Yamaha FZ 25 2021 Manual

FORWARD

This supplementary service manual has been prepared to introduce new service and data for the

FZ 25 & FZS 25 (FZN250-A & FZN250D-A) BS-VI 2021 For complete information procedures it is

necessary to use this supplementary service manual together with the following manual.

FZN250 2017 SERVICE MANUAL: B97-F8197-E0

FZ 25 & FZS 25 (FZN250-A & FZN250D-A) BS-VI 2021

SUPPLEMENTARY SERVICE MANUAL

July 2020

Any reproduction or unauthorized use without the

written permission of

India Yamaha Motor Pvt. Ltd.

is expressly prohibited.

B9X-F8197-E0.book Page 1 Thursday, July 16, 2020 2:28 PM

EAS20071

IMPORTANT

This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

B9X-F8197-E0.book Page 2 Thursday, July 16, 2020 2:28 PM

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

●The manual is divided into chapters and each chapter is divided into sections. The current sec-

tion title “1” is shown at the top of each page.

●Sub-section titles “2” appear in smaller print than the section title.

●To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

●Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

●Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

●A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

●Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

G088877

B9X-F8197-E0.book Page 3 Thursday, July 16, 2020 2:28 PM

EAS20101

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINTION SYMBOL DEFINTION

Serviceable with engine mounted Molybdenum disulfide oil

Filling fluid Brake fluid

Lubricant Wheel bearing grease

Special tool Lithium-soap-based grease

Tightening torque Molybdenum disulfide grease

Wear limit, clearance Silicone grease

Engine speed Apply locking agent (LOCTITE®).

Electrical data Replace the part with a new one.

Engine oil

B9X-F8197-E0.book Page 4 Thursday, July 16, 2020 2:28 PM

TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS2

PERIODIC CHECKS AND

ADJUSTMENTS3

CHASSIS 4

ENGINE 5

ELECTRICAL SYSTEM 6

TROUBLESHOOTING 7

B9X-F8197-E0.book Page 5 Thursday, July 16, 2020 2:28 PM

B9X-F8197-E0.book Page 6 Thursday, July 16, 2020 2:28 PM

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

FEATURES......................................................................................................1-1

OUTLINE OF THE ABS............................................................................. 1-1

ABS COMPONENT FUNCTIONS .............................................................1-5

ABS OPERATION ...................................................................................1-10

ABS WARNING LIGHT AND OPERATION.............................................1-13

INDICATOR LIGHTS AND WARNING LIGHT ........................................1-15

MULTI-FUNCTION DISPLAY..................................................................1-15

HANDLEBAR SWITCHES.......................................................................1-18

SIDESTAND ............................................................................................1-18

SPECIAL TOOLS..........................................................................................1-19

B9X-F8197-E0.book Page 1 Thursday, July 16, 2020 2:28 PM

GEN

INFO

B9X-F8197-E0.book Page 2 Thursday, July 16, 2020 2:28 PM

1-1

GEN

INFO

FEATURES

GENERAL INFORMATION

EAS20008

FEATURES

EAS30683

OUTLINE OF THE ABS

1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the

front and rear brakes independently.

2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of

the vehicle.

3. The hydraulic unit assembly, which is the main component of the ABS, is centrally located on the

vehicle to increase mass centralization.

ABS layout

1. ABS test coupler

2. ABS control unit fuse

3. ABS solenoid fuse

4. ABS motor fuse

5. ABS warning light

6. Front wheel sensor rotor

7. Front wheel sensor

8. Hydraulic unit assembly

9. Rear wheel sensor rotor

10.Rear wheel sensor

B9X-F8197-E0.book Page 1 Thursday, July 16, 2020 2:28 PM

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