and valve springs (yp125r) 5-21 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin t...

  • Page 267: 5-22

    Valves and valve springs (yp125r) 5-22 tip where the valve seat and valve face contacted one another, the blueing will have been re- moved. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Lap: • valve face • valve seat tip after replacing the cylinder head or replacing the valve and valve guide...

  • Page 268: 5-23

    Valves and valve springs (yp125r) 5-23 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas37p1018 installing the valves the following procedure applies to all of the ...

  • Page 269: 5-24

    Valves and valve springs (yp125r) 5-24 4. Install: • valve cotters “1” tip install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment “2”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a s...

  • Page 270: Cylinder and Piston (Yp125R)

    Cylinder and piston (yp125r) 5-25 eas37p1019 cylinder and piston (yp125r) removing the cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp125r)” on page 5-7. 1 timing chain guide (exhaust side) 1 2 cylinder 1 3 cylinder gasket 1 4 dowel pin 2 5 clip 2...

  • Page 271: Cylinder and Piston (Yp125R)

    Cylinder and piston (yp125r) 5-26 eas37p1020 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” notice eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent them f...

  • Page 272: Cylinder and Piston (Yp125R)

    Cylinder and piston (yp125r) 5-27 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the pisto...

  • Page 273: Cylinder and Piston (Yp125R)

    Cylinder and piston (yp125r) 5-28 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Eas37p1022 checking the piston pin 1. Check: • pis...

  • Page 274: Cylinder and Piston (Yp125R)

    Cylinder and piston (yp125r) 5-29 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” tip • apply engine oil to the piston pin. • make sure the punch mark “a” on the piston points towards the exhaust side of the cylinder. • before installing the piston pin clips, cover the crankcase ope...

  • Page 275: 5-30

    V-belt automatic transmission (yp125r) 5-30 eas37p1137 v-belt automatic transmission (yp125r) removing the v-belt case cover order job/parts to remove q’ty remarks bottom cover/air filter case refer to “general chassis” on page 4-1. 1 v-belt case cover 1 2 v-belt case air duct joint 1 3 v-belt case ...

  • Page 276: 5-31

    V-belt automatic transmission (yp125r) 5-31 * apply bel-ray assembly lube®. Removing the v-belt, primary sheave and secondary sheave order job/parts to remove q’ty remarks 1 primary sheave nut/washer 1/1 2 primary fixed sheave 1 3 washer 1 4 secondary sheave nut 1 5 spacer 1 6 clutch housing 1 7 sec...

  • Page 277: 5-32

    V-belt automatic transmission (yp125r) 5-32 * apply bel-ray assembly lube®. Disassembling the secondary sheave order job/parts to remove q’ty remarks 1 clutch carrier nut 1 2 clutch carrier 1 3 clip 3 4 clutch carrier plate 1 5 clutch shoe spring 3 6 compression spring 1 7 spring seat 1 8 guide pin ...

  • Page 278: 5-33

    V-belt automatic transmission (yp125r) 5-33 eas37p1025 removing the primary sheave 1. Remove: • v-belt case tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • primary sheave nut “1” • washer • pr...

  • Page 279: 5-34

    V-belt automatic transmission (yp125r) 5-34 eas37p1027 disassembling the secondary sheave 1. Remove: • clutch carrier nut “1” tip while compressing the compression spring with the clutch spring holder “2” and clutch spring holder arm “3”, remove the clutch carrier nut. Eas37p1028 checking the clutch...

  • Page 280: 5-35

    V-belt automatic transmission (yp125r) 5-35 eas37p1031 checking the primary sheave 1. Check: • primary sliding sheave • primary fixed sheave • spacer cracks/damage/wear → replace the primary sliding sheave and primary fixed sheave as a set. Eas37p1032 checking the primary sheave weights the followin...

  • Page 281: 5-36

    V-belt automatic transmission (yp125r) 5-36 • primary sliding sheave • spacer • primary sheave weights • cam 2. Lubricate: • oil seal • primary sliding sheave • spacer tip fill the notches of the primary sliding sheave with grease. Apply grease to the inner surface of the primary sliding sheave as s...

  • Page 282: 5-37

    V-belt automatic transmission (yp125r) 5-37 • install the clutch carrier nut “2” with its tapered side “a” facing the clutch carrier. Eas37p1037 installing the v-belt 1. Install: • v-belt “1” • secondary sheave assembly “2” notice eca37p1004 do not allow grease to come in contact with the v-belt or ...

  • Page 283: 5-38

    V-belt automatic transmission (yp125r) 5-38 4. Install: • v-belt “1” • primary fixed sheave “2” • washer • primary sheave nut “3” tip install the v-belt in the primary sheave (when the pulley is at its widest position) and in the second- ary sheave (when the pulley is at its narrowest position), and...

  • Page 284: 5-39

    Starter clutch and generator (yp125r) 5-39 eas37p1038 starter clutch and generator (yp125r) removing the generator cover and stator coil order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-12. Muffler/exhaust pipe refer to “engine removal (yp125r)” o...

  • Page 285: 5-40

    Starter clutch and generator (yp125r) 5-40 removing the generator rotor and starter clutch order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 starter clutch idle gear shaft 1 4 starter clutch idle gear 1 5 generator rotor 1 6 woodruff key 1 7 starter clutch gear 1 8 starter clutch 1 for...

  • Page 286: 5-41

    Starter clutch and generator (yp125r) 5-41 eas37p1039 removing the generator 1. Remove: • generator cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor nut “1” • washer tip •...

  • Page 287: 5-42

    Starter clutch and generator (yp125r) 5-42 2. Check: • starter clutch idle gear • starter clutch gear burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear contact surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch operati...

  • Page 288: 5-43

    Starter clutch and generator (yp125r) 5-43 3. Apply: • sealant (onto the crankshaft position sensor/stator assembly lead grommet) 4. Install: • oil seal “1” 5. Install: • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. Sheave holder 90890-01701 primary cl...

  • Page 289: Electric Starter (Yp125R)

    Electric starter (yp125r) 5-44 eas37p1044 electric starter (yp125r) removing the starter motor order job/parts to remove q’ty remarks storage box/air filter case refer to “general chassis” on page 4-1. 1 starter motor lead 1 disconnect. 2 ground lead 1 disconnect. 3 starter motor 1 for installation,...

  • Page 290: Electric Starter (Yp125R)

    Electric starter (yp125r) 5-45 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor yoke 1 3 o-ring 1 4 armature assembly 1 5 shim * 6 brush 2 7 spring 2 8 front bracket/brush holder set 1 for assembly, reverse the disassembly pro- cedure. 1 7 3 5 4 2 8 6...

  • Page 291: Electric Starter (Yp125R)

    Electric starter (yp125r) 5-46 eas37p1045 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the prop...

  • Page 292: Electric Starter (Yp125R)

    Electric starter (yp125r) 5-47 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal • bushing damage/wear → replace the defective part(s)..

  • Page 293: Oil Pump (Yp125R)

    Oil pump (yp125r) 5-48 eas37p1046 oil pump (yp125r) removing the oil pump order job/parts to remove q’ty remarks starter clutch gear refer to “starter clutch and gener- ator (yp125r)” on page 5-39. 1 oil pump plate 1 2 oil pump assembly 1 3 oil pump housing cover 1 4 pin 1 5 oil pump driven gear 1 6...

  • Page 294: Oil Pump (Yp125R)

    Oil pump (yp125r) 5-49 eas37p1047 checking the oil pump 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housin...

  • Page 295: Oil Pump (Yp125R)

    Oil pump (yp125r) 5-50 tip when installing the inner rotor, align the pin “4” in the oil pump driven gear with the groove “a” in the inner rotor. 4. Check: • oil pump operation refer to “checking the oil pump” on page 5-49. Eas37p1049 installing the oil pump 1. Install: • oil pump assembly notice ec...

  • Page 296: Transmission (Yp125R)

    Transmission (yp125r) 5-51 eas37p1050 transmission (yp125r) removing the transmission order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-15. Final transmission oil drain. Refer to “changing the final trans- mission oil” on page 3-14. Secondary sheave assembly refer to ...

  • Page 297: Transmission (Yp125R)

    Transmission (yp125r) 5-52 11 drive axle 1 for installation, reverse the removal proce- dure. Removing the transmission order job/parts to remove q’ty remarks 11 7 10 9 6 5 3 3 4 6 5 2 1 (6) 8 8 11 7 9 e e e e e e e new new new new ls a b a b 16 nm (1.6 m • kgf, 11 ft • ibf) t.R. Ls.

  • Page 298: Transmission (Yp125R)

    Transmission (yp125r) 5-53 eas37p1051 removing the transmission 1. Remove: • transmission case cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas37p1052 checking the transmission 1. Check: • transmi...

  • Page 299: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-54 eas37p1054 crankshaft (yp125r) removing the crankshaft order job/parts to remove q’ty remarks engine refer to “engine removal (yp125r)” on page 5-1. Cylinder head refer to “cylinder head (yp125r)” on page 5-7. Piston refer to “cylinder and piston (yp125r)” on page 5-25. Belt...

  • Page 300: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-55 7 timing chain guide (intake side) 1 8 left crankcase 1 9 dowel pin 2 10 timing chain 1 11 right crankcase 1 12 crankshaft assembly 1 13 oil pump drive gear 1 14 bearing 1 15 oil seal 1 for installation, reverse the removal proce- dure. Removing the crankshaft order job/part...

  • Page 301: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-56 eas37p1055 disassembling the crankcase 1. Remove: • crankcase bolts tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • left crankcase “1” notice eca37p1007 tap on one sid...

  • Page 302: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-57 2. Measure: • big end side clearance out of specification → replace the crank- shaft. 3. Measure: • crankshaft width out of specification → replace the crank- shaft. 4. Check: • crankshaft sprocket “1” damage/wear → replace the crankshaft. • bearing “2” cracks/damage/wear → ...

  • Page 303: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-58 eas37p1062 checking the oil strainers 1. Check: • oil strainers damage → replace. Contaminants → clean with solvent. Eas37p1063 installing the crankshaft 1. Lubricate: • oil seals • bearings • oil pump drive gear 2. Install: • oil seal “1” (to the left crankcase) 3. Install:...

  • Page 304: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-59 eas37p1064 assembling the crankcase 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • sealant (onto the crankcase mating surfaces) tip do not allow any sealant to come into contact with the oil gallery. 3. Install: • timing chain...

  • Page 305: Crankshaft (Yp125R)

    Crankshaft (yp125r) 5-60 a 1.

  • Page 306: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-61 eas23710 engine removal (yp250r) removing the muffler and exhaust pipe order job/parts to remove q’ty remarks 1 o 2 sensor coupler 1 disconnect. 2 o 2 sensor 1 3 muffler 1 4 gasket 1 5 exhaust pipe 1 6 gasket 1 for installation, reverse the removal proce- dure. 3 4 5 2 1...

  • Page 307: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-62 disconnecting the leads and hoses order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-27. Coolant drain. Refer to “changing the coolant” on page 3-32. Air filter case refer to “general chassis” on page 4-1. Fuel injector ...

  • Page 308: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-63 8 ground lead 1 disconnect. For installation, reverse the removal proce- dure. Disconnecting the leads and hoses order job/parts to remove q’ty remarks 8 7 3 2 1 4 6 5 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R..

  • Page 309: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-64 removing the engine order job/parts to remove q’ty remarks rear brake caliper refer to “rear shock absorber as- semblies and swingarm” on page 4-61. Tip place a suitable stand under the engine. 1 mudguard 1 2 rear shock absorber 2 3 engine mounting nut/washer/bolt 1/1/1 ...

  • Page 310: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-65 eas23720 installing the engine 1. Install: • engine “1” • engine bracket “2” • engine bracket rods “3” • spacer “4” • engine mounting nut/washer/bolt “5” • engine bracket rod bolts/washers/nuts “6” • engine bracket nuts/bolts “7” • rear shock absorber assemblies “8” tip ...

  • Page 311: Engine Removal (Yp250R)

    Engine removal (yp250r) 5-66 tip tighten the muffler mounting bolts in the proper tightening sequence as shown. 7. Tighten: • exhaust pipe nuts 8. Tighten: • muffler joint bolt • o 2 sensor t r . . Exhaust pipe nut 20 nm (2.0 m·kgf, 14 ft·lbf) t r . . Muffler joint bolt 14 nm (1.4 m·kgf, 10 ft·lbf) ...

  • Page 312: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-67 eas24100 cylinder head (yp250r) removing the cylinder head order job/parts to remove q’ty remarks thermostat refer to “thermostat (yp250r)” on page 6-10. Engine refer to “engine removal (yp250r)” on page 5-61. 1 coolant temperature sensor 1 2 oil check bolt 1 3 v-belt cas...

  • Page 313: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-68 14 cylinder head gasket 1 15 dowel pin 2 for installation, reverse the removal proce- dure. Removing the cylinder head order job/parts to remove q’ty remarks 3 4 1 (4) 7 2 8 14 15 9 12 11 10 13 7 5 6 e new new new new new new new ls ls new new ls ls 10 nm (1.0 m • kgf, 7....

  • Page 314: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-69 eas24130 removing the cylinder head 1. Align: • “i” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the primary sheave nut on the left side of the crankshaft counterclockw...

  • Page 315: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-70 2. Check: • cylinder head damage/scratches → replace. • cylinder head water jacket mineral deposits/rust → eliminate. 3. Measure: • cylinder head warpage out of specification → resurface the cylinder head. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a strai...

  • Page 316: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-71 eas24230 installing the cylinder head 1. Tighten: • cylinder head nuts “1” • cylinder head bolts “2” tip • lubricate the cylinder head nuts and washers with engine oil. • tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them i...

  • Page 317: Cylinder Head (Yp250R)

    Cylinder head (yp250r) 5-72 c. Install the timing chain tensioner and gasket “5” onto the cylinder. D. Install the spring and timing chain tensioner cap bolt. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Turn: • crankshaft (turn the primary sheave nut on the left side of the crankshaft sever...

  • Page 318: Camshaft (Yp250R)

    Camshaft (yp250r) 5-73 eas23730 camshaft (yp250r) removing the rocker arms and camshaft order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp250r)” on page 5-67. 1 locknut 2 loosen. 2 adjusting screw 2 loosen. 3 lock plate 1 4 camshaft retainer 1 5 intake rocker arm shaft ...

  • Page 319: Camshaft (Yp250R)

    Camshaft (yp250r) 5-74 eas23770 removing the rocker arms and camshaft 1. Straighten the lock plate tabs “a”. 2. Remove: • lock plate “1” • camshaft retainer “2” 3. Remove: • rocker arm shafts • rocker arms tip remove the rocker arm shafts with the slide hammer bolt “1” and weight “2”. 4. Remove: • c...

  • Page 320: Camshaft (Yp250R)

    Camshaft (yp250r) 5-75 3. Check: • camshaft oil passage obstruction → blow out with compressed air. Eas23880 checking the rocker arms and rocker arm shafts the following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm damage/wear → replace. 2. Check: • rocke...

  • Page 321: Camshaft (Yp250R)

    Camshaft (yp250r) 5-76 3. Install: • exhaust rocker arm • exhaust rocker arm shaft tip make sure the exhaust rocker arm shaft is com- pletely pushed into the cylinder head. 4. Install: • intake rocker arm • intake rocker arm shaft “1” tip insert a guide stud (8 mm) “2” into the stud-bolt hole in the...

  • Page 322: 5-77

    Valves and valve springs (yp250r) 5-77 eas24270 valves and valve springs (yp250r) removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp250r)” on page 5-67. Rocker arms/camshaft refer to “camshaft (yp250r)” on page 5-73. 1 valve cotter ...

  • Page 323: 5-78

    Valves and valve springs (yp250r) 5-78 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • val...

  • Page 324: 5-79

    Valves and valve springs (yp250r) 5-79 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide r...

  • Page 325: 5-80

    Valves and valve springs (yp250r) 5-80 • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness “a” out of specification → replace the valve. 6. Measure: • valve stem runout out of specification → replace the valve. ...

  • Page 326: 5-81

    Valves and valve springs (yp250r) 5-81 tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice eca13790 do not let ...

  • Page 327: 5-82

    Valves and valve springs (yp250r) 5-82 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24340 installing the valves the following procedure applies to all of the va...

  • Page 328: 5-83

    Valves and valve springs (yp250r) 5-83 3. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • inner valve spring “4” • outer valve spring “5” • upper spring seat “6” (into the cylinder head) tip • make sure each valve is installed in its original place. • install the valve springs w...

  • Page 329: Cylinder and Piston (Yp250R)

    Cylinder and piston (yp250r) 5-84 eas24350 cylinder and piston (yp250r) removing the cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head (yp250r)” on page 5-67. 1 water pump outlet pipe 1 2 timing chain guide (exhaust side) 1 3 cylinder 1 4 cylinder gaske...

  • Page 330: Cylinder and Piston (Yp250R)

    Cylinder and piston (yp250r) 5-85 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” notice eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent them fro...

  • Page 331: Cylinder and Piston (Yp250R)

    Cylinder and piston (yp250r) 5-86 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the pisto...

  • Page 332: Cylinder and Piston (Yp250R)

    Cylinder and piston (yp250r) 5-87 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Eas24440 checking the piston pin 1. Check: • pisto...

  • Page 333: Cylinder and Piston (Yp250R)

    Cylinder and piston (yp250r) 5-88 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” tip • apply engine oil to the piston pin. • make sure the arrow mark “a” on the piston points towards the exhaust side of the cylinder. • before installing the piston pin clips, cover the crankcase ope...

  • Page 334: 5-89

    V-belt automatic transmission (yp250r) 5-89 eas24610 v-belt automatic transmission (yp250r) removing the v-belt case cover order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. 1 v-belt case air filter cover 1 2 v-belt case air filter element 1 3 v-belt case ...

  • Page 335: 5-90

    V-belt automatic transmission (yp250r) 5-90 removing the v-belt, primary sheave and secondary sheave order job/parts to remove q’ty remarks 1 primary sheave nut/washer 1/1 2 primary fixed sheave 1 3 secondary sheave bracket 1 4 secondary sheave nut 1 5 spacer 1 6 clutch housing 1 7 secondary sheave ...

  • Page 336: 5-91

    V-belt automatic transmission (yp250r) 5-91 * apply shell bt grease 3® (yamaha grease g 90793-40016). 15 spacer 4 for installation, reverse the removal proce- dure. Yamaha grease g 90793-40016 removing the v-belt, primary sheave and secondary sheave order job/parts to remove q’ty remarks ls ls ls ls...

  • Page 337: 5-92

    V-belt automatic transmission (yp250r) 5-92 * apply bel-ray assembly lube®. Disassembling the secondary sheave order job/parts to remove q’ty remarks 1 clutch carrier nut 1 2 clutch carrier 1 3 clip 3 4 clutch carrier plate 1 5 clutch shoe spring 3 6 compression spring 1 7 spring seat 1 8 guide pin ...

  • Page 338: 5-93

    V-belt automatic transmission (yp250r) 5-93 eas24620 removing the primary sheave 1. Remove: • v-belt case tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • primary sheave nut “1” • washer • prim...

  • Page 339: 5-94

    V-belt automatic transmission (yp250r) 5-94 eas24640 disassembling the secondary sheave 1. Remove: • clutch carrier nut “1” tip while compressing the compression spring with the clutch spring holder “2” and clutch spring holder arm “3”, remove the clutch carrier nut. Eas24650 checking the clutch hou...

  • Page 340: 5-95

    V-belt automatic transmission (yp250r) 5-95 eas24680 checking the primary sheave 1. Check: • primary sliding sheave • primary fixed sheave • spacer cracks/damage/wear → replace the primary sliding sheave and primary fixed sheave as a set. Eas24690 checking the primary sheave weights the following pr...

  • Page 341: 5-96

    V-belt automatic transmission (yp250r) 5-96 • primary sliding sheave • spacer • primary sheave weights • cam 2. Install: • primary sheave weights “1” • spacer “2” tip before installing the primary sheave weights, lu- bricate the inside and outside of each weight with shell bt grease 3®. Eas24730 ass...

  • Page 342: 5-97

    V-belt automatic transmission (yp250r) 5-97 eas24740 installing the v-belt 1. Install: • v-belt “1” • secondary sheave assembly “2” notice eca37p1011 do not allow grease to come in contact with the v-belt or secondary sheave assembly. Tip • install the v-belt with the printed arrow mark on the v-bel...

  • Page 343: 5-98

    V-belt automatic transmission (yp250r) 5-98 4. Install: • v-belt “1” • primary fixed sheave “2” • washer • primary sheave nut “3” notice eca37p1012 do not allow grease to contact the primary sheave assembly. Tip install the v-belt in the primary sheave (when the pulley is at its widest position) and...

  • Page 344: 5-99

    Starter clutch and generator (yp250r) 5-99 eas24480 starter clutch and generator (yp250r) removing the generator cover and stator coil order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-27. Muffler/exhaust pipe refer to “engine removal (yp250r)” on ...

  • Page 345: 5-100

    Starter clutch and generator (yp250r) 5-100 removing the generator rotor and starter clutch order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 starter clutch idle gear shaft 1 4 starter clutch idle gear 1 5 generator rotor 1 6 woodruff key 1 7 starter clutch gear 1 8 starter clutch 1 fo...

  • Page 346: 5-101

    Starter clutch and generator (yp250r) 5-101 eas24490 removing the generator 1. Remove: • generator cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor nut “1” • washer tip • ...

  • Page 347: 5-102

    Starter clutch and generator (yp250r) 5-102 2. Check: • starter clutch idle gear • starter clutch gear burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s contact surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch oper...

  • Page 348: 5-103

    Starter clutch and generator (yp250r) 5-103 3. Apply: • sealant (onto the crankshaft position sensor/stator assembly lead grommet) 4. Install: • oil seal “1” 5. Install: • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. Yamaha bond no. 1215 90890-85505 (t...

  • Page 349: Electric Starter (Yp250R)

    Electric starter (yp250r) 5-104 eas24780 electric starter (yp250r) removing the starter motor order job/parts to remove q’ty remarks storage box/air filter case refer to “general chassis” on page 4-1. 1 starter motor lead 1 disconnect. 2 ground lead 1 disconnect. 3 starter motor 1 for installation, ...

  • Page 350: Electric Starter (Yp250R)

    Electric starter (yp250r) 5-105 disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 o-ring 1 3 shim * 4 lock washer 1 5 oil seal 1 6 bearing 1 7 starter motor yoke 1 8 armature assembly 1 9 o-ring 1 10 shim * 11 brush holder set 1 12 starter motor r...

  • Page 351: Electric Starter (Yp250R)

    Electric starter (yp250r) 5-106 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the prope...

  • Page 352: Electric Starter (Yp250R)

    Electric starter (yp250r) 5-107 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing damage/wear → replace the bearing. Eas24800 assembling the starter motor 1. Install: • starter motor rear cover “1” • starter motor yoke “2” • starter motor front cover “3” tip align the match ...

  • Page 353: Oil Pump (Yp250R)

    Oil pump (yp250r) 5-108 eas24910 oil pump (yp250r) removing the oil pump order job/parts to remove q’ty remarks starter clutch gear refer to “starter clutch and gener- ator (yp250r)” on page 5-99. 1 oil baffle plate 1 2 oil pump assembly 1 3 oil pump gasket 1 4 circlip 1 5 washer 1 6 oil pump driven...

  • Page 354: Oil Pump (Yp250R)

    Oil pump (yp250r) 5-109 14 oil pump housing 1 for installation, reverse the removal proce- dure. Removing the oil pump order job/parts to remove q’ty remarks new new 4 1 5 6 7 9 9 2 8 13 11 14 12 10 3 ls e e m 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R. 12 nm (1.2 m • kgf, 8.7 ft • ibf) t.R..

  • Page 355: Oil Pump (Yp250R)

    Oil pump (yp250r) 5-110 eas24960 checking the oil pump 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing...

  • Page 356: Oil Pump (Yp250R)

    Oil pump (yp250r) 5-111 4. Check: • oil pump operation refer to “checking the oil pump” on page 5-110. Eas25020 installing the oil pump 1. Install: • oil pump assembly notice eca13890 after tightening the bolts, make sure the oil pump turns smoothly. T r . . Oil pump assembly bolt 7 nm (0.7 m·kgf, 5...

  • Page 357: Transmission (Yp250R)

    Transmission (yp250r) 5-112 eas26240 transmission (yp250r) removing the transmission order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-15. Final transmission oil drain. Refer to “changing the final trans- mission oil” on page 3-28. Secondary sheave assembly refer to “...

  • Page 358: Transmission (Yp250R)

    Transmission (yp250r) 5-113 12 primary driven gear 1 for installation, reverse the removal proce- dure. Removing the transmission order job/parts to remove q’ty remarks e e e e e a b ls new 5 3 16 nm (1.6 m • kgf, 11 ft • ibf) t.R. E.

  • Page 359: Transmission (Yp250R)

    Transmission (yp250r) 5-114 eas26250 removing the transmission 1. Remove: • transmission case cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas26300 checking the transmission 1. Check: • transmissi...

  • Page 360: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-115 eas25960 crankshaft (yp250r) removing the crankshaft order job/parts to remove q’ty remarks water pump assembly refer to “water pump (yp250r)” on page 6-12. Engine refer to “engine removal (yp250r)” on page 5-61. Cylinder head refer to “cylinder head (yp250r)” on page 5-67....

  • Page 361: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-116 6 timing chain guide retaining bolt 1 7 timing chain guide (intake side) 1 8 right crankcase 1 9 dowel pin 2 10 crankshaft assembly 1 11 timing chain 1 12 left crankcase 1 13 oil seal 1 for installation, reverse the removal proce- dure. Removing the crankshaft order job/par...

  • Page 362: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-117 eas25560 disassembling the crankcase 1. Remove: • crankcase bolts tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • right crankcase “1” tip • remove the right crankcase...

  • Page 363: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-118 eas24180 checking the timing chain and timing chain guide 1. Check: • timing chain damage/stiffness → replace the timing chain and camshaft sprocket as a set. 2. Check: • timing chain guide (intake side) damage/wear → replace. Eas26060 checking the crankshaft and connecting...

  • Page 364: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-119 eas25580 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compresse...

  • Page 365: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-120 notice eca13970 to avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Tip hold the connecting rod at top dead center (tdc) with one hand while turning the nut o...

  • Page 366: Crankshaft (Yp250R)

    Crankshaft (yp250r) 5-121.

  • Page 367: Cooling System

    6 cooling system radiator (yp125r) ..................................................................................... 6-1 checking the radiator.................................................................... 6-2 installing the radiator.............................................................

  • Page 368: Radiator (Yp125R)

    Radiator (yp125r) 6-1 eas37p1105 radiator (yp125r) removing the radiator order job/parts to remove q’ty remarks radiator cover/radiator air duct/bottom cov- er/footrest board refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-18. 1 radiator cap 1 2 coola...

  • Page 369: Radiator (Yp125R)

    Radiator (yp125r) 6-2 eas37p1106 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses cracks/damage → repla...

  • Page 370: Thermostat (Yp125R)

    Thermostat (yp125r) 6-3 eas37p1108 thermostat (yp125r) removing the thermostat order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-18. 1 radiator inlet hose 1 disconnect. 2 thermostat inlet hose 1 3 therm...

  • Page 371: Thermostat (Yp125R)

    Thermostat (yp125r) 6-4 eas37p1109 checking the thermostat 1. Check: • thermostat does not open at 70.5–73.5 °c (158.9–164.3 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a t...

  • Page 372: Water Pump (Yp125R)

    Water pump (yp125r) 6-5 eas37p1111 water pump (yp125r) removing the water pump order job/parts to remove q’ty remarks storage box/footrest board refer to “general chassis” on page 4-1. 1 thermostat inlet hose 1 disconnect. 2 radiator outlet hose 1 disconnect. 3 water pump housing cover 1 4 water pum...

  • Page 373: Water Pump (Yp125R)

    Water pump (yp125r) 6-6 eas37p1112 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 2. Remove: • bearing “1” tip remove the bearing from the outside of the wa- ter pump housing “2”. Eas37p1113 checking the wat...

  • Page 374: Water Pump (Yp125R)

    Water pump (yp125r) 6-7 • water pump housing plate 1 “3” tip • after installation, check that the impeller shaft rotates smoothly. • be sure to align the bolt holes in the water pump housing plate gasket and water pump housing plates. Make sure that the gasket does not block the holes “a” in the wat...

  • Page 375: Radiator (Yp250R)

    Radiator (yp250r) 6-8 eas26380 radiator (yp250r) removing the radiator order job/parts to remove q’ty remarks radiator cover/radiator air duct/bottom cov- er/footrest board refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-32. 1 radiator cap 1 2 coolant...

  • Page 376: Radiator (Yp250R)

    Radiator (yp250r) 6-9 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses cracks/damage → replace...

  • Page 377: Thermostat (Yp250R)

    Thermostat (yp250r) 6-10 eas26440 thermostat (yp250r) removing the thermostat order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-32. 1 radiator inlet hose 1 disconnect. 2 thermostat inlet hose 1 3 thermo...

  • Page 378: Thermostat (Yp250R)

    Thermostat (yp250r) 6-11 eas26450 checking the thermostat 1. Check: • thermostat does not open at 80.5–83.5 °c (176.9–182.3 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a th...

  • Page 379: Water Pump (Yp250R)

    Water pump (yp250r) 6-12 eas26500 water pump (yp250r) removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Bottom cover refer to “general chassis” on page 4-1. Generat...

  • Page 380: Water Pump (Yp250R)

    Water pump (yp250r) 6-13 a: oil pump side 9 circlip 1 10 impeller shaft 1 11 water pump seal 1 12 bearing 1 13 oil seal 1 for installation, reverse the removal proce- dure. Removing the water pump order job/parts to remove q’ty remarks new ls ls 12 11 13 new new new 7 8 10 9 5 6 4 3 2 1 ls ls a lt m...

  • Page 381: Water Pump (Yp250R)

    Water pump (yp250r) 6-14 eas26510 disassembling the water pump 1. Remove: • rubber damper holder “1” • rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) tip do not scratch the impeller shaft. 2. Remove: • water pump seal “1” tip remove the water pump seal from the inside of t...

  • Page 382: Water Pump (Yp250R)

    Water pump (yp250r) 6-15 3. Install: • rubber damper “1” • rubber damper holder “2” tip before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Notice eca14090 make sure the rubber damp...

  • Page 383: Fuel System

    7 fuel system fuel tank..................................................................................................... 7-1 removing the fuel tank .................................................................. 7-3 checking the fuel pressure .....................................................

  • Page 384: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks storage box/front cowling assembly/bottom cover refer to “general chassis” on page 4-1. 1 horn 1 2 fuel pump coupler 1 disconnect. 3 fuel sender coupler 1 disconnect. 4 fuel tank breather hose 1 5 fuel tan...

  • Page 385: Fuel Tank

    Fuel tank 7-2 15 radiator bracket 1 16 radiator bolt 2 17 fuel tank 1 for installation, reverse the removal proce- dure. Removing the fuel tank order job/parts to remove q’ty remarks new new lt 16 13 13 14 12 16 1 15 11 (4) (4) 10 8 9 3 7 6 2 5 17 4 13 nm (1.3 m • kgf, 9.4 ft • ibf) t.R. 7 nm (0.7 m...

  • Page 386: Fuel Tank

    Fuel tank 7-3 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose connector cover “1” 3. Remove: • fuel hose “2” notice eca37p1023 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the ho...

  • Page 387: Fuel Tank

    Fuel tank 7-4 c. Start the engine. D. Measure the fuel pressure. Faulty → replace the fuel tank (with fuel pump). E. Connect the fuel hose and install the fuel hose connector cover. Refer to “installing the fuel tank” on page 7-4. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas37p1072 installi...

  • Page 388: Throttle Body

    Throttle body 7-5 eas26970 throttle body removing the throttle body (yp125r) order job/parts to remove q’ty remarks storage box/footrest board refer to “general chassis” on page 4-1. 1 intake air pressure sensor hose 1 2 intake air pressure sensor coupler 1 disconnect. 3 intake air pressure sensor 1...

  • Page 389: Throttle Body

    Throttle body 7-6 15 intake manifold 1 16 intake manifold joint 1 for installation, reverse the removal proce- dure. Removing the throttle body (yp125r) order job/parts to remove q’ty remarks 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft • i...

  • Page 390: Throttle Body

    Throttle body 7-7 removing the throttle body (yp250r) order job/parts to remove q’ty remarks storage box/footrest board refer to “general chassis” on page 4-1. 1 intake air pressure sensor hose 1 2 intake air pressure sensor coupler 1 disconnect. 3 intake air pressure sensor 1 4 intake air pressure ...

  • Page 391: Throttle Body

    Throttle body 7-8 17 intake manifold joint 1 for installation, reverse the removal proce- dure. Removing the throttle body (yp250r) order job/parts to remove q’ty remarks 12 3 4 1 9 5 10 16 13 8 8 17 15 11 7 6 14 2 ls new new new e ls 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R. 10 nm (1.0 m • kgf, 7.2 ft...

  • Page 392: Throttle Body

    Throttle body 7-9 eas37p1074 removing the fuel hose 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose connector cover “1” 3. Disconnect: • fuel hose “2” notice eca37p1025 • be sure to disconnect the fuel hose by hand. Do not forcefully disconn...

  • Page 393: Throttle Body

    Throttle body 7-10 tip make sure that the recess “a” in the intake man- ifold joint is aligned with the thermostat cover. Eas37p1075 installing the fuel hose 1. Install: • fuel hose • fuel hose connector cover notice eca37p1026 when installing the fuel hose, make sure that it is securely connected, ...

  • Page 394: Throttle Body

    Throttle body 7-11.

  • Page 395: Electrical System

    8 electrical system ignition system ......................................................................................... 8-1 circuit diagram .................................................................................. 8-1 troubleshooting ......................................................

  • Page 396

    Electrical components...................................................................... 8-71 checking the switches ................................................................. 8-73 checking the bulbs and bulb sockets ................................... 8-76 checking the fuses .................

  • Page 398: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27100 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy /b gy ...

  • Page 399: Ignition System

    Ignition system 8-2 2. Crankshaft position sensor 5. Main switch 6. Ecu fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 18.Sidestand switch 29.Lean angle sensor 31.Ecu (engine control unit) 32.Ignition coil 33.Spark plug.

  • Page 400: Ignition System

    Ignition system 8-3 eas27120 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling 3. Storage compartment 4. Footrest board ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ n...

  • Page 401: Ignition System

    Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-73. Replace the main switch/immobilizer unit. 9. Check the sidestand switch. Refer to “checking the switches” on page 8-73. Replace the sidestand switch. 10.Check the lean...

  • Page 402: Electric Starting System

    Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb...

  • Page 403: Electric Starting System

    Electric starting system 8-6 5. Main switch 9. Ignition fuse 11.Signaling system fuse 12.Battery 13.Main fuse 14.Starter relay 15.Starter motor 16.Diode 17.Frame ground 18.Sidestand switch 20.Starting circuit cut-off relay 22.Start switch 24.Front brake light switch 46.Rear brake light switch.

  • Page 404: Electric Starting System

    Electric starting system 8-7 eas27180 starting circuit cut-off system operation if the main switch is set to “on” (switch circuit is closed), the starter motor can only operate if the fol- lowing conditions are met: • the brake lever is pulled to the handlebar (the brake switch is closed) and the si...

  • Page 405: Electric Starting System

    Electric starting system 8-8 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Starting circuit cut-off relay 6. Sidestand switch 7. Signaling system fuse 8. Front brake light switch 9. Rear brake light switch 10. Start switch 11. Diode 12. Starter relay 13. Starter motor.

  • Page 406: Electric Starting System

    Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling 3. Storage compartment ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, i...

  • Page 407: Electric Starting System

    Electric starting system 8-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the sidestand switch. Refer to “checking the switches” on page 8-73. Replace the sidestand switch. 9. Check the brake light switches (front and rear). Refer to “checking the switches” on page 8-73. Replace the brake light...

  • Page 408: Charging System

    Charging system 8-11 eas27200 charging system eas27210 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b l /w b b (blue) l /y b (blue) r /bl /r w w w w w2 w3 r w gy /bw /r r /l r /b g /l y /l b /w l/ w dg w /y br br /w ch g /y dg br ch g /yl /w br /w w /y r w3 w2 w b l /w (bla...

  • Page 409: Charging System

    Charging system 8-12 1. Ac magneto 3. Rectifier/regulator 12.Battery 13.Main fuse 17.Frame ground.

  • Page 410: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page 8-77. Replac...

  • Page 411: Charging System

    Charging system 8-14.

  • Page 412: Lighting System

    Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy /b gy...

  • Page 413: Lighting System

    Lighting system 8-16 5. Main switch 6. Ecu fuse 8. Turn signal/hazard fuse 9. Ignition fuse 10.Headlight fuse 11.Signaling system fuse 12.Battery 13.Main fuse 17.Frame ground 31.Ecu (engine control unit) 40.Headlight relay 42.Dimmer switch 43.Pass switch 49.Tail/brake light 55.Headlight 56.Auxiliary...

  • Page 414: Lighting System

    Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillights, license plate light, auxiliary lights or meter light. Tip • before troubleshooting, remove the following part(s): 1. Front cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok...

  • Page 415: Lighting System

    Lighting system 8-18 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 8-15. Properly connect or repair the lighting sys- tem wiring. Replace the ecu or meter assembly..

  • Page 416: Signaling System

    Signaling system 8-19 eas27270 signaling system eas27280 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy /b ...

  • Page 417: Signaling System

    Signaling system 8-20 2. Crankshaft position sensor 5. Main switch 6. Ecu fuse 8. Turn signal/hazard fuse 9. Ignition fuse 11.Signaling system fuse 12.Battery 13.Main fuse 17.Frame ground 23.Hazard switch 24.Front brake light switch 25.Coolant temperature sensor 30.Speed sensor 31.Ecu (engine contro...

  • Page 418: Signaling System

    Signaling system 8-21 eas27290 troubleshooting • any of the following fail to light: turn signal lights, brake lights, warning light or indicator lights. • the horn fails to sound. • the fuel meter fails to operate. • the coolant temperature meter fails to operate. • the speedometer fails to operate...

  • Page 419: Signaling System

    Signaling system 8-22 ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ 2. Check the horn. Refer to “checking the horn” on page 8-85. Replace the horn. 3. Check the en...

  • Page 420: Signaling System

    Signaling system 8-23 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the fuel meter, fuel level warning light, or both fail to come on. Ng → ok ↓ ng → ok ↓ the coolant temperature meter, coolant temperature warning light, or both fail to come on. Ng → ok ↓ 2. Check the turn signal switch. Refer to “checkin...

  • Page 421: Signaling System

    Signaling system 8-24 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ the tachometer fails to operate. Ng → ok ↓ ng → ok ↓ the air temperature meter fails to operate. Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or r...

  • Page 422: Signaling System

    Signaling system 8-25 ng → ok ↓ the v-belt replacement indicator fails to come on. Ng → ok ↓ ng → ok ↓ the engine oil change indicator fails to come on. Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 8-19. Properly connect or repair the signaling system wir...

  • Page 423: Signaling System

    Signaling system 8-26.

  • Page 424: Cooling System

    Cooling system 8-27 eas27300 cooling system eas27310 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy /b gy /...

  • Page 425: Cooling System

    Cooling system 8-28 5. Main switch 6. Ecu fuse 7. Radiator fan motor fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 25.Coolant temperature sensor 31.Ecu (engine control unit) 73.Radiator fan motor 74.Radiator fan motor relay.

  • Page 426: Cooling System

    Cooling system 8-29 eas27320 troubleshooting • the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling 3. Radiator cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition...

  • Page 427: Cooling System

    Cooling system 8-30

  • Page 428: Fuel Injection System

    Fuel injection system 8-31 eas27330 fuel injection system eas27340 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p...

  • Page 429: Fuel Injection System

    Fuel injection system 8-32 2. Crankshaft position sensor 4. Backup fuse (immobilizer unit and meter assembly) 5. Main switch 6. Ecu fuse 7. Radiator fan motor fuse 9. Ignition fuse 10.Headlight fuse 12.Battery 13.Main fuse 17.Frame ground 18.Sidestand switch 19.Fuel pump 25.Coolant temperature senso...

  • Page 430: Fuel Injection System

    Fuel injection system 8-33 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 431: Fuel Injection System

    Fuel injection system 8-34 when an abnormal signal is received from a sensor, the ecu processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating, depending on t...

  • Page 432: Fuel Injection System

    Fuel injection system 8-35 setting the diagnostic mode 1. Set the main switch to “off”. 2. Disconnect the self-diagnosis signal coupler, and then connect the fi diagnostic tool “1” as shown. 3. While pressing the “mode” button, set the main switch to “on”. Tip • “diag” appears on the lcd of the fi d...

  • Page 433: Fuel Injection System

    Fuel injection system 8-36 • if a diagnostic code number does not have a corresponding fault code number, the information is shown in “diagnostic code table”. (refer to “diagnostic code table” on page 8-54.) eas27481 troubleshooting details this section describes the measures per fault code number d...

  • Page 434: Fuel Injection System

    Fuel injection system 8-37 fault code no. 13 item intake air pressure sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 03 fi diagnostic tool display displays the intake air pressure. Checking method operate the throttle while pul...

  • Page 435: Fuel Injection System

    Fuel injection system 8-38 3 connections • intake air pressure sensor coupler • wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. 4 defective intake ...

  • Page 436: Fuel Injection System

    Fuel injection system 8-39 fault code no. 16 item throttle position sensor: stuck throttle position sensor is de- tected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 01 fi diagnostic tool display throttle angle • 9–22 (fully closed position) • 93–106 (fully opened...

  • Page 437: Fuel Injection System

    Fuel injection system 8-40 reinstatement method reconnecting the wiring and retracting the sidestand. Fault code no. 21 item coolant temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 06 fi diagnostic tool display displ...

  • Page 438: Fuel Injection System

    Fuel injection system 8-41 1 installed condition of intake air tempera- ture sensor. • check for looseness or pinching. 2 connections • intake air temperature sensor coupler • wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupl...

  • Page 439: Fuel Injection System

    Fuel injection system 8-42 reinstatement method starting the engine and operating it at idle. Fault code no. 30 item latch up detected. No normal signal is received from the lean angle sensor. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 08 fi diagnostic tool d...

  • Page 440: Fuel Injection System

    Fuel injection system 8-43 1 installed condition of o 2 sensor. • check for looseness or pinching. 2 connections • o 2 sensor coupler • wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair ...

  • Page 441: Fuel Injection System

    Fuel injection system 8-44 4 check fuel pressure. • refer to “checking the fuel pressure” on page 7-3. 5 defective o 2 sensor. • replace if defective. Reinstatement method starting the engine and operating it at idle. Fault code no. 33 item ignition coil: open or short circuit detected in the primar...

  • Page 442: Fuel Injection System

    Fuel injection system 8-45 fault code no. 37 item isc valve: engine speed is high when the engine is idling. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 54 actuation actuates and fully closes the isc valve, then opens it to the stand- by opening position when the ...

  • Page 443: Fuel Injection System

    Fuel injection system 8-46 probable cause of malfunction check or maintenance job 1 connections • injector coupler • wire harness ecu coupler • check the couplers for any pins that may be pulled out. • check the locking condition of the couplers. • if there is a malfunction, repair it and connect th...

  • Page 444: Fuel Injection System

    Fuel injection system 8-47 fault code no. 42 item speed sensor: no normal signals are received from the speed sensor. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 07 fi diagnostic tool display 0–999 checking method check that the number increases when the front whe...

  • Page 445: Fuel Injection System

    Fuel injection system 8-48 checking method compare with the actually measured battery voltage. (if the bat- tery voltage is low, perform recharging.) probable cause of malfunction check or maintenance job 1 connections • wire harness ecu coupler • main switch coupler • check the coupler for any pins...

  • Page 446: Fuel Injection System

    Fuel injection system 8-49 fault code no. 46 item power supply to the fuel injection system is not normal. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — fi diagnostic tool display — checking method — probable cause of malfunction check or maintenance job 1 connect...

  • Page 447: Fuel Injection System

    Fuel injection system 8-50 fault code no. 61 item isc (idle speed control) unit: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 54 actuation actuates and fully closes the isc valve, then opens it to the stand- by opening position when ...

  • Page 448: Fuel Injection System

    Fuel injection system 8-51 2 open or short circuit in wire harness. • repair or replace if there is an open or short circuit. • between meter assembly coupler and self-di- agnosis signal coupler. (yellow/blue–yellow/blue) • between self-diagnosis signal coupler and ecu coupler. (yellow/blue–yellow/b...

  • Page 449: Fuel Injection System

    Fuel injection system 8-52 fault code no. Er-3 item ecu internal malfunction (output signal error): data from the ecu cannot be received correctly. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — checking method — probable cause of malfunction check ...

  • Page 450: Fuel Injection System

    Fuel injection system 8-53 2 open or short circuit in wire harness. • repair or replace if there is an open or short circuit. • between meter assembly coupler and self-di- agnosis signal coupler. (yellow/blue–yellow/blue) • between self-diagnosis signal coupler and ecu coupler. (yellow/blue–yellow/b...

  • Page 451: Fuel Injection System

    Fuel injection system 8-54 eas30700 diagnostic code table tip the following tables contain information about diagnostic code numbers that do not have a correspond- ing fault code number. (these items are not listed in “troubleshooting details”.) diag- nostic code no. Item fi diagnostic tool dis- pla...

  • Page 452: Fuel Injection System

    Fuel injection system 8-55 communication error with the fi diagnostic tool lcd display symptom probable cause of malfunction waiting for con- nection.... No signals are received from the ecu. • improper connection in connecting lead. • the main switch is set to “off”. • malfunction in fi diagnostic ...

  • Page 453: Fuel Injection System

    Fuel injection system 8-56.

  • Page 454: Fuel Pump System

    Fuel pump system 8-57 eas27550 fuel pump system eas27560 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy /b ...

  • Page 455: Fuel Pump System

    Fuel pump system 8-58 5. Main switch 6. Ecu fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 19.Fuel pump 31.Ecu (engine control unit).

  • Page 456: Fuel Pump System

    Fuel pump system 8-59 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Storage box 2. Front cowling ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ecu, and ignition) refer to “checking the fus- es...

  • Page 457: Fuel Pump System

    Fuel pump system 8-60

  • Page 458: Immobilizer System

    Immobilizer system 8-61 eas27640 immobilizer system eas27650 circuit diagram r br /l br /r br /r r br /l b y /l lg r /w r /gb 2 b b b /wr /l y /l b1 b /l b2 b1 b l /w b b (blue) l /y b (blue) r /bl /r (blue) g /y r /b l /y w /y g /r gy /b gy /r p /w gy /b (black) (green) br /wg y/ b o /rb /w p gy gy...

  • Page 459: Immobilizer System

    Immobilizer system 8-62 4. Backup fuse (immobilizer unit and meter assembly) 5. Main switch 6. Ecu fuse 9. Ignition fuse 12.Battery 13.Main fuse 17.Frame ground 31.Ecu (engine control unit) 61.Immobilizer system indicator light 62.Multifunction meter 75.Self-diagnosis signal coupler 76.Immobilizer u...

  • Page 460: Immobilizer System

    Immobilizer system 8-63 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 461: Immobilizer System

    Immobilizer system 8-64 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with ...

  • Page 462: Immobilizer System

    Immobilizer system 8-65 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Tip do not start the engine with a standard...

  • Page 463: Immobilizer System

    Immobilizer system 8-66 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost sta...

  • Page 464: Immobilizer System

    Immobilizer system 8-67 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number ...

  • Page 465: Immobilizer System

    Immobilizer system 8-68 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 52 immobilizer unit codes between the key and immobilizer unit do no...

  • Page 466: Immobilizer System

    Immobilizer system 8-69 a. Light on b. Light off.

  • Page 467: Immobilizer System

    Immobilizer system 8-70

  • Page 468: Electrical Components

    Electrical components 8-71 eas27970 electrical components 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 22 23 24 25 26 28 29 30 27 21 14.

  • Page 469: Electrical Components

    Electrical components 8-72 1. Battery 2. Air temperature sensor 3. Ecu (engine control unit) 4. Front brake light switch 5. Rear brake light switch 6. Main switch/immobilizer unit 7. Fuel sender 8. Ignition coil 9. Fuel injector 10. Intake air temperature sensor 11. Intake air pressure sensor 12. Th...

  • Page 470: Electrical Components

    Electrical components 8-73 eas27980 checking the switches 1 2 3 4 br/w ch dg p b b b (blue) 10 5 7 6 8 9 br g/y on r br/l br/r off open lock p br/r r br/l g/y br r/y l/b b p dg y g br/w ch l/b g y r/y y dg ch br/w g/y br l/w w/y l/w dg w/y br br/w ch g/y.

  • Page 471: Electrical Components

    Electrical components 8-74 1. Start switch 2. Hazard switch 3. Front brake light switch 4. Main switch 5. Dimmer switch 6. Pass switch 7. Turn signal switch 8. Horn switch 9. Rear brake light switch 10. Sidestand switch.

  • Page 472: Electrical Components

    Electrical components 8-75 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and, if necessary, replace the switch. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes...

  • Page 473: Electrical Components

    Electrical components 8-76 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or bo...

  • Page 474: Electrical Components

    Electrical components 8-77 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in th...

  • Page 475: Electrical Components

    Electrical components 8-78 c. Set on the switches to verify if the electrical circuit is operational. D. If the fuse immediately blows again, check the electrical circuit. Warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wron...

  • Page 476: Electrical Components

    Electrical components 8-79 tip • the charge state of a vrla (valve regulated lead acid) battery can be checked by measur- ing its open-circuit voltage (i.E., the voltage when the positive battery terminal is discon- nected). • no charging is necessary when the open-cir- cuit voltage equals or exceed...

  • Page 477: Electrical Components

    Electrical components 8-80 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a constant volt- age charger a. Measure the open-circuit voltage prior to charging. Tip voltage should be measured 30 minutes after the engine is turned off. B. Connect a charger and ammeter to the bat...

  • Page 478: Electrical Components

    Electrical components 8-81 starting circuit cut-off relay starter relay headlight relay radiator fan motor relay eas37p1082 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazar...

  • Page 479: Electrical Components

    Electrical components 8-82 b. Set the main switch to “on”. C. Measure the turn signal/hazard relay input voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • turn signal/hazard relay output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a....

  • Page 480: Electrical Components

    Electrical components 8-83 c. Measure the primary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. C...

  • Page 481: Electrical Components

    Electrical components 8-84 b. Measure the crankshaft position sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28130 checking the lean angle sensor 1. Remove: • lean angle sensor 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 482: Electrical Components

    Electrical components 8-85 eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the crank- shaft position sensor/stator assembly. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect t...

  • Page 483: Electrical Components

    Electrical components 8-86 c. Measure the horn resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28230 checking the fuel sender 1. Remove: • fuel sender 2. Check: • fuel sender resistance out of specification → replace the fuel send- er. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 484: Electrical Components

    Electrical components 8-87 eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the speed sensor coupler (wire harness end) as shown. B. Set the main swit...

  • Page 485: Electrical Components

    Electrical components 8-88 d. Heat the coolant or let it cool down to the specified temperatures. E. Measure the coolant temperature sensor re- sistances. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • coolant temperature sensor eas28300 checking the throttle position sensor 1. Chec...

  • Page 486: Electrical Components

    Electrical components 8-89 c. Set the main switch to “on”. D. Measure the intake air pressure sensor out- put voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28420 checking the intake air temperature sensor 1. Remove: • intake air temperature sensor (from the air filter case) warning e...

  • Page 487: Electrical Components

    Electrical components 8-90 b. Immerse the air temperature sensor “1” in a container filled with water “2”. Tip make sure that the air temperature sensor termi- nals do not get wet. C. Place a thermometer “3” in the water. D. Heat the water or let it cool down to the spec- ified temperatures. E. Meas...

  • Page 488: Electrical Components

    Electrical components 8-91 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the v- belt replacement indicator reset coupler ter- minals. B. Check the v-belt replacement indicator reset coupler for continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 489: Troubleshooting

    9 troubleshooting troubleshooting..................................................................................... 9-1 general information ....................................................................... 9-1 starting failure/hard starting .....................................................

  • Page 490: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ad...

  • Page 491: Troubleshooting

    Troubleshooting 9-2 • faulty battery 2. Spark plug • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator • faulty spark plug cap 3. Ignition coil • faulty spark plug lead 4. Ignition system • faulty ecu • faulty crank...

  • Page 492: Troubleshooting

    Troubleshooting 9-3 chassis 1. Brake(s) • dragging brake electrical system 1. Spark plug • incorrect spark plug gap • incorrect spark plug heat range 2. Ignition system • faulty ecu eas28610 overcooling cooling system 1. Thermostat • thermostat stays open eas28620 poor braking performance • worn bra...

  • Page 493: Troubleshooting

    Troubleshooting 9-4 • improperly grounded circuit • faulty main switch • headlight bulb life expired tail/brake light does not come on • wrong tail/brake light bulb • too many electrical accessories • incorrect connection • burnt-out tail/brake light bulb tail/brake light bulb burnt out • wrong tail...

  • Page 494: Wiring Diagram

    Eas28740 wiring diagram yp125r/yp250r 2010 1. Ac magneto 2. Crankshaft position sensor 3. Rectifier/regulator 4. Backup fuse (immobilizer unit and meter assembly) 5. Main switch 6. Ecu fuse 7. Radiator fan motor fuse 8. Turn signal/hazard fuse 9. Ignition fuse 10. Headlight fuse 11. Signaling system...

  • Page 496

    Yamaha motor espaÑa, s.A..

  • Page 497

    Yp125r/yp250r 2010 wiring diagram yp125r/yp250r 2010 schÉma de cblage yp125r/yp250r 2010 schaltplan yp125r/yp250r 2010 schema elettrico yp125r/yp250r 2010 diagrama elÉctrico r br/l br/r br/r r br/l b y/l lg r/w r/g b2 b b b/w r/l y/l b1 b/l b2 b1 b l/w b b (blue) l/y b (blue) r/b l/r (blue) g/y r/b ...

  • Page 498

    Yp125r/yp250r 2010 wiring diagram yp125r/yp250r 2010 schÉma de cblage yp125r/yp250r 2010 schaltplan yp125r/yp250r 2010 schema elettrico yp125r/yp250r 2010 diagrama elÉctrico (blue) (blue) (blue) (black) (green) p (black) (black) (black) (black) (black) (black) (black) (black) y a wire harness sub-wi...