User manual YAMAHA YZ250F-2004

[. . . ] As the owner of a YZF-R7, you are benefiting from Yamaha's vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all your YZF-R7's advantages. The owner's service manual does not only instruct you in how to operate, inspect and basic maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help to keep your motorcycle in the best possible condition. [. . . ] Refer to "COWLINGS" in chapter 3. Refer to "CHANGING THE ENGINE OIL" in chapter 3. 1 2 3 4 5 6 7 8 9 Throttle stop screw holder Generator rotor cover Generator rotor cover gasket Dowel pin Generator rotor bolt Generator rotor Stator coil assembly coupler Stator coil assembly lead holder Stator coil assembly 1 1 1 2 1 1 1 1 1 Disconnect. For installation, reverse the removal procedure. 4 - 32 GENERATOR EB410110 ENG REMOVING THE GENERATOR 1 1. Remove: · generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: · generator rotor bolt 1 · washer NOTE: While holding the generator rotor 2 with the rotor holding tool 3, loosen the generator rotor bolt. Remove: · generator rotor 1 (with the flywheel puller 2 and rotor holding tool 3) Flywheel puller 90890-01080 EB410700 INSTALLING THE GENERATOR 1. Apply: · sealant (onto the stator coil assembly lead grommet) Yamaha bond No. Install: · generator rotor · washer · generator rotor bolt WARNING WARNING Always use a new generator rotor bolt. 4 - 33 CAUTION: ACHTUNG: · Clean the tapered portion of the crankshaft and the generator rotor hub with lacquer thinner. · Lubricate the generator rotor bolt threads with engine oil. GENERATOR ENG New 3. Tighten: · generator rotor bolt 1 T. R. 65 Nm (6. 5 m · kg, 47 ft · lb) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt. Install: · generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 4 - 34 PICKUP COIL PICKUP COIL ENG 45 Nm (4. 5 m · kg, 32 ft · Ib) 12 Nm (1. 2 m · kg, 8. 7 ft · Ib) T. R. E (6) LT 6 5 4 Nm (0. 4 m · kg, 2. 9 ft · Ib) T. 15 Nm (1. 5 m · kg, 11 ft · Ib) Order Job/Part Removing the pickup coil and pickup coil rotor Fuel tank Bottom cowling and front cowling Engine oil Q'ty Remarks Remove the parts in the order listed. NOTE: Measure the friction plate at four places. Friction plate #1 thickness 2. 9 ~ 3. 1 mm (0. 114 ~ 0. 122 in) <Limit>: 2. 8 mm (0. 110 in) Friction plate #2 thickness 3. 7 ~ 3. 9 mm (0. 146 ~ 0. 154 in) <Limit>: 3. 6 mm (0. 142 in) 4 - 42 CLUTCH EB405410 ENG CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. Check: · clutch plate Damage Replace the clutch plates as a set. Measure: · clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification Replace the clutch plates as a set. Maximum clutch plate warpage 0. 1 mm (0. 004 in) EB405430 CHECKING THE CLUTCH SPRING PLATE 1. Check: · clutch spring plate Damage Replace. Check: · clutch spring plate seat Damage Replace. EB405440 CHECKING THE CLUTCH HOUSING 1. Check: · clutch housing dogs Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. Check: · bearing Damage/wear Replace the clutch housing. 4 - 43 CLUTCH EB405450 ENG CHECKING THE CLUTCH BOSS 1. Check: · clutch boss splines Damage/pitting/wear Replace the clutch boss. [. . . ] Refer to the condition code list in "USER MODE" for details on the condition codes. Selecting this diagnosis code clears the condition code record of malfunctions stored in the ROM. If an error has occurred in a sensor signal, it was recorded in the ROM and the tachometer displays 10, 000 r/min. If no error has occurred, the tachometer displays 0 r/min. [. . . ]