TechOn.cloud

Category: general

  • Acura ILX Engine Oil Capacity and Type

    Production Years Trim (Engine) Engine Model/Code Engine Oil Capacity (Liters/US Quarts/UK Quarts)
    2013-2015 1.5 (111 Hp) Hybrid CVT LEA-MF6 3.6 L / 3.8 US qt / 3.17 UK qt
    2013-2015 2.0 (150 Hp) Automatic R20A1 3.7 L / 3.91 US qt / 3.26 UK qt
    2013-2015 2.4 (201 Hp) K24Z7 4.2 L / 4.44 US qt / 3.7 UK qt
    2016-2018 2.4 (201 Hp) Automatic K24V7 4.4 L / 4.65 US qt / 3.87 UK qt
    2019-Present 2.4 (201 Hp) Automatic K24V7 4.4 L / 4.65 US qt / 3.87 UK qt

  • Acura CSX Engine Oil Capacity and Type

    Generation Trim (Engine) Production Years Engine Model/Code Engine Displacement Engine Oil Capacity Engine Oil Specification
    CSX (facelift, 2009) 2.0 i 16V (157 Hp) 2009-2011 K20Z2 1998 cm3 4.2 L / 4.44 US qt 5W-20 / API SM
    CSX (facelift, 2009) 2.0 i 16V (157 Hp) Automatic 2009-2011 K20Z2 1998 cm3 4.2 L / 4.44 US qt 5W-20 / API SM
    CSX 2.0 i 16V (157 Hp) 2005-2008 K20Z2 1998 cm3 4.2 L / 4.44 US qt 5W-20 / API SM

  • Acura CL Engine Oil Capacity and Type

    Generation Trim (Engine) Production Years Engine Model/Code Engine Displacement Engine Oil Capacity Engine Oil Specification
    CL 2.3 i 16V (152 Hp) 1997-1999 F23A1 2254 cm3 4.3 L / 4.54 US qt 5W-30 / API SJ
    CL 3.0 i V6 24V (203 Hp) 1996-1999 J30A1 2997 cm3 4.4 L / 4.65 US qt 5W-30 / API SJ
    CL 2.3 i 16V (152 Hp) Automatic 1997-1999 F23A1 2254 cm3 4.3 L / 4.54 US qt 5W-30 / API SJ
    CL II 3.2 i V6 24V Type S (263 Hp) Automatic 2000-2003 J32A2 3210 cm3 4.4 L / 4.65 US qt 5W-20, 5W-30 / API SL
    CL II 3.2 i V6 24V Type S (263 Hp) 2000-2003 J32A2 3210 cm3 4.4 L / 4.65 US qt 5W-20, 5W-30 / API SL
    CL II 3.2 i V6 24V (228 Hp) Automatic 2000-2003 J32A1 3210 cm3 4.4 L / 4.65 US qt 5W-20, 5W-30 / API SL

  • 2025 RZR Pro R Manual Book

    INTRODUCTION

    TOOLS FOR SAFE RIDING

    VEHICLE TESTING

    VEHICLE-TO-VEHICLE COMMUNICATION (V2V)

    DEVICE COMPLIANCE STATEMENTS

    VEHICLE IDENTIFICATION NUMBERS

    SAFETY

    OWNER REQUIREMENTS

    DRIVER AND PASSENGER QUALIFICATIONS

    PREPARE VEHICLE FOR THE RIDE

    PREPARE YOURSELF, PASSENGERS, AND CARGO FOR THE RIDE

    DRIVING GUIDELINES

    SAFETY LABELS AND LOCATIONS

    Overview

    DRIVER INFORMATION WARNING — 2 PERSON

    LOAD / PASSENGER / TIRE PRESSURE WARNING (PRO R)

    DRIVER INFORMATION WARNING — 4 PERSON

    LOAD / PASSENGER / TIRE PRESSURE WARNING (PRO R 4)

    FEATURES AND CONTROLS

    COMPONENT LOCATIONS

    STANDARD STEERING WHEEL (IF EQUIPPED)

    SWITCHES

    AUXILIARY OUTLETS

    VEHICLE BATTERY CHARGE PORT

    ELECTRONIC POWER STEERING (EPS)

    AUDIO CONTROLS (IF EQUIPPED)

    DYNAMIX DV ACTIVE SUSPENSION (IF EQUIPPED)

    ELECTRONIC SHOCK DAMPING CONTROL

    ELECTRONIC STEERING RACK (EPS)

    SEATS

  • Buick Enclave Engine Oil Capacity

    The Buick Enclave is a full-size crossover SUV produced by General Motors since 2007. The first Enclave concept car was shown at the 2006 North American International Auto Show. It replaced the Buick Rendezvous, Rainier, and Terraza. The Enclave shares the GM Lambda platform with the Saturn Outlook, GMC Acadia, and Chevrolet Traverse. It has seating for seven passengers, with an optional second row bench seat increasing capacity to eight.
    The first generation Enclave was powered by a 3.6-liter High Feature V6 engine and had a six-speed automatic transmission. It was criticized in its first year for its transmission’s hesitation to downshift, but improvements were made in subsequent models. The Enclave has been noted for its heavy weight, particularly when equipped with all-wheel drive. The initial sales of the Enclave exceeded production capacity, leading to the addition of a third shift at the Delta Township plant.
    The second generation Enclave was revealed at the 2017 New York International Auto Show. This iteration moved upmarket, competing with premium crossover SUVs like the Volvo XC90 and Infiniti QX60. It features a sleeker design with a lower roofline and new lighting technology. The second generation Enclave utilizes the GM C1XX platform and comes standard with front-wheel drive, with an all-wheel drive option available.
    A Chinese version of the Enclave was introduced in late 2019, which is shorter and uses the GM C1 short wheelbase platform. Unlike its North American counterpart, it employs a 2.0-liter turbocharged engine mated to a nine-speed automatic transmission. The third generation Enclave was unveiled in April 2024, offering three trim levels: Preferred, Sport Touring, and Avenir. It is powered by a turbocharged 2.5-liter inline-four engine, and includes advanced driver assistance features like Super Cruise.
    Engine Oil Capacity
    Generation Modification (Engine) Engine Model/Code Engine Displacement Engine Oil Capacity Engine Oil Specification
    Enclave I 3.6 V6 (288 Hp) AWD LLT 3564 cm³ / 217.49 cu. in. 5.2 L / 5.49 US qt / 4.58 UK qt 5W-30 / GM6094M
    Enclave I (facelift 2013) 3.6 V6 (288 Hp) AWD LLT 3564 cm³ / 217.49 cu. in. 5.7 L / 6.02 US qt / 5.02 UK qt 5W-30 / GM dexos1
    Enclave II 3.6 V6 (310 Hp) AWD LFY 3564 cm³ / 217.49 cu. in. 5.7 L / 6.02 US qt / 5.02 UK qt 5W-30 / GM dexos1 0W-30 / GM dexos1 (<-29 °C)
    Enclave II (facelift 2022) 3.6 V6 (310 Hp) AWD LFY 3564 cm³ / 217.49 cu. in. 5.7 L / 6.02 US qt / 5.02 UK qt 5W-30 / GM dexos1 Gen2 0W-30 / GM dexos1 Gen2 (<-29 °C)
    Enclave III 2.5 Turbo (328 Hp) AWD LK0 2494 cm³ / 152.19 cu. in. 5.2 L / 5.49 US qt / 4.58 UK qt 0W-20 / GM dexos1 Gen 3

  • Buick Century Engine Oil Capacity

    The Buick Century is a model name used by Buick, a division of General Motors, for various cars from 1936 to 1942, 1954 to 1958, and from 1973 to 2005. Initially, the Century was a full-size performance car but transitioned to a mid-size model in later years. The first Century debuted in 1936, utilizing the smaller body of the Buick Special but equipped with the larger engine from the Roadmaster and Limited series, which gave it the nickname “the banker’s hot rod” due to its performance capabilities. The name was revived in 1954 with the same formula of combining a lighter body with a powerful engine, this time a V8, and included a station wagon in its lineup.
    During the 1970s, the Century name was repurposed for an intermediate-sized car, sharing its platform with other GM A-body vehicles like the Pontiac Grand Prix and Oldsmobile Cutlass Supreme. In 1973, the Century replaced the Skylark name for sedans, coupes, and some wagons, positioning it as a smaller model alongside the new Regal coupe. Over the years, the Century was offered with various engine options, including V6 and V8 engines, adapting to changing market demands and emission regulations. 
    In 1982, the Century switched to front-wheel drive, aligning with the Chevrolet Celebrity, Pontiac 6000, and Oldsmobile Cutlass Ciera on GM’s new A-body platform. This generation saw the Century offered as a coupe, sedan, and wagon, with regular updates throughout its production cycle to meet consumer preferences. By the late 1990s, the Century was refined further with a more conservative styling appealing to traditional buyers, and it was only available in a four-door sedan configuration, discontinuing the station wagon due to low sales.
    The last generation of the Century, introduced in 1997, focused on comfort and reliability, appealing largely to an older demographic. It maintained a simple, elegant design with a focus on interior comfort. This generation was powered by a 3.1-liter V6 engine up until its discontinuation in 2005, when it was replaced by the Buick LaCrosse. Throughout its long history, the Century was known for its blend of performance, comfort, and practicality, adapting to the automotive trends of each era while maintaining a consistent brand identity.

    Engine Oil Capacity

    Generation Modification (Engine) Start Year End Year Engine Model/Code Engine Displacement Engine Oil Capacity Oil Specification
    Century Wagon 3.1 i V6 (162 Hp) 1994 1997 L82 3136 cm³ / 191.37 cu. in. 4.2 L / 4.44 US qt 5W-30, 10W-30 / API SH, SJ
    Century Wagon 2.2 i (122 Hp) 1993 1997 LN2 2190 cm³ / 133.64 cu. in. 4.2 L / 4.44 US qt 5W-30, 10W-30 / API SH, SJ
    Century 2.2 (122 Hp) 1993 1997 LN2 2190 cm³ / 133.64 cu. in. 4.2 L / 4.44 US qt 5W-30, 10W-30 / API SH, SJ
    Century 3.1 V6 (162 Hp) 1994 1997 L82 3135 cm³ / 191.31 cu. in. 4.2 L / 4.44 US qt 5W-30, 10W-30 / API SH, SJ
    Century (W) 3.1 i V6 (162 Hp) 1997 1999 L82 3136 cm³ / 191.37 cu. in. 4.2 L / 4.44 US qt 5W-30, 10W-30 / API SH, SJ
    Century (W) 3.1 i V6 (177 Hp) 2000 2005 L82 3136 cm³ / 191.37 cu. in. 3.8 L / 4.02 US qt 5W-30 / GM6094M

  • Yamaha WR250F Maintenance Schedule (service parts Interval)

    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 longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

    PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months.

    • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
    No. Item Checks and maintenance jobs Initial Odometer readings
    600 mi (1000 km) or 1 month 1800 mi (3000 km) or 3 months 3000 mi (5000 km) or 6 months
    1 * Fuel line Check fuel hoses for cracks or damage.
    Replace if necessary.    		 ✓ ✓ ✓
    2 Spark plug Check condition.
    Adjust gap and clean.    		 ✓ ✓ ✓
    3 * Valve clearance Check and adjust valve clearance when engine is cold. ✓ ✓
    4 * Air filter element Clean with solvent and apply Yamaha foam air filter oil or other quality foam air filter oil.
    Replace if necessary.    		 ✓ ✓ ✓
    5 * Breather system Check ventilation hose for cracks or damage and drain any deposits. ✓ ✓ ✓
    Replace. Every 2 years
    6 * Fuel injection Adjust engine idling speed. ✓ ✓ ✓
    7 Exhaust system Check for leakage.
    Tighten if necessary.
    Replace gasket(s) if necessary.    		 ✓ ✓ ✓
    8 Engine oil Change (warm engine before draining). ✓ ✓ ✓
    9 Engine oil filter element Replace. ✓ ✓ ✓
    10 Engine oil strainer Clean. ✓ ✓ ✓

    GENERAL MAINTENANCE AND LUBRICATION CHART

    No. Item Checks and maintenance jobs Initial Odometer readings
    600 mi (1000 km) or 1 month 1800 mi (3000 km) or 3 months 3000 mi (5000 km) or 6 months
    1 Clutch Check operation.
    Adjust or replace cable.    		 ✓ ✓ ✓
    2 * Cooling system Check hoses for cracks of damage.
    Replace if necessary.    		 ✓ ✓ ✓
    Replace with ethylene glycol anti-freeze coolant every 1 year. Every 1 year
    3 * Spark arrester Clean. ✓
    4 * Front brake Check operation, fluid level, and for fluid leakage.
    Replace brake pads if necessary.    		 ✓ ✓ ✓
    Replace brake fluid every 1 year. Every 1 year
    5 * Rear brake Check operation, fluid level, and for fluid leakage.
    Replace brake pads if necessary.    		 ✓ ✓ ✓
    Replace brake fluid every 1 year. Every 1 year
    6 * Brake hoses Check for cracks or damage. ✓ ✓
    Replace. Every 4 years
    7 * Wheels Check runout, spoke tightness and for damage.
    Tighten spokes if necessary.    		 ✓ ✓ ✓
    8 * Tires Check tread depth and for damage.
    Replace if necessary.
    Check air pressure.
    Correct if necessary.    		 ✓ ✓ ✓
    9 * Wheel bearings Check bearings for smooth operation.
    Replace if necessary.    		 ✓ ✓ ✓
    10 * Swingarm pivot bearings Check bearing assemblies for looseness.
    Moderately repack with lithium-soap-based grease.    		 ✓ ✓ ✓
    11 Drive chain Check chain slack/alignment and condition.
    Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.    		 Every ride
    12 * Steering bearings Check bearing assemblies for looseness.
    Moderately repack with lithium-soap-based grease every 1200 mi (2000 km) or 12 months (whichever comes first).    		 ✓ ✓ ✓
    13 Brake and clutch lever pivot shafts Apply lithium-soap-based grease (all-purpose grease) or silicone grease lightly. ✓ ✓ ✓
    14 Brake pedal pivot shafts Apply lithium-soap-based grease (all-purpose grease) lightly. ✓ ✓ ✓
    15 Sidestand pivot Check operation.
    Apply lithium-soap-based grease (all-purpose grease) lightly.    		 ✓ ✓ ✓
    16 * Front fork Check operation and for oil leakage.
    Replace if necessary.    		 ✓ ✓
    17 * Shock absorber assembly Check operation and for oil leakage.
    Replace if necessary.    		 ✓ ✓
    18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. ✓ ✓
    19 * Control cables Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly. ✓ ✓ ✓
    20 * Throttle grip housing and cable Check operation and free play.
    Adjust the throttle cable free play if necessary.
    Lubricate the throttle grip housing and cable.    		 ✓ ✓ ✓
    21 * Chassis fasteners Check all chassis fitting and fasteners.
    Correct if necessary.    		 ✓ ✓ ✓
    22 Battery Check terminal for looseness and corrosion. ✓ ✓

    • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

    • Hydraulic brake service

      • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

      • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

      • Replace the brake hoses every four years and if cracked or damaged.

    MAINTENANCE INTERVALS FOR COMPETITION USE

    • The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

    • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below.

    • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

    No. Item Routine After break-in Every race Every third race (or 500 km) Every fifth race (or 1000 km) As required
    1 Engine oil Replace. ✓ ✓
    2 * Valve Check the valve clearances. ✓ ✓
    Check the valve seats and the valve stems for wear. ✓
    Replace. ✓
    3 * Valve spring Check the free length. ✓
    Replace. ✓
    4 * Valve lifter Check for scratches and wear. ✓
    Replace. ✓
    5 * Camshaft Inspect the camshaft surface.
    Inspect the decompression system.    		 ✓
    Replace. ✓
    6 * Timing chain Check for damage and sticking. ✓
    Replace. ✓ ✓
    7 * Timing chain tensioner Replace. ✓ ✓
    8 * Camshaft sprocket Check for wear on the teeth and for damage. ✓
    Replace. ✓
    9 * Piston Inspect crack.
    Inspect carbon deposits and eliminate them.    		 ✓ ✓
    Clean. ✓
    Replace.
    (It is recommended that the piston pin and ring are also replaced at the same time.)    		 ✓
    10 * Piston ring Check the ring end gap. ✓
    Replace. ✓ ✓
    11 * Piston pin Inspect. ✓
    Replace. ✓
    12 * Cylinder head Inspect carbon deposits and eliminate them.
    Change gasket.    		 ✓
    13 * Cylinder Inspect score marks.
    Inspect wear.    		 ✓
    Replace. ✓
    14 * Clutch Inspect housing, friction plate, clutch plate and spring. ✓ ✓
    Replace. ✓
    15 * Transmission Inspect. ✓
    Replace bearings. ✓
    16 * Shift fork, shift drum, guide bar Inspect wear. ✓
    17 * Generator rotor nut Retighten. ✓ ✓
    18 * Muffler Inspect and retighten. ✓ ✓
    Clean. ✓
    Replace. ✓
    19 * Crank Inspect and clean. ✓ ✓
    20 * Throttle body Inspect. ✓
    21 Spark plug Inspect and clean. ✓ ✓
    Replace. ✓
    22 Drive chain Lubricate, slack, alignment. ✓ ✓
    Replace. ✓
    23 * Cooling system Check coolant level and leakage. ✓ ✓
    Check radiator cap operation. ✓
    Replace coolant. Every two years ✓
    Inspect hoses. ✓
    24 Outside nuts and bolts Retighten. ✓ ✓
    25 Air filter Clean and lubricate. ✓ ✓
    Replace. ✓
    26 Oil filter Replace. ✓ ✓
    27 * Engine guard Replace. ✓
    28 * Frame Clean and inspect. ✓ ✓
    29 * Fuel tank, fuel pump Clean and inspect. ✓ ✓
    30 * Fuel hose Inspect. ✓
    Replace. Every four years ✓
    31 * Brake(s) Adjust lever position and pedal position. ✓ ✓
    Lubricate pivot point. ✓ ✓
    Check brake disc surface. ✓ ✓
    Check fluid level and leakage. ✓ ✓
    Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts. ✓ ✓
    Replace pads. ✓
    Replace brake fluid. Every one year ✓
    32 * Front fork(s) Inspect and adjust. ✓ ✓
    Replace oil. ✓ ✓
    Replace oil seal. ✓
    33 * Front fork oil seal and dust seal Clean and lubricate. ✓ ✓
    34 Protector guide Replace. ✓
    35 * Rear shock absorber Inspect and adjust. ✓ ✓
    Lubricate.
    (After rain ride)    		 ✓ ✓
    Retighten. ✓ ✓
    36 * Drive chain guard and roller Inspect. ✓ ✓
    37 * Drive chain stopper Inspect. ✓
    38 * Swingarm Inspect, lube and retighten. ✓ ✓
    39 * Relay arm, connecting rod Inspect, lube and retighten. ✓ ✓
    40 Sidestand Lubricate. ✓
    41 * Steering head Inspect free play and retighten. ✓ ✓
    Clean and lubricate. ✓
    Replace bearings. ✓
    42 * Tire, wheels Inspect air pressure, wheel run-out, tire wear and spoke looseness. ✓ ✓
    Retighten sprocket bolt. ✓ ✓
    Inspect bearings. ✓
    Replace bearings. ✓
    Lubricate. ✓
    43 Throttle, control cable Check routing and connection. ✓ ✓
    Lubricate. ✓ ✓

  • Yamaha WR250F Engine Maintenance

    ADJUSTING THE VALVE CLEARANCE

    • This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
    • Make sure that the valve clearance is checked or adjusted while the engine is cold (at room temperature).
    • While the valve clearance is checked or adjusted, make sure that the piston is positioned in the top dead center (TDC).

    1.Remove:

    2.Remove:

    • Spark plug
    • Cylinder head cover
      Refer to CAMSHAFT.
    3.Remove:

    • Timing mark accessing screw “1”
    • Crankshaft end accessing screw “2”
    • O-ring
    4.Check:

    • Valve clearance
      Out of specification → Regulate.
    Valve clearance (cold)

    • Intake
      0.12–0.19 mm (0.0047–0.0075 in)
    • Exhaust
      0.17–0.24 mm (0.0067–0.0094 in)
    a.Turn the crankshaft counterclockwise with a wrench.
    b.Align the top dead center (TDC) mark “a” on the generator rotor with the alignment mark “b” on the crankcase cover.

    Check that the alignment mark “c” on the camshaft sprocket and the alignment mark “d” on the intake camshaft sprocket are aligned with the edge of the cylinder head.
    c.Measure the valve clearance using a thickness gauge “1”.

    • Thickness gauge
      90890-03268
    • Feeler gauge set
      YU-26900-9
    Record the measured reading if the clearance is incorrect.
    5.Adjust:

    • Valve clearance
    a.Remove the camshaft (intake and exhaust).
    Refer to CAMSHAFT.
    b.Remove the valve lifter “2” and the adjusting pad “3” with a valve lapper “1”.

    • Place a cloth in the timing chain space to prevent adjusting pads from falling into the crankcase.
    • Identity each valve lifter and adjusting pad position very carefully so that they can be reinstalled in their original place.
    • Valve lapper (ø14)
      90890-04101
    • Valve lapper (ø14)
      YM-A8998
    c.Check the number on the originally installed adjusting pad.

    • The adjusting pad number “a” is indicated on the top of the adjusting pad.
    • For the number on the originally installed adjusting pad, convert the last digit of adjusting pad number as per the below table.
    d.Select an adjusting pad with a proper valve clearance from the adjusting pad selection table.

    • There are 25 types of adjusting pads, ranging from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 in), in increments of 0.05 mm (0.0020 in).
    • The field where the number on the originally installed adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace.

    Last digit of pad number
    Rounded value
    0, 1 or 2
    0
    4, 5 or 6
    5
    8 or 9
    10

    Example:
    Pad number = 148
    Rounded value = 150

    e.Install the new adjusting pads “4” and the valve lifters “5”.

    Do not twist adjusting pads and valve lifters forcibly during installation.
    • Apply the engine oil on the valve lifters.
    • Apply molybdenum disulfide oil to the valve stem ends.
    • Check that the valve lifters turn smoothly when rotated with your finger.
    • Make sure that valve lifters and adjusting pads are installed in place.
    • Make sure that adjusting pads are installed with their numbers facing upward.
    f.Install the camshafts (exhaust and intake).
    Refer to CAMSHAFT.
    g.Measure the valve clearance again.
    h.If the valve clearance is out of specification, repeat adjusting the valve clearance until it is within specification.

    VALVE CLEARANCE SHIM CHART

    INTAKE

    • Measured clearance
    • Installed pad number
    • Standard clearance

    Example:
    Valve clearance (cold) 0.12–0.19 mm (0.0047–0.0075 in)
    Installed is 175.
    Measured clearance 0.27 mm (0.0106 in)
    Replace 175 pad with 185 pad.
    Pad No. 175 = 1.75 mm (0.0689 in)
    Pad No. 185 = 1.85 mm (0.0728 in)

    EXHAUST

    • Measured clearance
    • Installed pad number
    • Standard clearance

    Example:
    Valve clearance (cold) 0.17–0.24 mm (0.0067–0.0094 in)
    Installed is 175.
    Measured clearance 0.32 mm (0.0126 in)
    Replace 175 pad with 185 pad.
    Pad No. 175 = 1.75 mm (0.0689 in)
    Pad No. 185 = 1.85 mm (0.0728 in)

    CHECKING THE ENGINE IDLING SPEED

    • Because the air pressure is lower at high altitudes, the air-fuel mixture will become richer. If the idling speed is low, turn the idle screw clockwise to increase the speed before the adjustment.
    • Before adjusting the engine idling speed, make sure that the air filter element is not clogged, the engine compression is proper, and the throttle grip free play is proper.
    • Adjust the engine idling speed with the starter knob pulled in completely.
    1.Start the engine, and warm this up until the oil has reached the specified temperature.
    2.Measure the coolant temperature using the Yamaha diagnostic tool.

    • Yamaha diagnostic tool USB (US)
      90890-03275
    • Yamaha diagnostic tool (A/I)
      90890-03273
    • Coolant temperature
      70–80 °C (158–176 °F)
    3.Install:

    • Digital tachometer
    • Digital tachometer
      90890-06760
    • Digital tachometer
      YU-39951-B
    Get the high tension cord “1” of the ignition coil pinched in the detector “a” of the digital tachometer.
    4.Measure:

    • Engine idling speed
      Out of specification → Regulate.
    • Engine idling speed
      1900–2100 r/min
    5.Adjust:

    • Engine idling speed
    a.Turn the idle screw “1” to make an adjustment.

    CHECKING THE THROTTLE GRIP

    Prior to adjusting throttle grip free play, the engine idling speed should be adjusted.
    1.Check:

    • Throttle grip free play “a”
      Out of specification → Regulate.
    • Throttle grip free play
      3.0–6.0 mm (0.12–0.24 in)
    2.Adjust:

    • Throttle grip free play
    a.Loosen the locknut “1”.
    b.Turn the adjuster “2” until the specified throttle grip free play is obtained.
    c.Tighten the locknut.

    After adjusting the throttle grip free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

    CHECKING THE SPARK PLUG

    1.Remove:

    Do not use too much force to pull the hose.
    Remove the fuel tank, turn this 180° clockwise, and put it in the frame “2” as shown.
    2.Remove:

    • Holder
    • Spark plug cap
    • Spark plug
      Refer to CAMSHAFT.
    In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder, clean it before removing the spark plug.
    3.Check:

    • Spark plug type
      Wrong type → Replace.
    • Manufacturer/model
      NGK/LMAR8E-J
    4.Check:

    • Electrode “1”
      Damage/wear → Replace the spark plug.
    • Insulator “2”
      Abnormal color → Replace the spark plug.
      Normal color is medium-to-light tan.
    5.Clean:

    • Spark plug
      (with a spark plug cleaner or a wire brush)
    6.Measure:

    • Spark plug gap “a”
      Out of specification → Adjust the spark plug gap.
    • Spark plug gap
      0.6–0.7 mm (0.024–0.028 in)
    7.Install:

    • Spark plug
    • Spark plug
      13 N·m (1.3 kgf·m, 9.6 lb·ft)
    Before installing the spark plug, clean the spark plug and gasket surface.
    8.Install:

    • Spark plug cap
    • Holder
    • Fuel tank
      Refer to FUEL TANK.
    • Shroud (left/right)
    • Side cover (left/right)
    • Seat
      Refer to GENERAL CHASSIS.

    CHECKING THE ENGINE OIL LEVEL

    1.Stand the vehicle upright on a level surface.
    2.Start the engine, warm this up for 2–3 minutes, and then stop the engine and wait about 1 minute.
    3.Check:

    • Oil level
      The engine oil level should be between the minimum level mark “a” and maximum level mark “b”.
      Below the minimum level mark → Add the recommended engine oil to the proper level.
    • Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives.
    • Do not allow foreign material to enter the crankcase.
    • Recommended brand
      YAMALUBE
    • SAE viscosity grades
      10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
    • Recommended engine oil grade
      API service SG type or higher, JASO standard MA

    CHANGING THE ENGINE OIL

    Stand the vehicle upright on a level surface.

    1.Start the engine, warm this up for several minutes, and then stop the engine and wait about 5 minutes.

    This model is equipped with an engine auto-stop system. The engine stops automatically if left idling for 7 minutes. If the engine stops, push the start switch to restart the engine.
    2.Place an oil pan under the drain bolt.
    3.Remove:

    • Engine guard
      Refer to ENGINE REMOVAL.
    • Oil filler cap “1”
    • Drain bolt (with gasket) “2”
    4.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.Replace the new O-ring “3”.

    c.Install the new oil filter element and the oil filter element cover.

    • Oil filter element cover bolt
      10 N·m (1.0 kgf·m, 7.4 lb·ft)
    5.To check the oil strainer, perform the following procedure.

    a.Remove the oil strainer “1”.
    b.Check the oil strainer.
    Damage → Replace.
    Clogging due to dirt → Wash with kerosene.
    c.Replace the new O-ring “2”.

    d.Install the oil strainer.

    • Oil strainer bolt
      10 N·m (1.0 kgf·m, 7.4 lb·ft)
    6.Install:

    • Gasket 
    • Drain bolt
    • Drain bolt
      20 N·m (2.0 kgf·m, 15 lb·ft)
    7.Pour the specified amount of engine oil into the oil filler cap hole.

    Engine oil quantity

    • Oil change
      0.73 L (0.77 US qt, 0.64 Imp.qt)
    • With oil filter removal
      0.75 L (0.79 US qt, 0.66 Imp.qt)
    • Quantity (disassembled)
      0.95 L (1.00 US qt, 0.84 Imp.qt)
    8.Install:

    • Oil filler cap
    9.Check:

    10.Check:

    • Engine oil pressure
    a.Slightly loosen the oil pressure check bolt “1”.

    When the engine is started with the check bolt removed, oil will spout; therefore, always loosen it before the checkup.
    b.Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt.

    Always keep the engine idling speed during the checkup without increasing the engine speed.
    If no engine oil seeps out after one minute, immediately turn the engine off so it will not seize.
    c.If no engine oil seeps out, check the engine oil for leaks, and the engine oil passage and the oil pump for damage.
    d.Check the oil pressure again.
    e.Tighten the oil pressure check bolt.

    • Oil pressure check bolt
      10 N·m (1.0 kgf·m, 7.4 lb·ft)
    11.Install:

    ADJUSTING THE CLUTCH LEVER FREE PLAY

    1.Check:

    • Clutch lever free play “a”
      Out of specification → Regulate.
    • Clutch lever free play
      7.0–12.0 mm (0.28–0.47 in)
    2.Adjust:

    • Clutch lever free play
    Handlebar side

    a.Turn the adjuster “1” until the specified clutch lever free play is obtained.

    If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.
    Clutch cable side

    a.Slide the clutch cable cover.
    b.Loosen the locknut “1”.
    c.Turn the adjuster “2” until the specified clutch lever free play is obtained.
    d.Tighten the locknut “1”.

    • Clutch cable locknut
      4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
    e.Return the clutch cable cover to its original position.

    ADJUSTING THE CLUTCH LEVER POSITION

    1.Adjust:

    • Clutch lever position “a”

    Loosen the locknut “1” and use the adjuster “2” to adjust the clutch lever position “a” as desired.

    2.Tighten:

    • Locknut
    • Locknut (clutch lever position)
      4.8 N·m (0.48 kgf·m, 3.5 lb·ft)

    CLEANING THE AIR FILTER ELEMENT

    1.Remove:

    • Sub-seat
      Refer to FUEL TANK CAP.
    • Air filter case cover “1”
    To remove the air filter case cover:

    • Raise the air filter case cover rear side while pushing the side “a” of the air intake duct from inside to unhook the ribs “b” on both sides of the air filter case cover from the air filter case “2”.
    • Slide the air filter case cover to the rear of the vehicle to remove the projection “c” from the hole “d” in the air filter case.
    2.Remove:

    • Air filter element guide “1”
    • Air filter element “2”
      (from the air filter element guide)
    • Seal “3”
      (from the air filter element)
    To remove the air filter element:

    • Release the band “a” from the projection “b”, and then move the air filter case assembly bracket “4” in the direction of the arrow to release the projection “c”.
    • Remove the air filter element and the air filter element guide as a set.
    3.Wash:

    • Air filter element
    a.After washing the element with air filter cleaner or kerosene, squeeze and dry it completely.

    Do not use gasoline or organic (acid/alkaline) volatile oil for washing.
    Do not twist the element when squeezing the element.
    4.Check:

    • Air filter element
      Damage → Replace.
    5.Apply:

    • Yamaha foam air filter oil or other quality foam air filter oil
    a.Put the air filter element into a plastic bag and drip the filter oil into the bag.
    b.With the element inside the bag, rub it thoroughly so that the element is evenly permeated with the oil.
    c.Wrap the element in a clean cloth, rub the element gently, and wipe off any excess oil.

    • The element should be permeated with oil so that it is wet but not dripping.
    • When replacing the element, permeate the element in oil by using the same procedure as when cleaning.
    6.Install:

    • Air filter case assembly bracket
      (if removed)
      Refer to THROTTLE BODY.
    • Seal “1”
      (to the air filter element)
    • Air filter element “2”
      (to the air filter element guide)
    • Air filter element guide “3”
    • Apply lithium-soap-based grease on the entire seal lips when installing the air filter element guide.
    • To install the air filter element:

      • Move the air filter case assembly bracket “4” to the rear of the vehicle.
      • Set the projection “a” on the air filter element guide to the air filter case assembly bracket and insert the projection “b” on the air filter element guide to the band “c”.
    7.Install:

    • Air filter case cover “1”
    • Fuel tank breather hose “2”
      (to the air filter case cover)
    • To install the air filter case cover:

      • Insert the projection “a” on air filter case cover to the hole “b” in the air filter case “3”.
      • Push the rear side of the air filter case cover to hook the ribs “c” to the air filter case.
    • Insert the fuel tank breather hose end with the protector into the steering shaft hole.
    • Fit the other end of the fuel tank breather hose into the projection on the fuel tank cap.
    • Route the fuel tank breather hose through the guide “d”, and then fit it into the groove “e” in the air filter case cover.
    8.Install:

    • Sub-seat

    CHECKING THE THROTTLE BODY JOINT

    1.Check:

    • Throttle body joint “1”
      Crack/damage → Replace.

    CHECKING THE FUEL LINE

    1.Remove:

    2.Check:

    • Fuel hose “1”
      Crack/damage → Replace.
      Loose connection → Connect properly.
    3.Install:

    CHECKING THE CYLINDER HEAD BREATHER HOSE

    1.Check:

    • Breather hose “1”
      Crack/damage → Replace.
      Loose connection → Connect properly.
    Make sure the cylinder head breather hose is routed correctly.

    CHECKING THE EXHAUST SYSTEM

    • Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
    • Do not start the engine when cleaning the exhaust system.
    1.Remove:

    2.Remove:

    • Exhaust pipe protector
    3.Check:

    • Exhaust pipe 1
    • Exhaust pipe 2
    • Silencer
      Crack/damage → Replace.
      Refer to ENGINE REMOVAL.
    4.Check:

    • Spark arrester
      Carbon deposits → clean
    5.Clean:

    • Spark arrester
    a.Remove the silencer cap screws “1”.

    b.Remove the spark arrester bolts “2”.

    c.Remove the tail pipe “3”, tail pipe gasket “4” and spark arrester “5”.

    Pull the spark arrester out of the muffler.
    d.Remove the spark arrester gasket “6”.

    e.Clean the spark arrester.

    Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits.
    f.Install the spark arrester gasket (new gasket) and spark arrester.

    Insert the spark arrester into the muffler and align the bolt holes.
    g.Install the tail pipe gasket (new gasket) and spark arrester bolts.

    • Spark arrester bolt
      5 N·m (0.5 kgf·m, 3.7 lb·ft)
    h.Install the silencer cap.

    • Silencer cap screw
      5 N·m (0.5 kgf·m, 3.7 lb·ft)
    First tighten the two screws “a” located horizontally apart, and then tighten the others.
    6.Check:

    • Gasket “1”
      Damage → Replace.
    7.Install:

    8.Install:

    • Exhaust pipe protector
    • Exhaust pipe protector screw
      10 N·m (1.0 kgf·m, 7.4 lb·ft)
      LOCTITE®

    CHECKING THE COOLANT LEVEL

    A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:
    Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
    1.Stand the vehicle upright on a level surface.
    2.Remove:

    • Radiator cap “1”
    3.Check:

    • Coolant level
      Maximum level “a” or below → Add coolant up to the maximum level.

      1.
      Radiator

    • Adding water instead of coolant lowers the antifreeze content. If, therefore, water is used instead of coolant, check, and if necessary, adjust the antifreeze concentration.
    • Use only distilled water. However, if distilled water is not available, soft water may be used.
    4.Start the engine, warm this up for several minutes, and then stop it.
    5.Check:

    • Coolant level
    Before checking the coolant level, wait a few minutes until the coolant has settled.

    CHECKING THE COOLING SYSTEM

    1.Remove:

    • Seat
    • Side cover (left/right)
    • Shroud (left/right)
      Refer to GENERAL CHASSIS.
    2.Check:

    • Radiator
    • Radiator hose
      Crack/damage → Replace.
      Refer to RADIATOR.
    3.Install:

    • Shroud (left/right)
    • Side cover (left/right)
    • Seat
      Refer to GENERAL CHASSIS.

    CHANGING THE COOLANT

    A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:
    Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
    1.Place a container under the engine.
    2.Remove:

    3.Remove:

    • Radiator cap
      Slowly loosen the radiator cap to drain coolant.

      When the radiator cap is loosened, coolant will gush out transversely; therefore, bring the container near to the outlet.
    4.Thoroughly flush the cooling system with clean tap water.
    5.Install:

    • Copper washer 
    • Coolant drain bolt
    • Coolant drain bolt
      10 N·m (1.0 kgf·m, 7.4 lb·ft)
    6.Pour coolant.

    • Recommended coolant
      High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine
    • Radiator (including all routes)
      0.93 L (0.98 US qt, 0.82 Imp.qt)
    • Coolant mixing ratio
      1:1 (Coolant:Water)
    • If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
    • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
    • If coolant is swallowed, induce vomiting and get immediate medical attention.
    • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.
    • Use only distilled water. However, if distilled water is not available, soft water may be used.
    • If coolant comes into contact with painted surfaces, immediately wash them with water.
    • Do not mix different types of antifreeze.
    7.Install:

    • Radiator cap
    8.Start the engine, warm this up for several minutes, stop it, and then wait for it to cool down.
    9.Check:

    10.Install:

  • Yamaha WR250F Cable Routing Diagram

    Frame and engine (front left side view)

    Components

    1. Clutch cable
    2. Throttle cable (return)
    3. Throttle cable (pull)
    4. Handlebar switch lead (left)
    5. Start switch lead
    6. Cable holder
    7. Handlebar switch coupler (left) (black, 6-pin)
    8. Start switch coupler (black, 2-pin)
    9. Rectifier/regulator coupler
    10. Tension arm
    11. Gear position switch lead
    12. Crankcase cover bolt (left)
    13. Radiator hose
    14. Stator coil assembly lead
    15. Gear position switch coupler (white, 3-pin)
    16. Stator coil assembly coupler (gray, 2-pin)
    17. Grommet
    18. Crankcase breather hose
    19. Lower engine bracket
    20. Radiator breather hose
    21. Holder
    22. Bracket

    Instructions

    A. Adjust slack in the handlebar switch lead (left) and start switch lead at the vehicle’s front side of the cable holder.

    B. Pass the handlebar switch lead (left) and the start switch lead between the frame and the cable holder. Pass the handlebar switch lead (left) above the start switch lead.

    C. Insert the handlebar switch 6-pin coupler (left) (black) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

    D. Insert the rectifier/regulator 2-pin coupler (not colored) and rectifier/regulator 3-pin coupler (not colored) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

    E. Pass the rectifier/regulator lead (wire harness side) to the inside of the tension arm (the side of the vehicle).

    F. Route the gear position switch lead along the crankcase cover while making sure that there is no looseness of the lead.

    G. Fasten the clutch cable and stator coil assembly lead with a plastic locking tie. The fastening position should be between the crankcase cover bolt (left) and the crankcase cover bolt (left), as shown. Place the lock portion of the plastic locking tie to the outside of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

    H. Bring the protector of the clutch cable into contact with the radiator hose, and pass it to the outside of the gear position switch lead and the stator coil assembly lead (the outside of the vehicle).

    I. Pass the stator coil assembly lead behind the radiator. Be sure the lead will not be pinched between the radiator and the tension arm. Make sure that the stator coil assembly lead does not get caught between the radiator and the gear position switch 3-pin coupler (white).

    J. After connecting the gear position switch 3-pin coupler (white), attach the coupler cover.

    K. After connecting the stator coil assembly 2-pin coupler (gray), attach the coupler cover.

    L. Fasten the clutch cable, gear position switch lead, and stator coil assembly lead over the grommet with the plastic locking tie. Place the lock portion of the plastic locking tie to the front of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

    M. Route the crankcase breather hose between the radiator and the frame, and in front of the lower boss of the radiator.

    N. Route the crankcase breather hose at the rear of the vehicle where the radiator breather hose is located.

    O. Route the radiator breather hose between the radiator hose and the crankcase breather hose. Then, route it inside the vehicle’s lower engine bracket.

    P. Clamp the clutch cable at the front of the lead (the front of the vehicle).

    Q. Insert the clip portion of the clamp into the frame. The lock part should face toward the front of the vehicle. Cut off the end of the remaining portion. (The direction of the end does not matter.)

    R. When installing the dampers and the lower handlebar holders in the front hole, be sure to route the handlebar switch lead (left) as shown in the illustration.

    Frame and engine (rear left side view)

    Components

    1. Wire harness
    2. Rear frame
    3. Plastic locking tie
    4. Starter relay coupler (black, 4-pin)
    5. Negative battery lead
    6. Starter relay
    7. Starter motor lead
    8. Taillight lead
    9. CCU (Communication Control Unit)
    10. Taillight coupler
    11. Starter relay cover
    12. Diode
    13. Engine mounting bracket boss
    14. Wire harness (resistor lead)
    15. Resistor
    16. Rear fender (projection)
    17. Positive battery lead
    18. CCU coupler
    19. Starter motor
    20. Clamp

    Instructions

    A. Fasten the resistor lead, starter motor lead, negative battery lead, and starter relay lead to the rear frame with the plastic locking tie between the branch of the wire harness and the battery bracket. Point the end of the lock portion and end of the plastic locking tie to the lower side of the vehicle.

    B. Route the negative battery lead inside the vehicle along the starter motor lead.

    C. Insert the starter relay into the battery bracket, and secure it.

    D. Route the starter motor lead between the starter relay and the rear frame. Adjust any slack between the starter relay and the plastic locking tie of the rear frame.

    E. No slack to the rear side of the vehicle.

    F. Place the taillight coupler inside the frame.

    G. Install the starter relay cover over the starter relay.

    H. Route the starter motor lead through the inside of the engine mounting bracket boss and along the front side of the vehicle behind the engine mounting bracket boss.

    I. Insert the clip of the clamp into the rear frame. Fasten the starter motor lead and wire harness at the green tape position of the wire harness. Place the starter motor lead under the vehicle’s wire harness. Place the lock portion of the plastic locking tie to the lower part of the vehicle, and then cut off the end by pointing it to the outside of the vehicle.

    J. Point the lock portion of the plastic locking tie toward the lower side of the vehicle and the end toward the outside of the vehicle, and then cut off the end.

    K. Point the starter motor lead to the outside, and then install it.

    L. Insert the projection of the resistor rubber band into the battery bracket. Then, fasten the resistor securely by sliding it to the front side of the vehicle.

    M. Route the positive battery lead on the outside of the projection on the rear fender (outside the vehicle).

    N. Insert the clip of the CCU coupler into the battery bracket from the rear side of the vehicle. When doing so, fasten the CCU coupler so that it is positioned as shown.

    Frame and engine (front right side view)

    Components

    1. Cylinder head breather hose
    2. High tension cord
    3. Radiator fan motor lead
    4. Radiator fan motor lead coupler
    5. Upper radiator boss
    6. Throttle position sensor lead
    7. Air filter breather hose
    8. Clip
    9. 3-way joint
    10. Crankcase breather hose
    11. Lower radiator boss
    12. Radiator breather hose
    13. Throttle position sensor coupler (black, 3-pin)
    14. Radiator hose
    15. Tension arm

    Instructions

    A. Route the cylinder head breather hose through the inside of the coolant temperature sensor lead.

    B. Route the throttle position sensor lead on the outside of the air filter breather hose and cylinder head breather hose, inside the vehicle along the ignition coil.

    C. Install the clips as shown in the illustration. Then install the lower clip above the radiator stay.

    D. Align the red paint mark on the hose with the convex mark on the 3-way joint, and then install the cylinder head breather hoses.

    E. The radiator breather hose should be routed in the following order and via each mentioned point:

    • Upper radiator boss: At the rear of the vehicle.
    • Lower radiator boss: At the front of the vehicle.
    • Outside the vehicle: Past the cylinder head breather hose (when doing so, cross them at the bottom of the radiator).
    • For routing the remaining leads, refer to the diagram “Frame and engine (front left side view)”.

    F. After connecting the throttle position sensor 3-pin coupler (black), install the cover over it.

    G. Route the radiator fan motor lead inside the vehicle along the high tension cord.

    Frame and engine (rear right side view)

    Components

    1. Fuel pump coupler (black, 5-pin)
    2. Coolant temperature sensor coupler (black, 2-pin)
    3. High tension cord
    4. ECU lead
    5. Radiator fan motor relay lead
    6. Taillight coupler
    7. CCU sub-lead
    8. CCU (Communication Control Unit)
    9. Wire harness
    10. Resistor coupler
    11. Positive battery lead
    12. Radiator fan motor fuse
    13. ECU (Engine Control Unit)
    14. Radiator fan motor relay

    Instructions

    A. After connecting, install the cover over the fuel pump 5-pin coupler (black).

    B. Route the engine ground lead outside the vehicle past the high tension cord. When installing the engine ground lead terminal, it can face either way. Point the engine ground lead to the upper side of the vehicle, and then install it.

    C. Route the coolant temperature sensor lead outside the vehicle past the high tension cord. After connecting the coolant temperature sensor 2-pin coupler (black), install the cover over it.

    Handlebar (front view)

    Components

    1. Throttle cable
    2. Plastic locking tie
    3. Handlebar protector
    4. Clutch cable
    5. Handlebar switch lead (left)
    6. Front brake hose
    7. Headlight lead
    8. Multi-function display coupler (black, 4-pin)
    9. Speed sensor coupler (black, 3-pin)
    10. Start switch lead
    11. Speed sensor lead
    12. Meter bracket
    13. Wire harness

    Instructions

    A. Fasten at the center of both sides of the clamps.

    B. Secure the handlebar switch lead (left) to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

    C. Pass the throttle cable, clutch cable, handlebar switch lead (left), start switch lead, and speed sensor lead between the wire guide of the meter bracket and the handle crown in no particular order.

    D. Fasten the wire harness and speed sensor lead to the meter bracket using the plastic locking tie. When fastening, turn the steering to the left with no slack. The speed sensor lead should be fastened at the gray tape. Face the end of the plastic locking tie to the right side of the vehicle, and cut off the excess.

    E. Route the headlight lead along the left side of the vehicle.

    F. Connect the headlight lead to the headlight.

    G. Route the speed sensor lead in front of the vehicle’s wire harness.

    H. Insert the multi-function display 4-pin coupler (black) into the bracket and secure it. After securing, install the cover.

    I. Insert the speed sensor 3-pin coupler (black) into the bracket and secure it. After securing, install the cover.

    J. After fastening the speed sensor lead, route it in a “U” shape along the start switch lead, passing through the bottom of the front brake hose.

    K. Secure the start switch lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

    L. Fasten the start switch lead and speed sensor lead with the plastic locking tie at the front side of the handlebar. Place both leads above the lower part of the handlebar.

    M. Secure the start switch lead and speed sensor lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

    N. Secure the handlebar and handlebar protector with the plastic locking tie. Point the lock portion of the plastic locking tie to the lower side of the vehicle. The direction of the end does not matter.

    O. Fasten the speed sensor lead at the painted portion. The placement of the front brake hose does not matter.

    P. Ensure a 70–110° angle.

    Q. Align the lead in the vertical direction of the vehicle.

    R. Maintain a gap of 5 mm (0.20 in).

    S. Fasten the painted portion of the speed sensor lead at the shrinking tube of the front brake hose.

    Frame and engine (top view)

    Components

    1. Ignition coil lead
    2. Coolant temperature sensor lead
    3. Engine ground lead
    4. Air filter breather hose
    5. Intake air pressure sensor coupler (dark blue, 3-pin)
    6. Fuel injector coupler (gray, 2-pin)
    7. Intake air temperature sensor coupler (black, 2-pin)
    8. Tank rail
    9. Air filter case
    10. Spark plug cap
    11. Cylinder head cover
    12. Damper
    13. Fuel hose
    14. Starter motor lead
    15. Wire harness

    Instructions

    A. Install the terminal so that the lead is positioned above the vehicle. Connect the black cover of the ignition coil lead to the black terminal of the ignition coil, and the white cover to the green terminal.

    B. Route the coolant temperature sensor lead, engine ground lead, and high tension cord outside the vehicle, passing the air filter breather hose.

    C. Insert the projection of the main harness into the hole in the tank rail.

    D. Maintain a ±10° alignment.

    E. Position components on the right side of the vehicle.

    F. Insert the spark plug cap fully into the cylinder head cover, ensuring there is no clearance between the cap and the cover.

    G. Place the fuel hose on the flat surface on the upper side of the damper.

    H. Route the starter motor lead along the damper and secure it with a clamp.

    I. Place the wire harness on the flat surface on the upper side of the damper.

    J. Insert the clip portion of the clamp into the air filter case.

    Frame and battery (top view)

    Components

    1. Radiator fan motor relay lead
    2. ECU lead
    3. Battery
    4. Radiator fan motor fuse
    5. Negative battery lead
    6. CCU (Communication Control Unit)
    7. Positive battery lead
    8. ECU (Engine Control Unit)
    9. Radiator fan motor relay
    10. Holder
    11. Rear frame
    12. Radiator fan motor fuse lead
    13. Wire harness (resistor lead)
    14. Plastic locking tie

    Instructions

    A. Install the radiator fan motor fuse to the battery bracket.

    B. Point the terminal of the negative battery lead to the inside of the vehicle and install it.

    C. After connecting the positive battery lead in the direction shown in the illustration, place the cover over it.

    D. After connecting the ECU coupler, secure the coupler cover over it.

    E. After connecting the radiator fan motor relay to the wire harness, install the cover over the radiator fan motor relay. Point the portion connected to the wire harness toward the left side of the vehicle, then secure the radiator fan motor relay to the holder.

    F. Insert the holder with the ECU installed into the battery box bracket. When doing so, secure the ECU so that its connector points to the left side of the vehicle.

    G. Install the terminal in the specified direction as shown in the diagram.

    H. Ensure the radiator fan motor fuse lead has sufficient slack at the rear side of the vehicle, routed past the plastic locking tie.

    I. Route the positive battery lead under the lower part of the vehicle’s negative battery lead and over the resistor lead.

    J. Ensure the resistor lead has sufficient slack at the rear side of the vehicle, routed past the plastic locking tie.

    K. Align components towards the rear side of the vehicle.

    Rear brake (right side view)

    Components

    1. Protector
    2. Rear brake caliper
    3. Bleed screw
    4. Rear brake hose
    5. Brake pedal
    6. Rear brake master cylinder assembly
    7. Swingarm
    8. Rear shock absorber assembly

    Instructions

    A. The orientation of the spring (upward or downward) does not matter when installed.

    B. Pass the rear brake hose into the designated rear brake hose holders.

    C. Route the rear brake hose so that it avoids interference with the spring of the rear shock absorber assembly.

    D. Ensure the rear brake hose is not excessively twisted during installation.

    E. Install the rear brake hose with the bended portion of the metal part facing as illustrated in the diagram.

    F. Ensure the metal part of the rear brake hose makes contact with the stopper of the rear brake master cylinder.

    G. Ensure the metal part of the rear brake hose makes contact with the stopper of the rear brake caliper.

    Front brake (front view and left side view)

    Components

    1. Speed sensor lead
    2. Front brake hose
    3. Clamp
    4. Protector
    5. Speed sensor

    Instructions

    A. Clamp the shrinking tube portion of the speed sensor lead securely.

    B. Ensure any slack in this section is properly absorbed.

    C. Pass the front brake hose and speed sensor lead through the guide on the headlight body. Scratching during this process is acceptable.

    D. Align the paint mark on the front brake hose with the upper end of the clamp during installation. The orientation around the circumference does not matter.

    E. Ensure the metal part of the front brake hose contacts the stopper of the front brake caliper.

    F. Securely clamp the speed sensor lead to the hooks on the protector at three specified locations.

    Taillight (top view and left side view)

    Components

    1. Taillight lead
    2. Taillight
    3. Clamp
    4. Rear fender (projection)

    Instructions

    A. Ensure there is no slack in the taillight lead.

    B. Route the taillight lead inside the projection of the rear fender.

    C. Insert the taillight lead all the way through.

  • Yamaha TT-R110E Maintenance

    Periodic maintenance chart for the emission control system 

    TIP 
    •  From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. 
    •  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech- nical skills.
    No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
    1000 km
    (600 mi) or
    1 month or
    30 hours    		 3000 km
    (1800 mi) or
    6 months or
    90 hours    		 5000 km
    (3000 mi) or
    12 months or
    150 hours
    1 * Fuel line • Check fuel hoses for cracks or damage.
    • Replace if necessary    		 ✔️ ✔️
    2 Spark plug • Check condition.
    • Adjust gap and clean.    		 ✔️ ✔️
    3 * Valve clearance • Check operation.
    • Adjust brake pedal free play and replace brake shoes if necessary.    		 ✔️
    4 Air filter element • Clean with solvent.
    • Replace if necessary    		 ✔️ ✔️
    5 * Crankcase breather sys- tem • Check ventilation hose for cracks or damage and drain any deposits.
    • Replace if necessary.    		 ✔️ ✔️ ✔️
    6 * Carburetor • Check engine idling speed and starter operation. • Adjust if necessary ✔️ ✔️ ✔️
    7 Exhaust system • Check for leakage.
    • Tighten if necessary.
    • Replace gasket(s) if necessary    		 ✔️ ✔️
    8 * Spark arrester • Clean. ✔️
    9 Engine oil • Change (warm engine before draining). ✔️ ✔️ ✔️

    General maintenance and lubrication chart 

    TIP 
    • From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. 
    • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech- nical skills.
    No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
    1000 km
    (600 mi) or
    1 month or
    30 hours    		 3000 km
    (1800 mi) or
    6 months or
    90 hours    		 5000 km
    (3000 mi) or
    12 months or
    150 hours
    1 * Clutch Check operation.
    Adjust if necessary.    		 ✔️ ✔️ ✔️
    2 * Front brake Check operation.
    Adjust brake lever free play and replace brake shoes if necessary.    		 ✔️ ✔️ ✔️
    3 * Rear brake Check operation.
    Adjust brake pedal free play and replace brake shoes if necessary.    		 ✔️ ✔️ ✔️
    4 * Wheels Check runout, spoke tightness and for damage.
    Tighten spokes if necessary.    		 ✔️ ✔️ ✔️
    5 * Tires Check tread depth and for damage.
    Replace if necessary.
    Check air pressure.
    Correct if necessary.    		 ✔️ ✔️
    6 * Wheel bearings Check bearings for smooth operation.
    Replace if necessary.    		 ✔️ ✔️
    7 * Swingarm pivot bushes Check bush assemblies for looseness.
    Lubricate with molybdenum disulfide grease.    		 ✔️ ✔️
    8 Drive chain Check chain slack/alignment and condition.
    Adjust and lubricate chain with Yamaha chain lubricant or other suitable chain lubricant thoroughly.    		 Every ride
    9 * Steering bearings Check bearing assemblies for looseness.
    Moderately repack with lithium-soap-based grease.    		 ✔️ ✔️
    10 * Chassis fasteners Check all chassis fitting and fasteners.
    Correct if necessary.    		 ✔️ ✔️ ✔️
    11 Brake lever pivot shaft Apply lithium-soap-based grease lightly. ✔️ ✔️
    12 Brake pedal pivot shaft Apply lithium-soap-based grease lightly. ✔️ ✔️
    13 Sidestand pivot Check operation.
    Apply lithium-soap-based grease lightly.    		 ✔️ ✔️
    14 * Front fork Check operation and for oil leakage.
    Replace if necessary.    		 ✔️ ✔️
    15 * Shock absorber assem-
    bly    		 Check operation and for oil leakage.
    Replace if necessary.    		 ✔️
    16 * Control cables Apply Yamaha cable lubricant or other suitable cable lu- bricant thoroughly. ✔️ ✔️ ✔️
    17 * Throttle grip Check operation.
    Check throttle grip free play, and adjust if necessary.
    Lubricate cable and grip housing.    		 ✔️ ✔️ ✔️

    TIP 

    • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

    Removing and installing panels

    Checking the spark plug

    Engine oil

    Cleaning the air filter element

    Cleaning the spark arrester

    Adjusting the carburetor

    Adjusting the engine idling speed

    Checking the throttle grip free play

    Valve clearance

    Tires

    Spoke wheels

    Adjusting the clutch free play

    Adjusting the brake lever free play

    Adjusting the brake pedal free play

    Checking the front and rear brake shoes

    Drive chain slack

    Checking the steering

    Front wheel

    Rear wheel

    Troubleshooting

    Troubleshooting chart