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Yamaha YZ 2016 Series User Manual

Yamaha YZ 2016 Series
392 pages
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2016
OWNER’S SERVICE MANUAL
YZ250FXG
B29-28199-11LIT-11626-29-53
YZ250FXG 2016
q
Read this manual carefully before operating this vehicle.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2015.07––0.3 × 1
!
(E)
B29-28199-11_cover_12mm.indd 1 2015/06/15 12:00:27

Table of Contents

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Yamaha YZ 2016 Series Specifications

General IconGeneral
ManufacturerYamaha
Final DriveChain
Front BrakeHydraulic single disc brake
Brakes FrontHydraulic single disc brake
Rear BrakeHydraulic single disc brake
Brakes RearHydraulic single disc brake
Tires Front80/100-21
Tires Rear100/90-19
ModelYZ
Front SuspensionKYB Speed-Sensitive System inverted fork
Suspension FrontKYB Speed-Sensitive System inverted fork
Rear SuspensionKYB single shock
Suspension RearKYB single shock

Summary

General Information

Location of Important Labels

Identifies key labels on the vehicle for safe operation and information.

Description

Explains vehicle components and their functions, including diagrams.

Identification

Details vehicle and engine serial numbers for parts and security.

Included Parts

Lists and describes accessories provided with the vehicle.

Important Information

Crucial notes on preparation, parts, and general servicing precautions.

Basic Service Information

Guidelines for electrical system handling, checks, and troubleshooting.

Special Tools

Lists required special tools for accurate adjustment and assembly procedures.

Control Functions

Explains operation of switches, levers, pedals, and grips.

Specifications

General Specifications

Provides overall dimensions, weight, and model details.

Engine Specifications

Detailed technical data for engine type, displacement, fuel, oil, and cooling system.

Chassis Specifications

Technical data for frame, wheels, tires, brakes, steering, and suspension.

Electrical Specifications

Details voltage, ignition, ECU, battery, and starting system specifications.

Tightening Torques

Specifies standard and assembly-specific torque values for fasteners.

Lubrication Points and Lubricant Types

Lists recommended lubricants for engine and chassis components.

Lubrication System Chart and Diagrams

Visual representation of the engine's oil flow and lubrication paths.

Cable Routing Diagram

Illustrates correct routing for wires, cables, and hoses.

Periodic Checks and Adjustments

Maintenance Intervals

Recommended service intervals for various vehicle components and checks.

Pre-Operation Inspection and Maintenance

Essential checks before riding for safety, performance, and readiness.

Engine

Procedures for checking and adjusting engine oil, coolant, and related systems.

Chassis

Maintenance and checks for brakes, drive chain, forks, suspension, wheels, and steering.

Electrical System

Procedures for checking and testing spark plugs, ignition timing, and battery.

Chassis

General Chassis

Procedures for removing body panels, seat, and number plate.

Front Wheel

Steps for removing, checking, and installing the front wheel assembly.

Rear Wheel

Steps for removing, checking, and installing the rear wheel assembly.

Front Brake

Detailed procedures for front brake caliper and master cylinder maintenance.

Rear Brake

Detailed procedures for rear brake caliper and master cylinder maintenance.

Handlebar

Procedures for removing, checking, and installing the handlebar and controls.

Front Fork

Procedures for fork leg removal, disassembly, assembly, and installation.

Steering Head

Procedures for steering head removal, checking, and installation.

Rear Shock Absorber Assembly

Procedures for rear shock absorber removal, disassembly, and assembly.

Swingarm

Procedures for swingarm removal, checking, and installation.

Chain Drive

Procedures for drive chain removal, checking, and installation.

Engine

Engine Removal

Step-by-step instructions for removing the engine from the vehicle.

Camshaft

Procedures for camshaft removal, checking, and installation.

Cylinder Head

Procedures for cylinder head removal, checking, and installation.

Valves and Valve Springs

Procedures for valve and spring removal, checking, and installation.

Cylinder and Piston

Procedures for cylinder and piston removal, checking, and installation.

Electric Starter

Procedures for starter motor removal, checking, and assembly.

Clutch

Procedures for clutch removal, checking, and installation.

Kickstater

Procedures for kick shaft removal, checking, and installation.

Shift Shaft

Procedures for shift shaft removal, checking, and installation.

Oil Pump and Balancer Gear

Procedures for oil pump and balancer gear removal, checking, and assembly.

Generator and Starter Clutch

Procedures for generator and starter clutch removal, checking, and installation.

Crankcase

Procedures for crankcase separation, bearing removal, and assembly.

Crankshaft Assembly and Balancer Shaft

Procedures for crankshaft and balancer shaft removal, checking, and installation.

Transmission

Procedures for transmission removal, checking, and installation.

Cooling System

Radiator

Procedures for radiator removal, checking, and handling.

Water Pump

Procedures for water pump removal, checking, assembly, and installation.

Fuel System

Fuel Tank

Procedures for fuel tank and fuel pump removal, checking, and installation.

Throttle Body

Procedures for checking and adjusting throttle body components and sensors.

Electrical System

Ignition System

Circuit diagram and troubleshooting for the ignition system.

Electric Starting System

Circuit diagram and troubleshooting for the electric starting system.

Charging System

Circuit diagram and troubleshooting for the charging system.

Cooling System (For JPN)

Circuit diagram and troubleshooting for the cooling system (Japan market).

Fuel Injection System

Circuit diagram, diagnostic tool usage, and troubleshooting for FI system.

Fuel Pump System

Circuit diagram and troubleshooting for the fuel pump system.

Electrical Components

Identification and checking procedures for various electrical parts.

Troubleshooting

General Information

Overview of troubleshooting guidelines and referencing repair procedures.

Starting Failures

Common causes and checks for engine starting problems.

Incorrect Engine Idling Speed

Potential causes for unstable or incorrect engine idling.

Poor Medium-and-High-Speed Performance

Factors affecting vehicle performance at higher speeds.

Shifting Is Difficult

Potential issues causing difficult gear shifting.

Shift Pedal Does Not Move

Reasons for a non-functional shift pedal.

Jumps Out of Gear

Causes for the transmission disengaging unintentionally.

Clutch Slips

Issues leading to clutch slippage.

Clutch Drags

Problems causing the clutch to drag.

Overheating

Potential causes for engine and cooling system overheating.

Overcooling

Potential causes for engine overcooling.

Poor Braking Performance

Factors affecting brake system performance.

Front Fork Oil Leaking

Causes and checks for front fork oil leaks.

Faulty Front Fork Legs

Common issues with front fork leg components.

Unstable Handling

Factors contributing to poor vehicle handling.

List of Self-Diagnostic and Fail-Safe Actions

Table of diagnostic codes, symptoms, and troubleshooting steps.

Tuning

Chassis

Chassis-related tuning adjustments for suspension and drive components.

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