Yamaha WR250R Service Manual
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Yamaha WR250R Service Manual

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2008
SERVICE MANUAL
WR250RX(C)
WR250XX(C)
LIT-11616-21-66
32C-28197-10

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  • Page 1 2008 SERVICE MANUAL WR250RX(C) WR250XX(C) LIT-11616-21-66 32C-28197-10...
  • Page 3 EAS20050 WR250RX(C)/WR250XX(C) SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, December 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-21-66...
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 5: How To Use This Manual

    HOW TO USE THIS MANUAL EAS20090 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.

  • Page 6: Symbols

    SYMBOLS EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER............1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM ....................1-3 MULTI-FUNCTION DISPLAY..............1-4 IMPORTANT INFORMATION ................1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-8 REPLACEMENT PARTS .................1-8 GASKETS, OIL SEALS AND O-RINGS ...........1-8 LOCK WASHERS/PLATES AND COTTER PINS........1-8 BEARINGS AND OIL SEALS..............1-8 CIRCLIPS....................1-9...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS32D1017 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS32D1018 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator is installed in the fuel rail, and maintains the fuel pressure that is applied to the fuel injector at 245–255 kPa (34.8–36.3 psi) (2.45–2.55 kg/cm ).

  • Page 13: Multi-Function Display

    FEATURES EAS32D1004 MULTI-FUNCTION DISPLAY Measurement mode: EWA32D1008 a speedometer (which shows the riding speed) WARNING a distance-compensation tripmeter (which Be sure to stop the vehicle before making shows the accumulated distance traveled any setting changes to the multi-function since set to zero and which can be calibrated display.
  • Page 14 FEATURES continuously until the button is released. NOTE: Indicator “ ” comes on when tripmeter A is se- To set the clock lected, and indicator “ ” comes on when 1. Push the “SELECT 1” button for at least two tripmeter B is selected.
  • Page 15 FEATURES counting, repeat steps 3 and 4. Measurement mode (for calibrating the dis- tance-compensation tripmeter’s reading) The distance-compensation tripmeter is a fea- ture intended to provide a more accurate tripmeter reading for enduro riding. Calibrating this meter in accordance with the distances specified on the enduro course map will help fa- miliarize the rider with the course.
  • Page 16 FEATURES system. Refer to “FUEL INJECTION SYSTEM” on page 8-29. 1. Error code display ECA32D1007 CAUTION: If the display indicates an error code, the ve- hicle should be checked as soon as possible in order to avoid engine damage.

  • Page 17: Important Information

    5. Keep all parts away from any source of fire. ate. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 18: Circlips

    IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2”...

  • Page 19: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: Lead NOTE: Coupler If there is no continuity, clean the terminals. Connector When checking the wire harness, perform 2.

  • Page 20: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Spacer (crankshaft installer) 5-63 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 Steering nut wrench 3-25 90890-01403 Spanner wrench YU-33975...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder 4-42, 4-44 90890-01454 Spoke nipple wrench (8–9) 3-31 90890-01522 YM-01522 Sheave holder 5-53, 5-54 90890-01701 Primary clutch holder YS-01880-A Compression gauge 90890-03081 Engine compression tester YU-33223 Pocket tester 1-10, 5-32, 90890-03112 8-65, 8-66, 8-67, 8-71,...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 7-7, 8-80, 8-81 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Fuel pressure adapter 90890-03176 YM-03176 Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Mechanical seal installer 90890-04145 Universal clutch holder 5-38, 5-40...
  • Page 24 5-20 90890-04117 YM-04117 Valve guide reamer (4.5ø) 5-20 90890-04118 YM-04118 Rotor puller 5-53 90890-04142 YM-04142 Ignition checker 8-74 90890-06754 Opama pet-4000 spark checker YM-34487 Digital tachometer 3-6, 3-9 90890-06760 YU-39951-B Yamaha bond No. 1215 (Three Bond 5-60 No.1215®) 90890-85505 1-15...

  • Page 25: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ...............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS.................2-9 ELECTRICAL SPECIFICATIONS..............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 CHASSIS....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-25 LUBRICATION DIAGRAMS ..............2-25 COOLING SYSTEM DIAGRAMS..............2-29 CABLE ROUTING..................2-31 Front rear brake hose...................2-39 Throttle body....................2-41...

  • Page 26: General Specifications

    Wheelbase WR250R 1420 mm (55.9 in) WR250X 1425 mm (56.1 in) Ground clearance WR250R 295 mm (11.61 in) (CAL) WR250R 300 mm (11.81 in) (U49) WR250X 260 mm (10.24 in) (CAL) WR250X 265 mm (10.43 in) (U49) Minimum turning radius 2300 mm (90.6 in)

  • Page 27: Engine Specifications

    Starting system Electric starter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity WR250R 7.2 L (1.90 US gal) (1.58 Imp.gal) (CAL) WR250R 7.6 L (2.01 US gal) (1.67 Imp.gal) (U49) WR250X 7.2 L (1.90 US gal) (1.58 Imp.gal) (CAL) WR250X 7.6 L (2.01 US gal) (1.67 Imp.gal)
  • Page 28 ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 15.36 cm (0.94 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance...
  • Page 29 ENGINE SPECIFICATIONS Valve face width B (intake) 1.840 mm (0.0724 in) Valve face width B (exhaust) 2.260 mm (0.0890 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 1.15–1.45 mm (0.0453–0.0571 in) Limit 1.00 mm (0.04 in)
  • Page 30 ENGINE SPECIFICATIONS Spring rate K2 (intake) 40.90 N/mm (233.54 lb/in) (4.17 kgf/mm) Spring rate K1 (exhaust) 31.47 N/mm (179.69 lb/in) (3.21 kgf/mm) Spring rate K2 (exhaust) 40.90 N/mm (233.54 lb/in) (4.17 kgf/mm) Installed compression spring force (intake) 147.00–169.00 N (33.05–37.99 lbf) (14.99–17.23 kgf) Installed compression spring force (exhaust) 147.00–169.00 N (33.05–37.99 lbf)
  • Page 31 ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring...
  • Page 32 Foam air-filter oil or engine oil Throttle body Type/quantity 38EIS/1 Manufacturer MIKUNI ID mark WR250R 32C3 00 (CAL) WR250R 3D71 10 (U49) WR250X 32C3 00 (CAL) WR250X 3D71 10 (U49) Fuel injection sensor 248–278 Ω Crankshaft position sensor Intake air pressure sensor output voltage 3.75–4.25 V...
  • Page 33 ENGINE SPECIFICATIONS 60.0 °C (140.00 °F) Oil temperature Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)

  • Page 34: Chassis Specifications

    Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front WR250R 125 kPa (18 psi) (1.25 kgf/cm WR250X 200 kPa (29 psi) (2.00 kgf/cm Rear WR250R 175 kPa (25 psi) (1.75 kgf/cm WR250X 200 kPa (29 psi) (2.00 kgf/cm Loading condition 90–185 kg (198–408 lb)
  • Page 35 Front brake lever free play 5.0–8.0 mm (0.20–0.31 in) Front disc brake Disc outside diameter × thickness WR250R 250.0 × 3.5 mm (9.84 × 0.14 in) WR250X 298.0 × 4.0 mm (11.73 × 0.16 in) Brake disc thickness limit WR250R 3.0 mm (0.12 in) WR250X 3.5 mm (0.14 in)
  • Page 36 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in) Drive chain Type/manufacturer 520V/DAIDO Link quantity Drive chain slack WR250R 38.0–48.0 mm (1.50–1.89 in) WR250X 40.0–50.0 mm (1.57–1.97 in) 15-link length limit 239.3 mm (9.42 in) 2-11...

  • Page 37: Electrical Specifications

    TBDF88/DENSO Ignition coil Model/manufacturer F6T558/MITSUBISHI 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ AC magneto Model/manufacturer F3D7/YAMAHA Standard output 14.0 V, 350 W@5000 r/min 0.168–0.252 Ω (W-W) Stator coil resistance Rectifier/regulator Regulator type Semi conductor-short circuit Model/manufacturer SH678-11/SHINDENGEN No load regulated voltage 14.1–14.9 V...
  • Page 38 ELECTRICAL SPECIFICATIONS Starter motor Model/manufacturer SM-14/MITSUBA Power output 0.50 kW 0.0040–0.0050 Ω Armature coil resistance Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 7.16–9.52 N (25.77–34.27 oz) (730–971 gf) Commutator diameter 28.0 mm (1.10 in) Limit 27.0 mm (1.06 in) Mica undercut (depth)
  • Page 39 ELECTRICAL SPECIFICATIONS Spare fuse 15.0 A Spare fuse 10.0 A Spare fuse 7.5 A 2-14...

  • Page 40: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- A.
  • Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain guide bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Plate (impeller shaft side) 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil filter element cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil pump bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil pump cover bolt...

  • Page 42: Chassis Tightening Torques

    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake the Drive sprocket nut 95 Nm (9.5 m•kg, 69 ft•lb) Stopper screw (stopper lever) 22 Nm (2.2 m•kg, 16 ft•lb) Shift pedal bolt 18 Nm (1.8 m•kg, 13 ft•lb) Stator assembly bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Crankshaft position sensor bolt 10 Nm (1.0 m•kg, 7.2 ft•lb)
  • Page 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Taillight cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Helmet hanger screw 10 Nm (1.0 m•kg, 7.2 ft•lb) Front fender bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Sidecover screw 10 Nm (1.0 m•kg, 7.2 ft•lb) Sidecover stay bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Horn bolt...
  • Page 44 Front fork axle nut 63 Nm (6.3 m•kg, 46 ft•lb) Front wheel axle pinch bolt 23 Nm (2.3 m•kg, 17 ft•lb) Front brake disc bolt (WR250R) 12 Nm (1.2 m•kg, 8.7 ft•lb) Front brake disc bolt (WR250X) 23 Nm (2.3 m•kg, 17 ft•lb) Spoke (front, rear) 3 Nm (0.3 m•kg, 2.2 ft•lb)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Headlight unit bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear brake hose holder screw 2 Nm (0.2 m•kg, 1.4 ft•lb) Front drive chain guide bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Delivery pipe screw 5 Nm (0.5 m•kg, 3.6 ft•lb) Canister cover bolt...

  • Page 46: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication points Lubrication types Oil seal lips O-rings Bearings Camshaft cap bolt head Cylinder head bolt threads Camshaft profile, journal Decompression system moving parts Valve stem, stem end Valve lifter surface Crank assembly (crankshaft pin surface) Both sliding surfaces of connecting rod big end...

  • Page 47: Chassis

    Main axle and drive axle Shift drum Shift fork and shift fork guide bars Shift shaft Shift shaft washer, spacer inner surface Yamaha bond No. 1215 Cylinder head cover gasket (Three Bond No. 1215®) Yamaha bond No. 1215 Cylinder head semicircular surface (Three Bond No.
  • Page 48 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication points Lubrication types Brake lever bolt Brake lever and front brake master cylinder Adjusting screw (brake lever) Rear brake master cylinder push rod (boot mount groove) Brake caliper piston seal Brake caliper dust seal Brake caliper support bolt Brake pad support bolt Clutch lever cable...
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...

  • Page 50: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Timing chain tensioner 3. Piston cooler 4. Oil filter 5. Main axle 6. Delivery pipe 7. Drive axle 8. Oil pump 9. Relief valve 10. Oil strainer 11. Oil pan 2-26...
  • Page 52 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump assembly 2. Relief valve 3. Main axle 4. Delivery pipe 5. Drive axle 6. Crankshaft 7. Oil filter 8. Oil strainer 2-28...

  • Page 54: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-29...
  • Page 55 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Radiator inlet hose 4. Radiator outlet hose 5. Recovery tank hose 6. Cap 7. Side cover stay 8. Water pump housing cover 9. Impeller shaft 2-30...

  • Page 56: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-31...
  • Page 57 CABLE ROUTING L. Pass the ECU lead between the intake solenoid 1. Starter motor lead hose and connector. 2. Coolant temperature sensor lead M. Wrap the connectors with a cover for protection. 3. Speed sensor lead N. Fasten the starter motor lead, negative battery 4.
  • Page 58 CABLE ROUTING 2-33...
  • Page 59 CABLE ROUTING 1. Clamp 2. Throttle position sensor lead 3. Fan motor lead A. Fasten the breather hose using a clamp. B. Fasten the throttle position sensor connector cover and the rear brake switch lead using a cable tie. C. Insert the fan motor lead into the concave sec- tion of guide air, and pass them backward through the hole.
  • Page 60 CABLE ROUTING 2-35...
  • Page 61 CABLE ROUTING 1. Ignition coil lead 2. Fuel pump lead 3. Injector lead 4. Throttle position sensor lead 5. Rear brake switch lead 6. Right rear turn signal light lead 7. License plate light lead 8. Taillight lead 9. Left rear turn signal light lead 10.
  • Page 62 CABLE ROUTING 2-37...
  • Page 63 CABLE ROUTING M. Route the left front turn signal light lead above 1. Throttle cable (accelerator) the meter lead from behind the handlebar 2. Throttle cable (decelerator) switch left lead, and connect them at the meter 3. Right handlebar switch lead position.

  • Page 64: Front Rear Brake Hose

    Front rear brake hose Front rear brake hose 2-39...
  • Page 65 Front rear brake hose 1. Front brake hose 2. Hose guide 3. Union bolt 4. Copper washer 5. Front brake caliper assembly 6. Rear brake disc 7. Rear brake caliper assembly 8. Copper washer 9. Union bolt 10. Rear brake hose 11.

  • Page 66: Throttle Body

    Throttle body Throttle body 2-41...
  • Page 67 Throttle body 1. Breather hose 2. Air filter case assembly 3. Pipe 4. Throttle body assembly 5. Radiator inlet hose 6. Radiator 7. Throttle body joint 8. FID hose 9. Vacuum hose 10. Pressure sensor 11. Bend hose 12. ITS boost hose 13.

  • Page 68: Canister (For California)

    Canister (for California) Canister (for California) 2-43...
  • Page 69 Canister (for California) 1. Fuel tank 2. Hose (Fuel tank–roll over valve) 3. Canister cover 4. Canister 5. A.C. magneto lead 6. Neutral switch lead 7. Recovery tank hose 8. Roll over valve 9. Holder 10. Hose 11. Clip A. Face the clip end forward of the vehicle. B.
  • Page 70 Canister (for California) 2-45...

  • Page 71: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE................3-1 INTRODUCTION..................3-1 Periodic maintenance chart for the emission control system ....3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE ENGINE IDLING SPEED..........3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY .......3-6 CHECKING THE SPARK PLUG ..............3-8 CHECKING THE IGNITION TIMING............3-8 MEASURING THE COMPRESSION PRESSURE........3-9 CHECKING THE ENGINE OIL LEVEL ............3-10...
  • Page 72 ELECTRICAL SYSTEM .................3-33 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES .................3-33 REPLACING THE HEADLIGHT BULB ............3-33 ADJUSTING THE HEADLIGHT BEAM ............3-33...

  • Page 73: Periodic Maintenance

    Replace if necessary. Check the air cut-off valve, Air induction sys- reed valve, and hose for √ √ damage. Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 74 General maintenance and lubrication chart EAS32164 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi ITEM ROUTINE (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) 1 month 6 months 12 months...
  • Page 75 27 * switches Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.

  • Page 76: Engine

    ENGINE Out of specification → Adjust. EAS20471 ENGINE Valve clearance (cold) EAS20520 Intake ADJUSTING THE VALVE CLEARANCE 0.13–0.20 mm (0.0051–0.0079 in) The following procedure applies to all of the Exhaust valves. 0.23–0.30 mm (0.0091–0.0118 in) NOTE: Valve clearance adjustment should be made MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM on a cold engine, at room temperature.
  • Page 77 ENGINE Before removing the cam chain and camshaft, Valve pad range Nos. 120–240 connect the cam chain using a wire so that it 120–240 mm does not drop in the crankcase. Valve pad thickness (4.72–9.45 in) b. Remove the valve lifter “1” and the valve pad 25 thicknesses in 0.05 “2”...

  • Page 78: Adjusting The Engine Idling Speed

    ENGINE NOTE: Digital tachometer Refer to “CAMSHAFT” on page 5-6. 90890-06760 Lubricate the camshaft bearings, camshaft YU-39951-B lobes and camshaft journals. First, install the exhaust camshaft. 4. Measure: Align the camshaft sprocket marks with the Engine idling speed edge of the cylinder head. Out of specification →...
  • Page 79 ENGINE NOTE: Throttle cable free play If the specified throttle cable free play cannot be 3.0–5.0 mm (0.12–0.20 in) obtained on the throttle body side of the cable, 2. Remove: use the adjusting nut on the handlebar side. Seat MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Side cover (left/right) Handlebar side Air scoop (left/right)

  • Page 80: Checking The Spark Plug

    ENGINE Seat Spark plug gap Refer to “GENERAL CHASSIS” on page 4-1. 0.6–0.7 mm (0.024–0.028 in) EAS20690 CHECKING THE SPARK PLUG 1. Remove: Seat Side cover (left/right) Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. 2.

  • Page 81: Measuring The Compression Pressure

    ENGINE (Red/black ignition coil leads) Digital tachometer 5. Install: Timing light Air scoop (left/right) 90890-03141 Side cover (left/right) Inductive clamp timing light Seat YU-03141 Refer to “GENERAL CHASSIS” on page 4-1. Digital tachometer Timing mark accessing screw 90890-06760 YU-39951-B EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl-...

  • Page 82: Checking The Engine Oil Level

    ENGINE Piston, valves, cylinder head gasket or pis- Same as without oil ton possibly defec- tive → Repair. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8. Install: Spark plug Spark plug 13 Nm (1.3 m•kg, 9.4 ft•lb) 7. Measure: Compression pressure 9. Install: Out of specification → Refer to steps (c) and Ignition coil assembly (d).

  • Page 83: Changing The Engine Oil

    ENGINE 3. Remove: Type Engine oil filler cap “1” YAMALUBE 4, SAE 10W-30 or Engine oil drain bolt “2” SAE 20W-40 (along with the gasket) Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13360 CAUTION: Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.

  • Page 84: Adjusting The Clutch Cable Free Play

    ENGINE ter element cover. Oil filter element cover bolt (M10) 10 Nm (1.0 m•kg, 7.2 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6. Check: Engine oil drain bolt gasket Oil filter element drain bolt gasket Damage → Replace. b. Start the engine and keep it idling until engine 7.

  • Page 85: Cleaning The Air Filter Element

    ENGINE obtained. EAS20941 CLEANING THE AIR FILTER ELEMENT Direction “a” 1. Remove: Clutch cable free play is increased. Air filter check hose Direction “b” NOTE: Clutch cable free play is decreased. On the bottom of the air filter case is a check hose.

  • Page 86: Checking The Throttle Body Joint

    ENGINE Recommended oil Foam air filter oil or engine oil 3. Install: Fuel tank 9. Install: Refer to “FUEL TANK” on page 7-1. Air filter element frame Air scoop (left/right) ECA14401 Side cover (left/right) CAUTION: Seat Never operate the engine without the air filter Refer to “GENERAL CHASSIS”...

  • Page 87: Checking The Cylinder Head Breather Hose

    ENGINE EAS21050 CHECKING THE CYLINDER HEAD Exhaust pipe nut “1” 20 Nm (2.0 m•kg, 14 ft•lb) BREATHER HOSE Exhaust pipe and muffler bolt “2” 1. Remove: 20 Nm (2.0 m•kg, 14 ft•lb) Seat Muffler and muffler bracket bolt Side cover (left/right) “3”...

  • Page 88: Cleaning The Spark Arrester

    ENGINE tension as for pulley cable 1. e. Tighten both locknuts “1” with specification. Locknut 6 Nm (0.6 m•kg, 4.3 ft•lb) 3. Check: EXUP system operation NOTE: Check operation by self-diagnostics diagnosis mode No.“53”. Refer to “FUEL INJECTION SYSTEM” on page f.

  • Page 89: Checking The Canister (For California Only)

    ENGINE Make sure the vehicle is upright. 2. Remove: Seat Air scoop Refer to “GENERAL CHASSIS” on page 4-1. 3. Check: Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level.

  • Page 90: Changing The Coolant

    ENGINE Radiator inlet hose “2” Radiator outlet hose “3” Cracks/damage → Replace. Refer to “RADIATOR” on page 6-1, “THER- MOSTAT” on page 6-4 and “WATER PUMP” on page 6-6. EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
  • Page 91 ENGINE 10.Fill: ter. Cooling system Do not mix different types of antifreeze. (with the specified amount of the recom- 11.Install: mended coolant) Radiator cap 12.Fill: Recommended antifreeze Coolant reservoir High-quality ethylene glycol anti- (with the recommended coolant to the maxi- freeze containing corrosion inhib- itors for aluminum engines mum level mark “a”)

  • Page 92: Chassis

    CHASSIS erably reduce braking performance. EAS21140 CHASSIS ECA13490 CAUTION: EAS21170 ADJUSTING THE FRONT DISC BRAKE After adjusting the brake lever position, 1. Check: make sure there is no brake drag. Brake lever free play “a” Out of specification → Adjust. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21200 ADJUSTING THE REAR DISC BRAKE...

  • Page 93: Checking The Brake Fluid Level

    CHASSIS Locknut 12 Nm (1.2 m•kg, 8.7 ft•lb) EWA13050 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.

  • Page 94: Checking The Rear Brake Pads

    CHASSIS EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Rear brake pad Wear indicators “1” almost touch the brake disc → Replace the brake pads as a set. Refer to “REAR BRAKE”...

  • Page 95: Bleeding The Hydraulic Brake System

    CHASSIS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: the system is disassembled. a brake hose is loosened, disconnected or replaced. A. Front the brake fluid level is very low. B. Rear brake operation is faulty. d.

  • Page 96: Adjusting The Drive Chain Slack

    16 Nm (1.6 m•kg, 12 ft•lb) e. Tighten the wheel axle nut. Wheel axle nut 125 Nm (12.5 m•kg, 90 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Drive chain slack WR250R EAS21440 38.0–48.0 mm LUBRICATING THE DRIVE CHAIN WR250X The drive chain consists of many interacting 40.0–50.0 mm...

  • Page 97: Checking And Adjusting The Steering Head

    CHASSIS vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate. Steam clean- ing, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosene to clean the drive chain.

  • Page 98: Checking The Front Fork

    CHASSIS hold the lower ring nut and tighten the upper ring nut until their slots are aligned. NOTE: Make sure the special washer tabs “a” sit cor- rectly in the ring nut slots “b”. EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

  • Page 99: Air Bleeding From Front Fork

    CHASSIS during touring, the air pressure increases in the fork and the suspension will become less flexi- ble. Bleed following procedure. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Stand the vehicle vertically using an appropriate LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL...
  • Page 100 Rebound damping is decreased (suspen- sion is softer). Rebound damping Maximum (hard) 3 click(s) out* Standard 12 click(s) out* (WR250R) 13 click(s) out* (WR250X) Minimum (soft) 25 click(s) out* * With the adjusting knob fully turned in Spring length “c”...

  • Page 101: Checking The Tires

    Standard 0–90 kg (0–198 lb) 10 click(s) out* (WR250R) Front 7 click(s) out* (WR250X) WR250R 125 kPa (18 psi) (1.25 Minimum (soft) kgf/cm 12 click(s) out* WR250X 200 kPa (29 psi) (2.00 * With the adjusting screw fully turned in...
  • Page 102 1. Tire tread depth cerning handling characteristics can be giv- en if a tire combination other than one 2. Side wall approved by Yamaha is used on this vehicle. 3. Wear indicator Wear limit (front) Front tire 0.8 mm (0.03 in)

  • Page 103: Checking The Wheels

    CHASSIS EAS21670 Spoke nipple wrench (8–9) CHECKING THE WHEELS 90890-01522 The following procedure applies to both of the YM-01522 wheels. 1. Check: Wheel Spoke (front/rear) Damage/out-of-round → Replace. 3 Nm (0.3 m•kg, 2.2 ft•lb) EWA13260 WARNING NOTE: Never attempt to make any repairs to the Be sure to tighten the spokes before and after wheel.

  • Page 104: Lubricating The Pedal

    CHASSIS Brake lever Silicone grease Clutch lever Lithium-soap-based grease EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommented lubricant Lithium-soap-based grease 3-32...
  • Page 105 ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-59. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-59. 4. Install: EAS21780 REPLACING THE HEADLIGHT BULB Headlight bulb Fasten the new headlight bulb with the head- EWA13320 WARNING light bulb holder.
  • Page 106 ELECTRICAL SYSTEM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3-34...
  • Page 107 ELECTRICAL SYSTEM 3-35...
  • Page 108 ELECTRICAL SYSTEM 3-36...
  • Page 109 CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL .....................4-2 REMOVING THE FRONT WHEEL ............4-4 CHECKING THE FRONT WHEEL ............4-4 DISASSEMBLING THE FRONT WHEEL..........4-5 ASSEMBLING THE FRONT WHEEL............4-5 INSTALLING THE FRONT WHEEL (DISC) ..........4-5 REAR WHEEL....................4-7 REMOVING THE REAR WHEEL.............4-9 DISASSEMBLING THE REAR WHEEL ...........4-9 CHECKING THE REAR WHEEL .............4-9 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-9 ASSEMBLING THE REAR WHEEL ............4-10...
  • Page 110 FRONT FORK ....................4-39 REMOVING THE FRONT FORK LEGS...........4-42 DISASSEMBLING THE FRONT FORK LEGS.........4-42 CHECKING THE FRONT FORK LEGS ...........4-43 ASSEMBLING THE FRONT FORK LEGS..........4-43 INSTALLING THE FRONT FORK LEGS ..........4-47 STEERING HEAD ..................4-49 REMOVING THE LOWER BRACKET .............4-51 CHECKING THE STEERING HEAD............4-51 INSTALLING THE STEERING HEAD............4-51 REAR SHOCK ABSORBER ASSEMBLY .............4-53 HANDLING THE REAR SHOCK ABSORBER.........4-54...
  • Page 111 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the cowling 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 112: Front Wheel

    Use a suitable stand to raise the front wheel off the ground. Front wheel axle pinch bolt Loosen. Front wheel axle nut Front wheel axle For Europe Front wheel assembly Collar Collar Front brake disc Wheel ring Only WR250R For installation, reverse the removal proce- dure.
  • Page 113 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 114: Removing The Front Wheel

    FRONT WHEEL EAS21890 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 115: Disassembling The Front Wheel

    FRONT WHEEL Oil seals MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Install the new wheel bearings and oil seals in the reverse order of disassembly. ECA14130 CAUTION: Do not contact the wheel bearing inner race or balls. Contact should be made only with the outer race. NOTE: EAS21910 Use a socket “1”...
  • Page 116 FRONT WHEEL...

  • Page 117: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 125 Nm (12.5 m kg, 90 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 35 Nm (3.5 m kg, 25 ft • • 16 Nm (1.6 m kg, 12 ft •...
  • Page 118 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left/right) Bearing (left/right) Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 119: Removing The Rear Wheel

    REAR WHEEL Oil seals EAS22040 REMOVING THE REAR WHEEL Refer to “CHECKING THE FRONT WHEEL” 1. Stand the vehicle on a level surface. on page 4-4. EWA13120 2. Check: WARNING Tire Securely support the vehicle so that there is Rear wheel no danger of it falling over.

  • Page 120: Assembling The Rear Wheel

    REAR WHEEL b. Clean the rear wheel drive hub with a clean Drive chain slack cloth, especially the surfaces that contact the WR250R 38.0–48.0 mm sprocket. (1.50–1.89 in) c. Install the new rear wheel sprocket. WR250X 40.0–50.0 mm (1.57–1.97 in) Rear wheel sprocket self-locking 4.

  • Page 121: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 23 Nm (2.3 m kg, 17 ft • • 17 Nm (1.7 m kg, 12 ft • • 17 Nm (1.7 m kg, 12 ft • • WR250X 2.5 Nm (0.25 m kg, 1.8 ft •...
  • Page 122 FRONT BRAKE Removing the front brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 123 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 4-13...
  • Page 124 FRONT BRAKE Removing the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 125 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 126: Introduction

    CHECKING THE FRONT BRAKE DISC 1. Remove: Front wheel Brake disc thickness limit Refer to “FRONT WHEEL” on page 4-2. WR250R 3.0 mm (0.12 in) 2. Check: WR250X 3.5 mm (0.14 in) Front brake disc Damage/galling → Replace. 5. Adjust: 3.

  • Page 127: Replacing The Front Brake Pads

    FRONT BRAKE 2. Install: Brake pads Brake disc bolt WR250R:12 Nm (1.2 m•kg, 8.7 Brake pad spring ft•lb) NOTE: LOCTITE® Always install new brake pads, and a brake pad WR250X:23 Nm (2.3 m•kg, 17 spring as a set. ft•lb) LOCTITE®...

  • Page 128: Removing The Front Brake Caliper

    FRONT BRAKE 4. Check: Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.

  • Page 129: Assembling The Front Brake Caliper

    FRONT BRAKE Brake caliper cylinders “2” Front brake caliper bracket Scratches/wear → Replace the brake caliper 23 Nm (2.3 m•kg, 17 ft•lb) assembly. Brake hose union bolt Brake caliper body “3” 30 Nm (30. m•kg, 22 ft•lb) Cracks/damage → Replace the brake caliper assembly.

  • Page 130: Removing The Front Brake Master Cylinder

    FRONT BRAKE brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. When refilling, be careful that water does not enter the brake fluid reservoir.

  • Page 131: Assembling The Front Brake Master Cylinder

    FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake com- ponents. 2. Install: Recommended fluid Copper washers “1”...
  • Page 132 FRONT BRAKE brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. When refilling, be careful that water does not enter the brake master cylinder reser- voir.

  • Page 133: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 2.5 Nm (0.25 m kg, 1.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear wheel...
  • Page 134 REAR BRAKE Removing the rear brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 135 REAR BRAKE Disassembling the rear brake master cylinder 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 4-25...
  • Page 136 REAR BRAKE Removing the rear brake calipers 30 Nm (3.0 m kg, 22 ft • • 17 Nm (1.7 m kg, 12 ft • • 2.5 Nm (0.25 m kg, 1.8 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 137 REAR BRAKE Disassembling the rear brake calipers 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 138: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.0 mm (0.16 in) EWA14100 WARNING Disc brake components rarely require disas- 5. Adjust: Brake disc deflection sembly. Therefore, always follow these pre- ventive measures: Refer to “CHECKING THE FRONT BRAKE Never disassemble brake components un- DISC”...

  • Page 139: Removing The Rear Brake Caliper

    REAR BRAKE and a brake pad spring as a set. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 5. Check: Brake pedal operation Soft or spongy feeling →...

  • Page 140: Checking The Rear Brake Caliper

    REAR BRAKE EWA13550 WARNING Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. Never try to pry out the brake caliper pis- ton. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals.

  • Page 141: Removing The Rear Brake Master Cylinder

    REAR BRAKE BLE ROUTING” on page 2-30. and plastic parts. Therefore, always clean up any spilt brake fluid immediately. ECA14170 CAUTION: 5. Bleed: When installing the brake hose onto the Brake system brake caliper “1”, make sure the brake pipe Refer to “BLEEDING THE HYDRAULIC “a”...

  • Page 142: Assembling The Rear Brake Master Cylinder

    REAR BRAKE Obstruction → Blow out with compressed air. EAS22750 2. Check: INSTALLING THE REAR BRAKE MASTER Brake master cylinder kit CYLINDER Damage/wear → Replace. 1. Install: 3. Check: Copper washers Master cylinder reservoir cap Brake hoses Cracks/damage → Replace. Union bolt Brake master cylinder reservoir diaphragm Brake hose union bolt...
  • Page 143 REAR BRAKE brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance. When refilling, be careful that water does not enter the brake fluid reservoir.

  • Page 144: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 145 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft •...

  • Page 146: Removing The Handlebars

    HANDLEBAR EAS22860 EAS22921 REMOVING THE HANDLEBARS INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
  • Page 147 HANDLEBAR NOTE: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Align projection “a” of slot cable housing with a. Slightly coat the handlebar left end with a rub- hole “b” of the handlebar. ber adhesive. Slightly coat the end of slot cable and inside of Install the handlebar grip on the handlebar by throttle grip with lithium-soap-based grease.
  • Page 148 HANDLEBAR 9. Adjust: Clutch cable free play Refer to “ADJUSTING THE CLUTCH CA- BLE FREE PLAY” on page 1-14. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 10.Adjust: Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 1-8. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4-38...

  • Page 149: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 30 Nm (3.0 m kg, 22 ft • • 23 Nm (2.3 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 150 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • 15 Nm (1.5 m kg, 11 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Parts to remove Q’ty Remarks Front fork cap bolt O-ring Spring seat...
  • Page 151 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • 15 Nm (1.5 m kg, 11 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure.

  • Page 152: Removing The Front Fork Legs

    FRONT FORK EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that 2.

  • Page 153: Checking The Front Fork Legs

    FRONT FORK 6. Remove: 3. Check: Inner tube “1” Damper rod “1” Damage/wear → Replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Obstruction → Blow out all of the oil passag- a. Hold the front fork leg horizontally. es with compressed air. b. Securely clamp the brake caliper bracket in a vise with soft jaws.
  • Page 154 FRONT FORK EWA13660 WARNING Make sure the oil levels in both front fork legs are equal. Uneven oil levels can result in poor han- dling and a loss of stability. NOTE: When assembling the front fork leg, be sure to replace the following parts: Piston metal Slide metal...
  • Page 155 FRONT FORK ECA32D1008 CAUTION: Face stamp "a" of the oil seal toward the front caliper mount during assembling. NOTE: Before installing the oil seal, lubricate its lips with lithium soap base grease. Lubricate the outer surface of the inner tube with fork oil.
  • Page 156 FRONT FORK 13.Lubricate: Front fork Recommended oil Suspension oil 01 Quantity 613.0 cm (20.73 US oz) (21.62 Imp.oz) ECA14230 10.Install: CAUTION: Stopper ring “1” Be sure to use the recommended fork oil. (in the slot of outer tube) Other oils may have an adverse effect on front fork performance.

  • Page 157: Installing The Front Fork Legs

    FRONT FORK ate the oil, then measure the fork oil level. ECA32D1010 CAUTION: Add the suspension oil to the top level of in- ner tube and deaerate the oil. If the oil is be- low this level, each part is not lubricated and you cannot get the desired spring perfor- mance.
  • Page 158 FRONT FORK top face becomes 3 mm, and tighten it tempo- rarily. 2. Tighten: Lower bracket pinch bolt “1” Lower bracket pinch bolt 20 Nm (2.0 m•kg, 14 ft•lb) 3. Tighten: Cap bolt “2” Cap bolt 30 Nm (30. m•kg, 22 ft•lb) 4.

  • Page 159: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the headlight unit, meter assembly and front fender 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • •...
  • Page 160 STEERING HEAD 120 Nm (12.0 m kg, 87 ft • • 38 Nm (3.8 m kg, 27 ft • • Loosen fully 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • Order Job/Parts to remove Q’ty...

  • Page 161: Removing The Lower Bracket

    STEERING HEAD bracket with a floor chisel “2” and hammer. EAS23110 REMOVING THE LOWER BRACKET c. Install a new bearing races. 1. Stand the vehicle on a level surface. ECA14270 EWA13120 CAUTION: WARNING If the bearing race is not installed properly, Securely support the vehicle so that there is the steering head pipe could be damaged.
  • Page 162 STEERING HEAD Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 1-27. 3. Install: Upper bracket Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: Front fork legs Refer to “FRONT FORK” on page 4-39. NOTE: Temporarily tighten the upper and lower bracket pinch bolts.

  • Page 163: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kg, 29 ft • • 80 Nm (8.0 m kg, 58 ft • • 70 Nm (7.0 m kg, 51 ft •...

  • Page 164: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling Connecting arm bolt “1”...

  • Page 165: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY Damage/wear → Replace. 2. Check: Bearings Oil seals Damage/pitting → Replace. 3. Check: Collar Damage/scratches → Replace. EAS23270 INSTALLING THE RELAY ARM 1. Lubricate: EAS23310 Oil seal INSTALLING THE REAR SHOCK Bearings ABSORBER ASSEMBLY Collar 1. Install: Rear shock absorber assembly Recommended lubricant NOTE:...

  • Page 166: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 85 Nm (8.5 m kg, 62 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 70 Nm (7.0 m kg, 51 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 167: Removing The Swingarm

    SWINGARM 2. Check: EAS23350 REMOVING THE SWINGARM Pivot shaft 1. Stand the vehicle on a level surface. Roll the pivot shaft on a flat surface. EWA13120 Bends → Replace. WARNING EWA13770 Securely support the vehicle so that there is WARNING no danger of it falling over.
  • Page 168 5. Install: Rear wheel Refer to “REAR WHEEL” on page 4-7. 6. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26. Drive chain slack WR250R 38.0–48.0 mm (1.50–1.89 in) WR250X 40.0–50.0 mm (1.57–1.97 in) 4-58...

  • Page 169: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 95 Nm (9.5 m kg, 69 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 170: Removing The Drive Chain

    CHAIN DRIVE of the drive chain as shown in the illustration. EAS23420 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 171: Checking The Drive Sprocket

    CHAIN DRIVE c. Remove the drive chain from the kerosene and completely dry it. ECA14290 CAUTION: This motorcycle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain.
  • Page 172 Stake the nut “1”. 5. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26. Drive chain slack WR250R 38.0–48.0 mm (1.50–1.89 in) WR250X 40.0–50.0 mm (1.57–1.97 in) ECA13550 CAUTION: A drive chain that is too tight will overload...

  • Page 173: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-5 INSTALLING THE SHIFT PEDAL ............5-5 CAMSHAFT....................5-6 REMOVING THE CAMSHAFT..............5-8 CHECKING THE CAMSHAFT ..............5-8 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-10 CHECKING THE TIMING CHAIN TENSIONERS ........5-10 CHECKING THE DECOMPRESSION SYSTEM ........5-11 INSTALLING THE CAMSHAFTS .............5-11 CYLINDER HEAD ..................5-14 REMOVING THE CYLINDER HEAD ............5-15...
  • Page 174 SHIFT SHAFT ....................5-43 CHECKING THE SHIFT SHAFT ..............5-44 CHECKING THE STOPPER LEVER ............5-44 INSTALLING THE SHIFT SHAFT ............5-44 OIL PUMP AND BALANCER GEAR .............5-45 REMOVING THE OIL PUMP ..............5-47 CHECKING THE OIL PUMP ..............5-47 ASSEMBLING THE OIL PUMP..............5-47 INSTALLING THE OIL PUMP AND BALANCER GEAR......5-48 GENERATOR AND STARTER CLUTCH ............5-50 REMOVING THE GENERATOR..............5-53 CHECKING THE STARTER CLUTCH.............5-53...

  • Page 175: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 42 Nm (4.2 m kg, 30 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 176 ENGINE REMOVAL Removing the shift pedal, leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 95 Nm (9.5 m kg, 69 ft • • 10 Nm (1.0 m kg, 7.2 ft 18 Nm (1.8 m kg, 13 ft •...
  • Page 177 ENGINE REMOVAL Removing the shift pedal, leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 95 Nm (9.5 m kg, 69 ft • • 10 Nm (1.0 m kg, 7.2 ft 18 Nm (1.8 m kg, 13 ft •...
  • Page 178 ENGINE REMOVAL 85 Nm (8.5 m kg, 62 ft • • 67 Nm (6.7 m kg, 48 ft • • 56 Nm (5.6 m kg, 41 ft • • 113 Nm (11.3 m kg, 82 ft • • Order Job/Parts to remove Q’ty Remarks NOTE:...

  • Page 179: Installing The Engine

    ENGINE REMOVAL EAS23720 EAS32D1009 INSTALLING THE ENGINE INSTALLING THE SHIFT PEDAL 1. Install: 1. Install: Engine assembly “1” Shift pedal Pivot shaft “2” Shift pedal bolt Down tube “3” 18 Nm (1.8 m•kg, 13 ft•lb) Down tube bolt (rear lower side) “4” Down tube bolt (front upper side) “5”...

  • Page 180: Camshaft

    CAMSHAFT EAS23730 CAMSHAFT Removing the cylinder head cover 12 Nm (1.2 m kg, 8.7 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Side cover (left/right) 4-1.
  • Page 181 CAMSHAFT REMOVING THE CAMSHAFT 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Timing mark accessing screw Crankshaft end cover Timing chain tensioner assembly Camshaft cap...

  • Page 182: Removing The Camshaft

    CAMSHAFT EAS23800 REMOVING THE CAMSHAFT 1. Remove: Crankshaft end cover Timing mark accessing screw 2. Align: TDC on the generator rotor (mark on the crankcase cover) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When piston is at TDC on the compression 7.
  • Page 183 CAMSHAFT Camshaft lobe dimension limit Intake A 34.550–34.650 mm (1.3602–1.3642 in) Limit 35.450 mm (1.3957 in) Intake B 25.953–26.053 mm (1.0218–1.0257 in) Limit 25.853 mm (1.0178 in) 4. Measure: Exhaust A Camshaft-journal-to-camshaft-cap clearance 34.850–34.950 mm Out of specification → Measure the camshaft (1.3720–1.3760 in) journal diameter.

  • Page 184: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFT a. 1/4 tooth b. Correct LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 1. Timing chain roller 5. Measure: 2. Camshaft sprocket Camshaft journal diameter “a” Out of specification → Replace the camshaft. EAS23960 CHECKING THE TIMING CHAIN Within specification → Replace the cylinder TENSIONERS head and the camshaft caps as a set. The following procedure applies to both of the Camshaft journal diameter timing chain tensioners.

  • Page 185: Checking The Decompression System

    CAMSHAFT 2. Install: Intake camshaft sprocket LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Exhaust camshaft sprocket MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM EAS32D1001 a. Turn the crankshaft counterclockwise. CHECKING THE DECOMPRESSION b. When piston is at TDC on the compression SYSTEM stroke, align the mark “a” on the generator ro- 1. Check: tor with the mark “b”...
  • Page 186 CAMSHAFT 5. Install: Timing chain tensioner MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Using a finger, push and insert timing chain tensioner rod “1” into the timing chain tensioner housing. NOTE: Push the timing chain tensioner rod in direction “a”, and turn the timing chain tensioner body “2” in direction “b”...
  • Page 187 CAMSHAFT d. Unlock the camshaft chain tensioner by turn- Refer to “ADJUSTING THE VALVE CLEAR- ing the crankshaft counterclockwise, and ten- ANCE” on page 3-4. sion the timing chain. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6. Turn: Crankshaft (several turns counterclockwise) 7. Check: The TDC mark of rotor, and the mark of crankshaft case cover MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.

  • Page 188: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Camshaft Refer to“CAMSHAFT” on page 5-6. Hose (thermostat cover) Refer to“THERMOSTAT”...

  • Page 189: Removing The Cylinder Head

    CYLINDER HEAD EAS24130 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. Cylinder head bolts “1” (M6×60) b. Measure the warpage. Cylinder head bolts “2” (M10×154) c. If the limit is exceeded, resurface the cylinder Cylinder head bolts “3”...
  • Page 190 CYLINDER HEAD 2. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: Cylinder head bolts (M10×140 )“1” Cylinder head bolts (M10×155)“2” Cylinder head bolts (M6×60 )“3” Cylinder head bolt (M10) 40 Nm (4.0 m•kg, 29 ft•lb) Cylinder head bolt (M6) 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE:...
  • Page 191 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to“CYLINDER HEAD” on page 5-14. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal...

  • Page 192: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 193: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 2. Replace: EAS24290 Valve guide CHECKING THE VALVES AND VALVE NOTE: GUIDES To ease valve guide removal and installation, The following procedure applies to all of the and to maintain the correct fit, heat the cylinder valves and valve guides.

  • Page 194: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: NOTE: After replacing the valve guide, reface the valve Valve stem runout Out of specification → Replace the valve. seat. NOTE: When installing a new valve, always replace Valve guide remover (ø4.5) 90890-04116 the valve guide. YM-04116 If the valve is removed or replaced, always re- Valve guide installer (ø4.5)
  • Page 195 VALVES AND VALVE SPRINGS face should be lapped. ECA32D1012 CAUTION: This model uses titanium intake valves. Titaium valves that have been used to lap the valve seats must not be used. Always re- place lapped valves with new valves. NOTE: When replacing the cylinder head, replace the valves without lapping the valve seats and MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM...

  • Page 196: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide and Compressed valve spring force “a” Out of specification → Replace the valve onto the valve seat to make a clear impres- sion.

  • Page 197: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: EAS24320 CHECKING THE VALVE LIFTERS Valve “1” The following procedure applies to all of the Spring seat “2” valve lifters. Valve stem seal “3” 1. Check: Valve spring “4” Valve lifter Valve spring retainer “5” Damage/scratches →...
  • Page 198 VALVES AND VALVE SPRINGS stalled in its original position. 5. To fasten the valve cotters “1” onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 6.

  • Page 199: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to“CYLINDER HEAD” on page 5-14. Cylinder Dowel pin Water pipe O-ring Cylinder gasket Piston pin clip...

  • Page 200: Removing The Piston

    CYLINDER AND PISTON Vertical scratches → Rebore or replace the EAS24380 REMOVING THE PISTON cylinder, and replace the piston and piston 1. Remove: rings as a set. Piston pin clips “1” 2. Measure: Piston pin “2” Piston-to-cylinder clearance Piston “3” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM ECA13810 a.

  • Page 201: Checking The Piston Rings

    CYLINDER AND PISTON d. If out of specification, replace the cylinder, 2. Install: piston and piston rings as a set. Piston ring e. Calculate the piston-to-cylinder clearance (into the cylinder) with the following formula. NOTE: Level the piston ring into the cylinder with the Piston-to-cylinder clearance = piston crown.

  • Page 202: Installing The Piston And Cylinder

    CYLINDER AND PISTON EAS24450 Piston pin outside diameter INSTALLING THE PISTON AND CYLINDER 16.991–17.000 mm 1. Install: (0.6689–0.6693 in) Top ring “1” Limit 2nd ring “2” 16.971 mm (0.668 in) Lower oil ring rail “3” Upper oil ring rail “4” Oil ring expander “5”...
  • Page 203 CYLINDER AND PISTON 4. Lubricate: Piston Piston rings Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: Piston ring end gaps a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail e.

  • Page 204: Starter Motor

    STARTER MOTOR EAS24780 STARTER MOTOR Removing the starter motor 5 Nm (0.5 m kg, 3.6 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat/Air scoop (left/ritht) 4-1.
  • Page 205 STARTER MOTOR Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Lock washer Armature assembly Starter motor yoke Starter motor rear cover Brush holder set For assembly, reverse the disassembly pro- cedure. 5-31...

  • Page 206: Checking The Starter Motor

    STARTER MOTOR EAS24790 CHECKING THE STARTER MOTOR Pocket tester 90890-03112 1. Check: Analog pocket tester Commutator YU-03112-C Dirt → Clean with 600 grit sandpaper. 2. Measure: Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1” 0.004–0.005 Ω...

  • Page 207: Assembling The Starter Motor

    STARTER MOTOR 7. Check: Gear teeth Damage/wear → Replace the gear. 8. Check: Bearing Oil seal Damage/wear → Replace the defective part (s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: Brush holder “1” NOTE: Align the tab on the brush seat with the slot in the starter motor rear cover “2”.

  • Page 208: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 209 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 210 CLUTCH Removing the clutch 1(5) 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 75 Nm (7.5 m kg, 54 ft • • 80 Nm (8.0 m kg, 58 ft • •...
  • Page 211 CLUTCH Removing the push lever shaft 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-1. Clutch Refer to “CLUTCH” on page 5-34. Clutch cable Clutch cable holder Push lever shaft Push lever spring...

  • Page 212: Removing The Clutch

    CLUTCH Damage/wear → Replace the friction plates EAS25070 REMOVING THE CLUTCH as a set. You need not drain the coolant and engine oil if 2. Measure: you do not service the primary drive gear. Friction plate thickness You can reach the clutch housing removal step Out of specification →...

  • Page 213: Checking The Clutch Springs

    CLUTCH ratic clutch operation. EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: Clutch spring Damage → Replace the clutch springs as a set. 2. Measure: Clutch spring free length Out of specification → Replace the clutch springs as a set.

  • Page 214: Checking The Primary Drive Gear

    CLUTCH EAS25200 CHECKING THE PRIMARY DRIVE GEAR Universal clutch holder 90890-04086 1. Check: YM-91042 Primary drive gear Damage/wear → Replace the primary drive and primary driven gears as a set. Clutch boss nut Excessive noise during operation → Replace 75 Nm (7.5 m•kg, 54 ft•lb) the primary drive and primary driven gears as a set.
  • Page 215 CLUTCH 7. Install: Friction plates Clutch plates NOTE: First, install a friction plate and then alternate be- tween a clutch plate and a friction plate. 8. Install: Push plate Push rod (onto the clutch pressure plate.) 9. Install: 12.Adjust: Push rod Push lever position Ball MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM...
  • Page 216 CLUTCH 14.Install: Oil cleaner element Refer to “CHANGING THE ENGINE OIL” on page 3-11. 15.Install: Water pump housing cover Refer to “WATER PUMP” on page 6-6. 16.Fill: Crankcase (with the specified amount of the engine oil) Refer to “CHANGING THE ENGINE OIL” on page 3-11.
  • Page 217 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Shift pedal Refer to “ENGINE REMOVAL” on page 5-1. Clutch housing Refer to “CLUTCH” on page 5-34. Shift shaft Plate washer Stopper lever spring...

  • Page 218: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft Shift lever Bends/damage/wear → Replace. Shift lever spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 219: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR EAS24911 OIL PUMP AND BALANCER GEAR Removing the oil pump 10 Nm (1.0 m kg, 7.2 ft 50 Nm (5.0 m kg, 36 ft • • • • Order Job/Parts to remove Q’ty Remarks Clutch/Primary drive gear Refer to“CLUTCH”...
  • Page 220 OIL PUMP AND BALANCER GEAR Disassembling the oil pump 2 Nm (0.2 m kg, 1.4 ft • • Order Job/Parts to remove Q’ty Remarks Pump cover Outer rotor Inner rotor Dowel pin Plain washer Driven gear Circlip Relief valve assembly Oil pump housing For installation, reverse the removal proce- dure.

  • Page 221: Removing The Oil Pump

    OIL PUMP AND BALANCER GEAR EAS24940 REMOVING THE OIL PUMP Inner-rotor-to-outer-rotor-tip clearance 1. Drain: Less than Engine oil 0.120 mm (0.0047 in) (completely from the crankcase) Outer-rotor-to-oil-pump-housing Refer to “CHANGING THE ENGINE OIL” on clearance page 3-11. 0.090–0.160 mm (0.0004–0.0013 2.

  • Page 222: Installing The Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR Recommended lubricant Engine oil 2. Install: Oil pump housing “1” Relief valve assembly Driven gear “2” Dowel pin “3” Outer rotor “4” Inner rotor “5” Oil pump cover 3. Install: Drive gear “1” Oil pump cover screw Balancer weight gear “2”...
  • Page 223 OIL PUMP AND BALANCER GEAR 6. Install: Be sure to bend the lock washer tab along to the nut side face. 5-49...

  • Page 224: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator 10 Nm (1.0 m kg, 7.2 ft • • 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft • • ’ Order Job/Parts to remove Remarks...
  • Page 225 GENERATOR AND STARTER CLUTCH Removing the generator 10 Nm (1.0 m kg, 7.2 ft • • 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft • • ’ Order Job/Parts to remove Remarks Bearing Starter clutch side plate Starter clutch assembly...
  • Page 226 GENERATOR AND STARTER CLUTCH Disassembling the damper assembly ’ Order Job/Parts to remove Remarks Circlip Limiter disc Starter reduction gear Limiter disc Outer torque limiter Circlip For installation, reverse the removal proce- dure. 5-52...

  • Page 227: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: Generator rotor nut “1” Washer NOTE: While holding the generator rotor “3” with the sheave holder “2”, loosen the generator rotor nut. Do not allow the sheave holder to touch the projection on the generator rotor.

  • Page 228: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH NOTE: Clean the tapered portion of the crankshaft and the generator rotor hub. When installing the generator rotor, make sure the woodruff key is properly sealed in the key- way of the crankshaft. 2. Tighten: Generator rotor nut “1” Generator rotor nut 65 Nm (6.5 m•kg, 47 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL...
  • Page 229 GENERATOR AND STARTER CLUTCH 5-55...

  • Page 230: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 231 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft 10 Nm (1.0 m...
  • Page 232 CRANKCASE Removing the bearing and oil seal 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to“CRANKSHAFT ASSEMBLY AND Crankshaft assembly BALANCER SHAFT” on page 5-61. Transmission assembly Refer to“TRANSMISSION”...

  • Page 233: Disassembling The Crankcase

    CRANKCASE 4. Check: EAS25570 DISASSEMBLING THE CRANKCASE Nozzle 1. Remove: Delivery pipe Crankcase bolts Obstruction → Blow out with compressed air. NOTE: Bends/cracks/damage → Replace. Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 234 2. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 3. Apply: Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 (Three Bond No.1215®) 90890-85505 1. M6 × 90 mm 2. M6 × 65 mm 3. M6 × 45 mm 4.

  • Page 235: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS25970 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase. Refer to“CRANKCASE” on page 5-56. Balancer shaft Crankshaft assembly For installation, reverse the removal proce- dure.

  • Page 236: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS26000 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: Crankshaft assembly “1” NOTE: Remove the crankshaft assembly by using the crankcase separating tool “2”. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B 3. Measure: Crankshaft width Out of specification → Replace the crank- shaft.
  • Page 237 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT “2”, adapter (M12) “3” and spacer “4”. Crankshaft installer pot “1” 90890-01274 Installing pot YU-90058 Crankshaft installer bolt “2” 90890-01275 Bolt YU-90060 Adapter (M12) “3” 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) “4” 90890-04081 Pot spacer YM-91044 ECA13970 CAUTION:...

  • Page 238: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to“CRANKCASE” on page 5-56. Shift fork guide bar Shift drum Shift fork-R Shift fork-C Shift fork-L Main axle assembly Drive axle assembly O-ring Collar...
  • Page 239 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 6th pinion gear 3rd pinion gear Circlip Washer 5th pinion gear Main axle Circlip Plain washer 1st wheel gear Washer Collar 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear Circlip...
  • Page 240 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks Drive axle For installation, reverse the removal proce- dure. 5-66...

  • Page 241: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: Shift fork pawl “2” drum assembly. Bends/damage/scoring/wear →...

  • Page 242: Installing The Shift Forks And Shift Drum Assembly

    TRANSMISSION 2. Measure: EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT Drive axle runout DRUM ASSEMBLY (with a centering device and dial gauge “1”) 1. Install: Out of specification → Replace the drive axle. Shift fork guide bar “1” Drive axle runout limit Shift fork-R “2”...

  • Page 243: Installing The Transmission

    TRANSMISSION EAS26340 INSTALLING THE TRANSMISSION 1. Install: Transmission 2. Check: Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-69...
  • Page 244 TRANSMISSION 5-70...

  • Page 245: Cooling System

    COOLING SYSTEM RADIATOR.....................6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 THERMOSTAT....................6-4 CHECKING THE THERMOSTAT ............6-5 INSTALLING THE THERMOSTAT ASSEMBLY ........6-5 WATER PUMP ....................6-6 CHECKING THE WATER PUMP.............6-7 ASSEMBLING THE WATER PUMP ............6-7...

  • Page 246: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 2 Nm (0.2 m kg, 1.4 ft •...

  • Page 247: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins “1” Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 248 RADIATOR b. Apply the 100 kPa (14.22 psi) (1.0 kg/cm pressure. c. Measure the indicated pressure with the gauge. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 249: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 2 Nm (0.2 m kg, 1.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Seat/Air panel (left/right) Refer to“GENERAL CHASSIS” on page 4-1. Fuel tank Refer to“FUEL TANK”...

  • Page 250: Checking The Thermostat

    THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. Check: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Thermostat “1” 2. Check: Does open 70.5–73.5°C Thermostat housing cover (158.9–164.3°F) → Replace. Cracks/damage → Replace. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: Thermostat “1” Thermostat cover “2” NOTE: Install the thermostat by facing breather hole up- ward.

  • Page 251: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to“CHANGING THE COOLANT” on Drains the coolant. page 3-18. Refer to“CHANGING THE ENGINE OIL” on Drains the engine oil page 3-11.

  • Page 252: Checking The Water Pump

    WATER PUMP EAS26530 CHECKING THE WATER PUMP 1. Check: Water pump housing cover Impeller shaft Plate Cracks/damage/wear → Replace. 2. Check: Impeller shaft gear Cracks/damage/chips → Replace. EAS26560 4. Lubricate: ASSEMBLING THE WATER PUMP Engine oil 1. Install: (to the bearing) Bearing 5.
  • Page 253 WATER PUMP Crankcase Refer to “CHANGING THE ENGINE OIL” on page 3-11. 9. Fill: Cooling system Refer to “CHANGING THE COOLANT” on page 3-18.
  • Page 254 WATER PUMP...

  • Page 255: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-2 REMOVING THE FUEL PUMP ..............7-2 INSTALLING THE FUEL PUMP...............7-2 INSTALLING THE FUEL TANK ...............7-2 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS..............7-6 CHECKING THE THROTTLE BODIES............7-6 CHECKING THE PRESSURE REGULATOR ..........7-6 CHECKING THE PRESSURE REGULATOR OPERATION....7-6 ADJUSTING THE THROTTLE POSITION SENSOR ......7-7 AIR INDUCTION SYSTEM................7-9 CHECKING THE AIR INDUCTION SYSTEM ..........7-12...

  • Page 256: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 257: Removing The Fuel Tank

    FUEL TANK EAS26630 EAS26700 REMOVING THE FUEL TANK INSTALLING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Install: fuel tank cap with a pump. Fuel pump 2. Remove: Fuel pump bolts Fuel hose coupler 4 Nm (0.4 m•kg, 2.9 ft•lb) ECA14700 CAUTION:...
  • Page 258 FUEL TANK...
  • Page 259 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Side cover (left/right) Air scoop (left/right) Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle cable Refer to “CAMSHAFT”...
  • Page 260 THROTTLE BODIES Disassembling the throttle body 3.5 Nm (0.4 m kg, 2.5 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Delivery pipe Injector Gasket Throttle position sensor For installation, reverse the removal proce- dure.

  • Page 261: Throttle Bodies

    THROTTLE BODIES EAS26980 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE INJECTORS a. Remove the fuel tank. EWA32D1009 Refer to “FUEL TANK” on page 7-1. WARNING b. Connect the pressure gauge “1” and adapter Replace the fuel injector with a new one if “2” to the fuel injection pipe. you have dropped or impacted it.

  • Page 262: Adjusting The Throttle Position Sensor

    THROTTLE BODIES gle, tighten the throttle position sensor EAS27030 ADJUSTING THE THROTTLE POSITION screws. SENSOR EWA32D1011 WARNING LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Replace the throttle position sensor with a new one if you have dropped or impacted it. NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted.
  • Page 263 THROTTLE BODIES...

  • Page 264: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
  • Page 265 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose 3. Air cut-off valve 4. Air induction system pipe 7-10...
  • Page 266 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 4-1. Side cover (left/right) Air scoop (left/right) Fuel tank...

  • Page 267: Checking The Air Induction System

    AIR INDUCTION SYSTEM 3. Check: EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air cut-off valve Air induction Cracks/damage → Replace. The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons.

  • Page 268: Canister (For California)

    AIR INDUCTION SYSTEM EAS32D12011 CANISTER (FOR CALIFORNIA) Removing the canister 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Canister cover Canister Hose (fuel tank–roll over valve) Roll over valve Hose (roll over valve–canister) Hose (canister–throttle body)

  • Page 269: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM .................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM ..................8-11 CIRCUIT DIAGRAM .................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM..................8-15 CIRCUIT DIAGRAM .................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM ..................8-19 CIRCUIT DIAGRAM .................8-19 TROUBLESHOOTING ................8-21 COOLING SYSTEM ..................8-25...
  • Page 270 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-75 CHECKING THE LEAN ANGLE SENSOR ..........8-75 CHECKING THE STATOR COIL .............8-76 CHECKING THE RECTIFIER/REGULATOR...........8-76 CHECKING THE HORN................8-77 CHECKING THE SPEED SENSOR............8-77 CHECKING THE FUEL SENDER (FUEL PUMP) ........8-78 CHECKING THE COOLANT TEMPERATURE SENSOR .......8-78 CHECKING THE RADIATOR FAN MOTOR ..........8-79 CHECKING THE THROTTLE POSITION SENSOR........8-79 CHECKING THE EXUP SERVO MOTOR ..........8-80...

  • Page 272: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 273 IGNITION SYSTEM 1. AC magneto 3. Main switch 4. Battery 5. Main fuse 8. Right handlebar switch 9. Engine stop switch 11. Relay unit 12. Sidestand switch 13. Neutral switch 14. Clutch switch 16. ECU 17. Ignition coil 18. Spark plug 27.

  • Page 274: Troubleshooting

    IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuses. (Main and ignition) →...
  • Page 275 IGNITION SYSTEM 10.Check the sidestand switch. → Refer to Replace the sidestand switch. “CHECKING THE SWITCHES” on page 8-63 OK↓ 11.Check the clutch switch. → Refer to Replace the clutch switch. “CHECKING THE SWITCHES” on page 8-63 OK↓ 12.Check the relay unit. →...

  • Page 276: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 277 ELECTRIC STARTING SYSTEM 3. Main switch 4. Battery 5. Main fuse 6. Starter relay 7. Starter motor 8. Right handlebar switch 9. Engine stop switch 10. Start switch 11. Relay unit 12. Sidestand switch 13. Neutral switch 14. Clutch switch 55.

  • Page 278: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
  • Page 279 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 280: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 1. Check the fuses. (Main, ignition and signal fuse) →...
  • Page 281 ELECTRIC STARTING SYSTEM OK↓ 11.Check the clutch switch. → Refer to Replace the clutch switch. “CHECKING THE SWITCHES” on page 8-63 OK↓ 12.Check the start switch. → Refer to Replace the right handlebar switch. “CHECKING THE SWITCHES” on page 8-63 OK↓...

  • Page 282: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 283 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Battery 5. Main fuse 8-12...

  • Page 284: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left) 1. Check the fuse. (Main) → Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-67 OK↓...
  • Page 285 CHARGING SYSTEM 8-14...

  • Page 286: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 287 LIGHTING SYSTEM 3. Main switch 4. Battery 5. Main fuse 16. ECU 34. High beam indicator 39. Front right turn signal/position light 40. Front left turn signal/position light 42. Headlight relay 43. Dimmer switch 44. Headlight 50. Tail/brake light 51. License light 54.

  • Page 288: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4.
  • Page 289 LIGHTING SYSTEM 8-18...

  • Page 290: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 291 SIGNALING SYSTEM 3. Main switch 4. Battery 5. Main fuse 11. Relay unit 13. Neutral switch 15. Fuel pump 16. ECU 23. Coolant temperature sensor 24. Speed sensor 30. Neutral indicator light 31. Coolant temperature warning light 33. Fuel level warning light 35.

  • Page 292: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light, turn signal indicator light and fuel level warning light. The horn fails to sound. The speedometer does not operate normally. The fuel indicator light does not come on. The coolant temperature warning light does not operate normally.
  • Page 293 SIGNALING SYSTEM This circuit is OK. The brake light fails to come on. 1. Check the front brake light switch. → Refer to Replace the front brake light switch. “CHECKING THE SWITCHES” on page 8-63 OK↓ 2. Check the rear brake light switch. →...
  • Page 294 SIGNALING SYSTEM 3. Check the entire signaling system ’ Properly connect or repair the signaling wiring. → Refer to “CIRCUIT DIAGRAM” on page system s wiring. ’ 8-19 OK↓ Replace the meter assembly. The speedometer fails to operate. Check the speed sensor. →...
  • Page 295 SIGNALING SYSTEM 8-24...

  • Page 296: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 297 COOLING SYSTEM 3. Main switch 4. Battery 5. Main fuse 16. ECU 23. Coolant temperature sensor 52. Radiator fan motor relay 53. Radiator fan motor 56. Ignition fuse 57. Radiator fan fuse 8-26...

  • Page 298: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan fails to operate. NOTE: Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank 5. Radiator cover 6. Drain the coolant. 1. Check the fuses. (Main, ignition and radiator fan fuse) →...
  • Page 299 COOLING SYSTEM 8-28...

  • Page 300: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 301 FUEL INJECTION SYSTEM 1. AC magneto 3. Main switch 4. Battery 5. Main fuse 6. Starter relay 8. Right handlebar switch 9. Engine stop switch 10. Start switch 11. Relay unit 12. Sidestand switch 13. Neutral switch 14. Clutch switch 15.

  • Page 302: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 303: Fail-Safe Actions (Substitute Characteristics Operation Control)

    FUEL INJECTION SYSTEM EAS27393 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
  • Page 304 FUEL INJECTION SYSTEM Able / Able / Fault code Item Symptom unable to unable to start drive Error is detected while reading or writ- Error in writing the ing on EEPROM (code re-registering amount of CO adjust- Able Able key code and throttle valve fully ment on EEPROM closed notification value).

  • Page 305: Troubleshooting Method

    FUEL INJECTION SYSTEM If malfunction the sensors or actuators, repair EAS27400 TROUBLESHOOTING METHOD or replace it. The engine operation is not normal and the If not malfunction the sensors and actuators, engine trouble warning light comes on. check and repair the engine inner parts. 1.
  • Page 306 FUEL INJECTION SYSTEM bers. 8. Verify the operation of the sensor or actuator. Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. Actuator operation Set the engine stop switch to “ON” to operate the actuator.
  • Page 307 FUEL INJECTION SYSTEM Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. Open or short circuit in wire harness. Defective crankshaft position sensor. No normal signals are received from the crankshaft Malfunction in pickup rotor. — position sensor.
  • Page 308 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open or short circuit in wiring harness. Defective speed sensor. No normal signals are Malfunction in vehicle speed sensor received from the speed sen- sor. detected unit. Malfunction in ECU.
  • Page 309 FUEL INJECTION SYSTEM Diagnos monitori Item Meter display Checking method ng code Pressure difference Displays the intake air pressure. Set “ ” the engine stop (atmospheric pressure-intake switch, and then push the air pressure) start switch. (If the display value changes, the perfor- mance is OK.) Intake air temperature Displays the intake air tempera-...
  • Page 310 FUEL INJECTION SYSTEM Diagnos monitori Item Meter display Checking method ng code Malfunction history code dis- — play No history History exists 12–70 (Fault detection code) (If code numbers more than one are detected, the display alternates every two seconds to show all the detected code numbers.
  • Page 311 FUEL INJECTION SYSTEM Diagnos monitori Item Actuation Checking method ng code Actuates the intake solenoid for five times every second. Check the operating sound of Intake solenoid Illuminates the engine trouble the solenoid five times. warning light. Actuates the fuel injection sys- tem relay for five times every second.

  • Page 312: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS27480 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed, restore the meter display ac- cording to the “Reinstatement method”.
  • Page 313 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor-open or short circuit detected. Diagnostic monitoring Intake air pressure sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Turning the main Intake air pressure sensor coupler switch ON.
  • Page 314 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor-open or short circuit detected. Diagnostic monitoring Throttle position sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of throttle position sen- Check the installed area for loose- Turning the main sor.
  • Page 315 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic monitoring Throttle position sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of throttle position sen- Check the installed area for loose- Reinstated by sor.
  • Page 316 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor is stuck. Diagnostic monitoring EXUP servo motor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector. Check the coupler for any pins that Turn the main EXUP servo motor coupler switch to “ON”.
  • Page 317 FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor-open or short circuit detected. Diagnostic monitoring Coolant temperature sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of coolant temperature Check the installed area for loose- Turning the main sensor.
  • Page 318 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor-open or short circuit detected. Diagnostic monitoring Intake air temperature sensor code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of intake air tempera- Check the installed area for loose- Turning the main ture sensor.
  • Page 319 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil. Diagnostic monitoring Ignition coil code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Starting the Ignition coil primary side coupler engine and oper-...
  • Page 320 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open or short circuit is detected in the neutral switch. Speed sensor Diagnostic monitoring code No. Neutral switch Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of speed sensor...
  • Page 321 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open or short circuit is detected in the neutral switch. Speed sensor Diagnostic monitoring code No. Neutral switch Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of neutral switch...
  • Page 322 FUEL INJECTION SYSTEM Fault code No. Symptom Supply power to the fuel injector and fuel pump is not normal. Diagnostic monitoring Fuel system voltage code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Starting the Relay unit coupler...
  • Page 323 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the FI system relay is not normal. Diagnostic monitoring — — code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Starting the Wire harness ECU coupler engine and oper-...
  • Page 324 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic monitoring — — code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Reinstated if nor- Main wire harness ECU coupler mal signal is...
  • Page 325 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic monitoring — — code No. Reinstatement Order Item/components and probable cause Check or maintenance job method Connected state of connector Check the coupler for any pins that Reinstated if nor- Main wire harness ECU coupler mal signal is...

  • Page 326: Fuel Pump System

    FUEL PUMP SYSTEM EAS27580 FUEL PUMP SYSTEM EAS27590 CIRCUIT DIAGRAM 8-55...
  • Page 327 FUEL PUMP SYSTEM 3. Main switch 4. Battery 5. Main fuse 8. Right handlebar switch 9. Engine stop switch 11. Relay unit 15. Fuel pump 16. ECU 56. Ignition fuse 58. EFI fuse 8-56...

  • Page 328: Trouble Shooting

    FUEL PUMP SYSTEM EAS27600 TROUBLE SHOOTING The fuel pump fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Fuel tank 1. Check the fuse (Main fuse, ignition fuse, EFI fuse) → Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 329 FUEL PUMP SYSTEM 8-58...

  • Page 330: Electrical Components

    ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS EAS32D1011 8-59...
  • Page 331 ELECTRICAL COMPONENTS 1. Main switch 2. Battery 3. Main fuse 4. Starter relay 5. ECU 6. Lean angle sensor 7. Intake solenoid 8. Throttle position sensor 9. Sidestand switch 10. Neutral switch 11. Rear brake switch 12. Fan motor 13. Rectifier/regulator 8-60...
  • Page 332 ELECTRICAL COMPONENTS 8-61...
  • Page 333 ELECTRICAL COMPONENTS 1. Horn 2. Fuse box 3. Starter motor 4. Radiator fan motor relay 5. Turn signal relay 6. Relay assembly 7. Headlight relay 8. Intake air temperature sensor 9. Coolant temperature sensor 10. Speed sensor 11. EXUP servo motor 12.

  • Page 334: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-63...
  • Page 335 ELECTRICAL COMPONENTS 1. Horn switch 2. Dimmer switch 3. Turn signal switch 4. Clutch switch 5. Neutral switch 6. Sidestand switch 7. Main switch 8. Engine stop switch 9. Start switch 10. Front brake switch 11. Rear brake switch 8-64...
  • Page 336 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 337: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS away from the bulb until it has cooled down. EAS27990 CHECKING THE BULBS AND BULB ECA14380 SOCKETS CAUTION: Check each bulb and bulb socket for damage or Be sure to hold the socket firmly when re- wear, proper connections, and also for continu- moving the bulb.

  • Page 338: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.

  • Page 339: Checking And Charging The Battery

    ELECTRICAL COMPONENTS OUT OF REACH OF CHILDREN. Amperage Fuses Q’ty Avoid bodily contact with electrolyte as it rating can cause severe burns or permanent eye Main injury. FIRST AID IN CASE OF BODILY CONTACT: Headlight EXTERNAL Signaling system Skin — Wash with water. Eyes —...
  • Page 340 ELECTRICAL COMPONENTS 3. Remove: Battery 4. Check: A. Open-circuit voltage Battery charge B. Charge of the battery MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM C. Temperature 20°C a. Connect a pocket tester to the battery termi- nals. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Positive tester probe → 5. Charge: positive battery terminal Negative tester probe →...
  • Page 341 ELECTRICAL COMPONENTS tery cool before reconnecting it. Hot d. Adjust the voltage so that the current is at the batteries can explode! standard charging level. As shown in the following illustration, the e. Set the time according to the charging time open-circuit voltage of an MF battery stabi- suitable for the open-circuit voltage.

  • Page 342: Checking The Relays

    ELECTRICAL COMPONENTS 6. Check: Result Battery terminals Continuity Dirt → Clean with a wire brush. (between “3” to “4”) Loose connection → Connect properly. 7. Install: Relay unit (starting circuit cut-off relay) Battery 8. Connect: Battery leads (to the battery terminals) 9.
  • Page 343 ELECTRICAL COMPONENTS Headlight relay b. Turn the main switch to “ON”. c. Measure turn signal relay applied voltage. 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Negative tester probe d. Check: Turn signal relay output voltage Result Out of specification →...

  • Page 344: Checking The Diode

    ELECTRICAL COMPONENTS Radiator fan motor relay Continuity Tester positive lead → Sky blue “1” Tester negative lead → Light green “2” No continuity Tester positive lead → Light green “2” Tester negative lead → Sky blue “1” Continuity Tester positive lead → Blue/ Green “3”...

  • Page 345: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS c. Check the diode for continuity. c. Turn the main switch to “ON” and engine stop d. Check the diode for no continuity. switch to “ ”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the start switch “...

  • Page 346: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Secondary coil resistance Pocket tester 8.50–11.50 kΩ 90890-03112 Analog pocket tester YU-03112-C MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Disconnect the spark plug cap from the igni- tion coil. Positive tester probe b. Connect the pocket tester (Ω × 1k) to the ig- Red “1”...

  • Page 347: Checking The Stator Coil

    ELECTRICAL COMPONENTS Tester positive probe Positive tester probe Blue “1” White “2” Negative tester probe Negative tester probe Yellow/Green “2” White “3” b. Measure the stator coil resistance. c. Incline the lean angle sensor. d. Measure the lean angle sensor out put volt- age.

  • Page 348: Checking The Horn

    ELECTRICAL COMPONENTS 2. Check: Horn sound Faulty sound → Adjust or replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction “a” or “b” until the specified horn sound is obtained. c. Start the engine and let it run at approximate- ly 5000 r/min.

  • Page 349: Checking The Fuel Sender (Fuel Pump)

    ELECTRICAL COMPONENTS b. Set the main switch to “ON”. b. Measure the resistance of the fuel sender. c. Elevate the rear wheel and slowly turn it. d. Measure the voltage (DC 5 V) of white and LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL black/blue. With the front wheel slowly rotat- ing, voltage alternates between 0 V and 5 V.

  • Page 350: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS from the wire harness. b. Connect the battery (DC 12 V) as shown. Positive tester probe Blue “1” Negative tester probe Black “2” b. Immerse the coolant temperature sensor in a container filled with coolant. NOTE: Make sure the coolant temperature sensor ter- minals do not get wet.

  • Page 351: Checking The Exup Servo Motor

    ELECTRICAL COMPONENTS sor shaft, check that the throttle position sen- EAS28410 CHECKING THE INTAKE AIR PRESSURE sor voltage is within the specified range. SENSOR The voltage does not change or it changes 1. Check: abruptly → Replace the throttle position sen- Intake air pressure sensor output voltage sor.

  • Page 352: Checking The Intake Solenoid

    ELECTRICAL COMPONENTS sensor to strong shocks. If the intake air Pocket tester temperature sensor is dropped, replace it. 90890-03112 2. Check: Analog pocket tester YU-03112-C Intake air temperature sensor resistance Out of specification → Replace. Intake air temperature sensor re- Tester positive lead sistance Red/White “1”...

  • Page 353: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ...................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ...........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING...............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM........9-3...

  • Page 354: Troubleshooting

    TROUBLESHOOTING Improperly installed fuse EAS28450 TROUBLESHOOTING 3. Spark plug (s) Incorrect spark plug gap EAS28460 GENERAL INFORMATION Incorrect spark plug heat range Fouled spark plug NOTE: The following guide for troubleshooting does not Worn or damaged electrode cover all the possible causes of trouble. It should Worn or damaged insulator 4.

  • Page 355: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Faulty spark plug cap EAS28560 FAULTY CLUTCH 3. Ignition coil (s) Clutch slips Faulty ignition coil 1. Clutch Cracked or broken ignition coil Improperly assembled clutch 4. Ignition system Loose or fatigued clutch spring ECU failure. Worn friction plate Faulty crankshaft position sensor Worn clutch plate 2.

  • Page 356: Overcooling

    TROUBLESHOOTING Clogged air filter element EAS28690 UNSTABLE HANDLING Chassis 1. Handlebar 1. Brake (s) Bent or improperly installed handlebar Dragging brake 2. Steering head components Electrical system Improperly installed upper bracket 1. Spark plug (s) Improperly installed lower bracket Incorrect spark plug gap (improperly tightened ring nut) Incorrect spark plug heat range Bent steering stem...
  • Page 357 TROUBLESHOOTING Faulty main switch Headlight bulb life expired Tail/brake light does not come on Too many electrical accessories Incorrect connection Turn signal does not come on Fuse open circuit Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit...
  • Page 358 TROUBLESHOOTING...

  • Page 359: Engine

    47.Left handlebar switch EAS28740 EAS28750 WIRING DIAGRAM COLOR CODE 48.Rear brake switch Black WR250R(X)/WR250X(X) 49.Front brake light switch Brown 2008 WIRING DIAGRAM 50.Tail/brake light Chocolate 51.License plate light 1.AC magneto Dark green 52.Radiator fan motor relay 2.Rectifier/regulator Green 53.Radiator fan motor 3.Main switch...
  • Page 362 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 363 WR250RX/WR250XX 2008 WR250RX/WR250XX 2008 WR250RX/WR250XX 2008 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN WR250RX/WR250XX 2008 WR250RX/WR250XX 2008...
  • Page 364 WR250RX/WR250XX 2008 WR250RX/WR250XX 2008 WR250RX/WR250XX 2008 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN WR250RX/WR250XX 2008 WR250RX/WR250XX 2008...

This manual is also suitable for:

Wr250x

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