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Yamaha YZ 2019 Series User Manual

Yamaha YZ 2019 Series
398 pages
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B29-28199-14LIT-11626-32-17
Read this manual carefully before operating this vehicle.
YZ250FXK
OWNER’S SERVICE MANUAL
YZ250FX
2019
PRINTED IN JAPAN
2018.04-0.3×1 !
(E)
PRINTED ON RECYCLED PAPER
2019
YZ250FXK
B29-28199-14_13mm.indd 1-3 2018/03/29 17:50:43

Table of Contents

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Yamaha YZ 2019 Series Specifications

General IconGeneral
BrandYamaha
ModelYZ 2019 Series
CategoryMotorcycle
LanguageEnglish

Summary

Introduction

Safety Information

Yamaha Motor Corporation, U.S.A. YZ Motorcycle Limited Warranty

How to Use This Manual

Symbols

General Information

Location of Important Labels

Identifies the location of crucial labels on the vehicle for safety and information.

Description

Provides an overview of the vehicle's main components and their identification.

Identification

Explains the importance of vehicle and engine serial numbers for parts ordering and identification.

Included Parts

Lists and describes the parts included with the motorcycle, such as tools and protectors.

Important Information

Covers essential details for disassembly, replacement parts, and handling of components like gaskets.

Basic Service Information

Provides fundamental guidelines for handling electrical systems and components safely.

Special Tools

Lists and illustrates special tools required for accurate adjustment and assembly procedures.

Control Functions

Describes the operation of various controls and indicators on the motorcycle.

Starting and Break-in

Details the correct procedures for starting the engine and the initial break-in period.

Maintenance After Break-in

Outlines the major maintenance tasks required after the break-in period for optimal performance.

Torque-Check Points

Specifies tightening torques for standard fasteners and critical assembly points.

Motorcycle Care and Storage

Provides instructions on proper cleaning, maintenance, and storage procedures for the motorcycle.

Specifications

General Specifications

Lists the overall dimensions, weight, and basic specifications of the motorcycle model.

Engine Specifications

Details technical specifications for the engine, including displacement, bore, stroke, and oil capacities.

Chassis Specifications

Provides specifications for the chassis, including frame, wheels, tires, brakes, and suspension components.

Electrical Specifications

Lists electrical system specifications, including voltage, ignition, battery, and component resistances.

Tightening Torques

Specifies the correct tightening torques for various engine and chassis components.

Lubrication Points and Lubricant Types

Details lubrication points and the recommended lubricant types for engine and chassis parts.

Lubrication System Chart and Diagrams

Illustrates the lubrication system with diagrams showing oil flow paths for engine components.

Cable Routing Diagram

Shows the correct routing and installation of various cables and wiring harnesses on the motorcycle.

Periodic Checks and Adjustments

Maintenance Intervals

Provides a schedule for regular maintenance checks and services based on operating hours or mileage.

Pre-Operation Inspection and Maintenance

Details essential checks to ensure the motorcycle is in good operating condition before riding.

Engine

Covers checks and adjustments for the engine, including coolant, oil, clutch, throttle, and valve clearance.

Chassis

Covers checks and adjustments for the chassis, including brakes, drive chain, tires, suspension, and steering.

Electrical System

Details checks and troubleshooting for various electrical components and systems.

Chassis

General Chassis

Covers the removal and installation of major chassis components like covers, seat, and rear fender.

Front Wheel

Provides procedures for removing, checking, disassembling, and assembling the front wheel.

Rear Wheel

Details the procedures for removing, checking, and installing the rear wheel and sprocket.

Front Brake

Covers the removal, disassembly, checking, and assembly of the front brake caliper and master cylinder.

Rear Brake

Details the removal, disassembly, checking, and assembly of the rear brake caliper and master cylinder.

Handlebar

Provides instructions for removing, checking, and installing the handlebar and its related components.

Front Fork

Covers the disassembly, checking, and assembly of the front fork legs and suspension components.

Steering Head

Details the procedures for removing, checking, and installing the steering head components.

Rear Shock Absorber Assembly

Covers the handling, removal, checking, and installation of the rear shock absorber assembly.

Swingarm

Provides procedures for removing, checking, and installing the swingarm and its related components.

Chain Drive

Covers the removal, checking, cleaning, and installation of the drive chain and sprockets.

Engine

Engine Removal

Details the procedures for removing the exhaust system, electronic parts, and the engine assembly.

Camshaft

Covers the removal, checking, and installation of the camshaft, timing chain, and related components.

Cylinder Head

Provides procedures for removing, checking, and installing the cylinder head and its components.

Valves and Valve Springs

Details the removal, checking, and installation of valves, valve springs, and related parts.

Cylinder and Piston

Covers the removal, checking, and installation of the cylinder, piston, and piston rings.

Electric Starter

Details the removal, checking, and assembly procedures for the electric starter motor.

Clutch

Covers the removal, checking, and installation of the clutch assembly and its components.

Shift Shaft

Provides procedures for removing, checking, and installing the shift shaft, forks, and related parts.

Oil Pump and Balancer Gear

Covers the removal, checking, and assembly of the oil pump and balancer gear components.

Generator and Starter Clutch

Details the removal, checking, and installation of the generator and starter clutch assemblies.

Crankcase

Covers the separation, disassembly, checking, and assembly of the crankcase.

Crankshaft Assembly and Balancer Shaft

Details the removal, checking, and installation of the crankshaft and balancer shaft assemblies.

Transmission

Covers the removal, checking, and installation of the transmission, shift drum, and shift forks.

Cooling System

Radiator

Covers the handling, checking, and removal/installation of the radiator and its related hoses.

Water Pump

Details the removal, checking, and assembly procedures for the water pump and its components.

Fuel System

Fuel Tank

Covers the removal, checking, and installation of the fuel tank, fuel pump, and fuel sender.

Throttle Body

Details the removal, checking, and adjustment procedures for the throttle body and its sensors.

Electrical System

Ignition System

Covers the circuit diagram and troubleshooting for the ignition system.

Electric Starting System

Details the circuit diagram, operation, and troubleshooting for the electric starting system.

Charging System

Provides the circuit diagram and troubleshooting guide for the charging system's components.

Signaling System

Covers the circuit diagram and troubleshooting for the motorcycle's signaling system (lights, horn).

Fuel Injection System

Details the circuit diagram, ECU self-diagnostics, and troubleshooting for the fuel injection system.

Fuel Pump System

Provides the circuit diagram and troubleshooting steps for the fuel pump system.

Electrical Components

Lists and describes checks for various electrical components like switches, bulbs, fuses, and sensors.

Troubleshooting

General Information

Provides a general guide to troubleshooting, emphasizing the importance of referring to specific manual procedures.

Starting Failures

Lists potential causes for engine starting failures related to cylinder, piston, air filter, crankcase, fuel system, and electrical system.

Incorrect Engine Idling Speed

Details potential causes for incorrect engine idling speed related to cylinder, air filter, and spark plug.

Poor Medium-and-High-Speed Performance

Lists potential causes for poor performance at medium and high speeds, including air filter and fuel system issues.

Shifting Is Difficult

Refers to the Clutch section for troubleshooting difficult shifting issues.

Shift Pedal Does Not Move

Lists potential causes for a non-moving shift pedal related to engine and transmission components.

Jumps Out of Gear

Details potential causes for the transmission jumping out of gear.

Clutch Slips

Lists potential causes for clutch slippage related to clutch assembly and engine oil condition.

Clutch Drags

Details potential causes for clutch drag related to clutch components and engine oil condition.

Overheating

Lists potential causes for engine and cooling system overheating.

Overcooling

Identifies potential causes for engine overcooling, primarily related to the coolant temperature sensor.

Poor Braking Performance

Lists potential causes for poor braking performance related to brake components and fluid.

Front Fork Oil Leaking

Identifies potential causes for front fork oil leaks, including damaged tubes and improper seal installation.

Faulty Front Fork Legs

Lists potential causes for faulty front fork legs, such as bent tubes or broken springs.

Unstable Handling

Details potential causes for unstable handling related to handlebar, steering head, suspension, and wheels.

List of Self-Diagnostic and Fail-Safe Actions

Provides a table of diagnostic codes, their descriptions, and related troubleshooting procedures.

Tuning

Chassis

Covers tuning adjustments for chassis components like sprockets, tire pressure, and suspension settings.

Kickstarter Kit (Optional Parts)

Details the parts location, setup, installation, and maintenance procedures for the optional kickstarter kit.

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