Yamaha 2009 YFM25RSEY Manuals

Manuals and User Guides for Yamaha 2009 YFM25RSEY. We have 1 Yamaha 2009 YFM25RSEY manual available for free PDF download: Service Manual

Yamaha 2009 YFM25RSEY Service Manual

Yamaha 2009 YFM25RSEY Service Manual (293 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 13.05 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Important Information
    11
    
    Preparation for Removal and Disassembly
    11
    
    Replacement Parts
    11
    
    Gaskets, Oil Seals and O-Rings
    12
    
    Lock Washers/Plates and Cotter Pins
    12
    
    Bearings and Oil Seals
    12
    
    Circlips
    12
  - Checking the Connections
    13
  - Special Tools
    14
Specifications

19
- General Specifications
  20
- Engine Specifications
  23
- Chassis Specifications
  29
- Electrical Specifications
  31
- Tightening Torques
  33
- Lubrication Points and Lubricant Types
  38
  - Engine
    38
- Lubrication System Chart and Diagrams
  40
  - Engine Oil Lubrication Chart
    40
  - Lubrication Diagrams
    42
- Cable Routing
  48
Periodic Checks and Adjustments

63
Chassis

99
- General Chassis
  
  103
- Front Wheel
  
  106
  - Removing the Front Wheels
    106
  - Checking the Front Wheels
    106
  - Checking the Front Wheel Hubs
    106
  - Checking the Front Brake Discs
    107
  - Installing the Front Wheel Hub Bearings
    107
  - Installing the Front Brake Discs
    107
  - Installing the Front Wheel Hubs
    107
  - Adjusting the Front Wheel Static Balance
    108
  - Installing the Front Wheels
    109
- Rear Wheel
  
  110
  - Removing the Rear Wheels
    111
  - Checking the Rear Wheels
    111
  - Checking the Rear Wheel Hubs
    111
  - Installing the Rear Wheel Hubs
    111
  - Adjusting the Rear Wheel Static Balance
    111
  - Installing the Rear Wheels
    111
- Rear Axle and Rear Axle Hub
  
  112
  - Removing the Rear Axle
    114
  - Checking the Rear Axle
    114
  - Checking the Rear Axle Hub
    114
  - Checking the Rear Wheel Sprocket
    115
  - Checking the Sprocket Bracket
    115
  - Installing the Rear Wheel Sprocket
    115
  - Installing the Rear Axle
    115
- Front Brake
  
  116
- Rear Brake
  
  128
  - Introduction
    133
  - Checking the Rear Brake Disc
    133
  - Replacing the Rear Brake Pads
    133
  - Removing the Rear Brake Caliper
    134
  - Disassembling the Rear Brake Caliper
    135
  - Checking the Rear Brake Caliper
    135
  - Assembling the Rear Brake Caliper
    135
  - Installing the Rear Brake Caliper
    136
  - Removing the Rear Brake Master Cylinder
    137
  - Checking the Rear Brake Master Cylinder
    137
  - Assembling the Rear Brake Master Cylinder
    138
  - Installing the Rear Brake Master Cylinder
    138
- Handlebar
  
  140
  - Removing the Handlebars
    141
  - Checking the Handlebar
    141
  - Installing the Handlebar
    141
- Steering Stem
  
  144
  - Checking the Steering Stem
    145
  - Installing the Steering Stem
    145
  - Installing the Lock Washer
    145
- Tie-Rods and Steering Knuckles
  
  147
  - Removing the Steering Knuckles
    147
  - Checking the Tie-Rods
    147
  - Checking the Steering Knuckles
    147
  - Installing the Tie-Rods
    147
- Front Arms and Front Shock Absorber Assemblies
  
  148
- Rear Shock Absorber Assembly
  
  152
- Swingarm
  
  155
  - Removing the Swingarm
    156
  - Checking the Swingarm
    156
  - Installing the Swingarm
    157
Engine

163
- Engine Removal
  
  169
  - Installing the Engine
    169
  - Installing the Muffler and Exhaust Pipe
    169
- Camshaft
  
  171
- Cylinder Head
  
  175
  - Removing the Cylinder Head
    177
  - Checking the Cylinder Head
    177
  - Checking the Timing Chain Guides
    178
  - Checking the Timing Chain Tensioner
    178
  - Installing the Cylinder Head
    179
- Valves and Valve Springs
  
  182
  - Removing the Valves
    182
  - Checking the Valves and Valve Guides
    182
  - Checking the Valve Seats
    184
  - Checking the Valve Springs
    186
  - Installing the Valves
    187
- Cylinder and Piston
  
  190
  - Removing the Piston
    190
  - Checking the Cylinder and Piston
    190
  - Checking the Piston Rings
    191
  - Checking the Piston Pin
    192
  - Installing the Piston and Cylinder
    192
- Clutch
  
  194
  - Removing the Clutch
    197
  - Checking the Friction Plates
    197
  - Checking the Clutch Plates
    198
  - Checking the Clutch Springs
    198
  - Checking the Clutch Housing
    198
  - Checking the Clutch Boss
    198
  - Checking the Pressure Plate
    199
  - Checking the Clutch Push Rods
    199
  - Checking the Primary Drive Gear
    199
  - Installing the Clutch
    199
- Oil Pump
  
  203
  - Removing the Oil Pump
    205
  - Checking the Oil Pump
    205
  - Assenbling the Balancer Weight Gear
    206
  - Installing the Oil Pump
    206
  - Installing the Balancer Weight Gear
    206
  - Checking the Shift Shaft
    208
  - Checking the Stopper Lever
    208
  - Installing the Shift Shaft
    208
- Pickup Coil Rotor and Starter Clutch
  
  211
  - Removing the Pickupcoil Rotor
    211
  - Checking the Starter Clutch
    211
  - Installing the Pickup Coil Rotor
    212
- Electric Starter
  
  214
  - Checking the Starter Motor
    216
  - Assembling the Starter Motor
    217
- Crankcase
  
  218
  - Disassembling the Crankcase
    220
  - Checking the Crankcase
    220
  - Assembling the Crankcase
    220
- Crankshaft Assembly
  
  222
  - Removing the Crankshaft Assembly
    223
  - Removing the Plunger Seal
    223
  - Checking the Crankshaft and Connecting Rod
    223
  - Checking the Timing Chain
    224
  - Checking the Crankshaft Sprocket
    224
  - Checking the Timing Chain Guide
    224
  - Installing the Plunger Seal
    224
  - Installing the Crankshaft Assembly
    224
- Transmission
  
  226
  - Removing the Transmission
    228
  - Checking the Shift Forks
    228
  - Checking the Shift Drum Assembly
    228
  - Checking the Transmission
    229
  - Installing the Shift Forks and Shift Drum Assembly
    230
Fuel System

231
- Fuel Tank
  
  232
  - Checking the Fuel Cock
    233
  - Checking the Fuel Cock Operation
    233
  - Removing the Fuel Tank
    233
- Carburetor
  
  234
  - Checking the Carburetor
    237
  - Assembling the Carburetor
    238
  - Installing the Carburetor
    239
Electrical System

241
- Ignition System
  
  242
  - Circuit Diagram
    242
  - Troubleshooting
    244
- Electric Starting System
  
  246
  - Circuit Diagram
    246
  - Starting Circuit Cut-Off System Operation
    248
  - Troubleshooting
    250
- Charging System
  
  252
  - Circuit Diagram
    252
  - Troubleshooting
    254
- Lighting System
  
  256
  - Circuit Diagram
    256
  - Troubleshooting
    258
- Signaling System
  
  260
  - Circuit Diagram
    260
  - Troubleshooting
    262
- Carburetor Heating System
  
  264
  - Circuit Diagram
    264
  - Troubleshooting
    266
- Electrical Components
  
  268
  - Checking the Switches
    270
  - Checking the Bulbs and Bulb Sockets
    273
  - Checking the Fuses
    274
  - Checking and Charging the Battery
    274
  - Checking the Relays
    278
  - Checking the Diode
    278
  - Checking the Spark Plug Cap
    279
  - Checking the Ignition Coil
    279
  - Checking the Pickup Coil
    280
  - Checking the Starter Motor Operation
    281
  - Checking the Stator Coil
    281
  - Checking the Rectifier/Regulator
    282
  - Checking the Thermo Switch
    282
  - Checking the Carburetor Warmer
    283
Troubleshooting

285
- General Information
  285
- General Information
  286
- Starting Failures
  286
- Troubleshooting
  286
- Faulty Clutch
  287
- Faulty Gear Shifting
  287
- Incorrect Engine Idling Speed
  287
- Jumps out of Gear
  287
- Poor Medium-And-High-Speed Performance
  287
- Shift Pedal Does Not Move
  287
- Faulty Lighting or Signaling System
  288
- Overheating
  288
- Poor Braking Performance
  288
- Unstable Handling
  288

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