Yamaha YZ 2018 Series Manuals

Manuals and User Guides for Yamaha YZ 2018 Series. We have 1 Yamaha YZ 2018 Series manual available for free PDF download: Owner's Service Manual

Yamaha YZ 2018 Series Owner's Service Manual

Yamaha YZ 2018 Series Owner's Service Manual (402 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18.12 MB

Table of Contents

Table of Contens

9
- Table of Contents
  9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Fuel Hose Joint Cover
  16
- Coupler for Connecting Optional Part
  16
- Spark Plug Wrench
  16
- Handlebar Protector
  16
- Nipple Wrench
  16
- Included Parts
  16
- Important Information
  17
- Preparation for Removal and Disassembly
  17
- Replacement Parts
  17
- Circlips
  18
- Bearings and Oil Seals
  18
- Lock Washers/Plates and Cotter Pins
  18
- Gaskets, Oil Seals and O-Rings
  18
- Basic Service Information
  19
- Electrical System
  19
- Special Tools
  23
- Start Switch
  29
- Clutch Lever
  29
- Engine Stop Switch
  29
- Warning Lights
  29
- Control Functions
  29
- Shift Pedal
  30
- Throttle Grip
  30
- Front Brake Lever
  30
- Rear Brake Pedal
  30
- Sidestand
  30
- Starter Knob/Idle Adjusting Screw
  30
- Fuel Tank Cap
  31
- Starting a Cold Engine
  32
- Air Filter Maintenance
  32
- Handling Note
  32
- Fuel
  32
- Starting and Break-In
  32
- Starting a Warm Engine
  33
- Break-In Procedures
  33
- Maintenance after Break-In
  34
- Major Maintenance
  34
- Torque-Check Points
  35
- Motorcycle Care and Storage
  37
- Care
  37
- Storage
  38
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  47
- Electrical Specifications
  50
- General Tightening Torque Specifications
  52
- Tightening Torques
  52
- Engine Tightening Torques
  53
- Chassis Tightening Torques
  56
- Engine
  59
- Lubrication Points and Lubricant Types
  59
- Chassis
  60
- Lubrication Diagrams
  62
- Lubrication System Chart and Diagrams
  62
- Cable Routing Diagram
  70
Periodic Checks and Adjustments

85
- Maintenance Intervals
  87
- General Inspection and Maintenance
  93
- Pre-Operation Inspection and Maintenance
  93
- Changing the Coolant
  94
- Checking the Coolant Level
  94
- Checking the Cooling System
  94
- Engine
  94
- Checking the Radiator Cap
  95
- Checking the Radiator Cap Valve Opening Pressure
  95
- Adjusting the Clutch Lever Free Play
  96
- Checking the Coolant Circulatory System for Leaks
  96
- Adjusting the Throttle Grip Free Play
  97
- Lubricating the Throttle Cable
  97
- Cleaning the Air Filter Element
  98
- Checking the Breather Hoses
  99
- Checking the Exhaust System
  99
- Checking the Throttle Body Joint
  99
- Checking the Engine Oil Level
  100
- Checking the Fuel Line
  100
- Changing the Engine Oil
  101
- Adjusting the Engine Idling Speed
  102
- Adjusting the Valve Clearance
  103
- Valve Clearance Shim Chart
  106
- Bleeding the Brake System
  108
- Chassis
  108
- Adjusting the Front Brake
  109
- Checking the Brake Hose
  109
- Adjusting the Rear Brake
  110
- Checking the Front Brake Pads
  110
- Checking the Rear Brake Pads
  112
- Checking the Brake Fluid Level
  113
- Checking the Rear Brake Pad Insulator
  113
- Adjusting the Drive Chain Slack
  114
- Air Bleeding from Front Fork
  115
- Checking the Front Fork Legs
  115
- Checking the Front Fork Protector Guide
  115
- Cleaning the Front Fork Oil Seal and Dust Seal
  115
- Adjusting the Front Fork Legs
  116
- Adjusting the Rear Shock Absorber Assembly
  117
- Checking the Rear Suspension
  117
- Checking the Swingarm Operation
  117
- Checking and Tightening the Spokes
  119
- Checking the Tires
  119
- Checking and Adjusting the Steering Head
  120
- Checking the Wheel Bearings
  120
- Checking the Wheels
  120
- Checking and Lubricating the Cables
  121
- Lubricating the Drive Chain
  121
- Lubricating the Levers
  121
- Lubricating the Pedal
  121
- Checking the Chassis Fasteners
  122
- Lubricating the Sidestand
  122
- Checking the Ignition Timing
  123
- Checking the Spark Plug
  123
- Electrical System
  123
- Checking and Charging the Battery
  124
Chassis

125
- General Chassis
  128
- Removing the Left Side Cover
  128
- Removing the Number Plate
  128
- Removing the Seat
  128
- Checking the Front Wheel
  130
- Front Wheel
  130
- Removing the Front Wheel
  130
- Assembling the Front Wheel
  131
- Disassembling the Front Wheel
  131
- Installing the Front Wheel
  132
- Checking and Replacing the Rear Wheel Sprocket
  134
- Checking the Rear Wheel
  134
- Disassembling the Rear Wheel
  134
- Rear Wheel
  134
- Removing the Rear Wheel
  134
- Assembling the Rear Wheel
  135
- Installing the Rear Wheel
  135
- Front Brake
  137
- Checking the Front Brake Disc
  141
- Disassembling the Front Brake Caliper
  141
- Introduction
  141
- Removing the Front Brake Caliper
  141
- Assembling the Front Brake Caliper
  142
- Checking the Front Brake Caliper
  142
- Installing the Brake Caliper Piston
  142
- Installing the Front Brake Caliper
  143
- Assembling the Front Brake Master Cylinder
  144
- Checking the Front Brake Master Cylinder
  144
- Removing the Front Brake Master Cylinder
  144
- Installing the Front Brake Master Cylinder
  145
- Rear Brake
  147
- Checking the Rear Brake Disc
  151
- Introduction
  151
- Assembling the Rear Brake Caliper
  152
- Checking the Rear Brake Caliper
  152
- Disassembling the Rear Brake Caliper
  152
- Removing the Rear Brake Caliper
  152
- Installing the Brake Caliper Piston
  153
- Installing the Rear Brake Caliper
  153
- Checking the Rear Brake Master Cylinder
  154
- Removing the Rear Brake Master Cylinder
  154
- Assembling the Rear Brake Master Cylinder
  155
- Installing the Rear Brake Master Cylinder
  155
- Handlebar
  157
- Checking the Handlebar
  159
- Installing the Handlebar
  159
- Removing the Handlebar
  159
- Front Fork
  164
- Disassembling the Front Fork Legs
  166
- Removing the Front Fork Legs
  166
- Checking the Front Fork Legs
  167
- Assembling the Front Fork Legs
  168
- Installing the Front Fork Legs
  175
- Steering Head
  177
- Checking the Steering Head
  178
- Installing the Steering Head
  178
- Removing the Lower Bracket
  178
- Rear Shock Absorber Assembly
  182
- Disposing of a Rear Shock Absorber
  184
- Handling the Rear Shock Absorber
  184
- Removing the Bearing
  184
- Removing the Rear Shock Absorber Assembly
  184
- Checking the Connecting Arm and Relay Arm
  185
- Checking the Rear Shock Absorber Assembly
  185
- Installing the Relay Arm
  185
- Installing the Rear Shock Absorber Assembly
  186
- Swingarm
  188
- Checking the Swingarm
  189
- Removing the Bearing
  189
- Removing the Swingarm
  189
- Installing the Swingarm
  190
- Chain Drive
  191
- Checking the Drive Chain
  192
- Removing the Drive Chain
  192
- Checking the Drive Sprocket
  193
- Checking the Rear Wheel Sprocket
  193
- Installing the Drive Chain
  193
- Engine
  195
- Cooling System
  277
Fuel System

285
- Fuel Tank
  286
- Checking the Fuel Pump Body
  287
- Installing the Fuel Pump
  287
- Removing the Fuel Pump
  287
- Removing the Fuel Tank
  287
- Checking the Fuel Sender
  288
- Installing the Fuel Sender
  288
- Installing the Fuel Tank
  288
- Removing the Fuel Sender
  288
- Checking and Replacing the Protector
  289
- Checking the Damper
  289
- Checking the Fuel Pressure
  289
- Throttle Body
  292
- Checking the Injector
  294
- Checking the Throttle Body
  294
- Checking the Throttle Body Joint
  294
- Adjusting the Throttle Position Sensor
  295
Electrical System

297
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Electric Starting System
  304
- Starting Circuit Cut-Off System Operation
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Signaling System
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- COOLING SYSTEM (for JPN)
  318
- Troubleshooting
  320
- Circuit Diagram
  322
- Fuel Injection System
  322
- Ecu Self-Diagnostic Function
  324
- Troubleshooting Method
  325
- Connecting the Yamaha Diagnostic Tool
  326
- Features of the Yamaha Diagnostic Tool
  326
- Functions of the Yamaha Diagnostic Tool
  326
- Yamaha Diagnostic Tool
  326
- Troubleshooting Details
  328
- Circuit Diagram
  348
- Fuel Pump System
  348
- Troubleshooting
  350
- Electrical Components
  352
- Checking the Switches
  356
- Checking the Bulbs and Bulb Sockets
  359
- Checking the Fuses
  359
- Checking and Charging the Battery
  360
- Checking the Relays
  363
- Checking the Diode
  364
- Checking the Ignition Coil
  365
- Checking the Ignition Spark Gap
  365
- Checking the Spark Plug Cap
  365
- Checking the Crankshaft Position Sensor
  366
- Checking the Lean Angle Sensor
  366
- Checking the Starter Motor Operation
  367
- Checking the Stator Coil
  367
- Checking the Fuel Sender
  368
- Checking the Rectifier/Regulator
  368
- Checking the Coolant Temperature Sensor
  369
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  369
- Checking the Resister
  369
- Checking the Intake Air Pressure Sensor
  370
- Checking the Throttle Position Sensor Input Voltage
  370
- Checking the Fuel Injector
  371
- Checking the Intake Air Temperature Sensor
  371
Troubleshooting

373
- General Information
  374
- Incorrect Engine Idling Speed
  374
- Starting Failures
  374
- Troubleshooting
  374
- Clutch Drags
  375
- Clutch Slips
  375
- Jumps out of Gear
  375
- Overheating
  375
- Poor Medium-And-High-Speed Performance
  375
- Shift Pedal Does Not Move
  375
- Shifting Is Difficult
  375
- Faulty Front Fork Legs
  376
- Front Fork Oil Leaking
  376
- Overcooling
  376
- Poor Braking Performance
  376
- Unstable Handling
  376
- Communication Error with Yamaha Diagnostic Tool
  378
- List of Diagnostic Codes
  378
- List of Self-Diagnostic and Fail-Safe Actions
  378
- Sensor Operation Table
  379
- Actuator Operation Table
  380
Tuning

381
- Chassis
  382
- Drive and Rear Wheel Sprockets Setting Parts
  382
- Selection of the Secondary Reduction Ratio (Sprocket)
  382
- Tire Pressure
  382
- Change in Amount and Characteristics of Fork Oil
  383
- Front Fork Setting
  383
- Setting of Spring after Replacement
  383
- Choosing Set Length
  384
- Front Fork Setting Parts
  384
- Rear Suspension Setting
  384
- Suspension Setting (Front Fork)
  387
- Suspension Setting (Rear Shock Absorber)
  388
- Kick Starter Kit (Optional Parts)
  390
- Parts Location
  390
- Setup Procedures
  392
- Starting the Engine
  395
- Maintenance
  396

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