Yamaha WR250F 2017 Manuals

Manuals and User Guides for Yamaha WR250F 2017. We have 1 Yamaha WR250F 2017 manual available for free PDF download: Owner's Service Manual

Yamaha WR250F 2017 Owner's Service Manual

Yamaha WR250F 2017 Owner's Service Manual (432 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.82 MB

Table of Contents

Table of Contens

11
- Table of Contents
  11
- General Information
  13
- Location of Important Labels
  15
- Description
  18
- Identification
  19
- Vehicle Identification Number
  19
- Engine Serial Number
  19
- Vehicle Emission Control Information Label
  19
- Handlebar Protector
  20
- Fuel Hose Joint Cover
  20
- Coupler for Connecting Optional Part
  20
- Nipple Wrench
  20
- Spark Plug Wrench
  20
- Included Parts
  20
- Important Information
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Gaskets, Oil Seals and O-Rings
  22
- Lock Washers/Plates and Cotter Pins
  22
- Bearings and Oil Seals
  22
- Circlips
  22
- Basic Service Information
  23
- Electrical System
  23
- Special Tools
  27
- Clutch Lever
  33
- Start Switch
  33
- Engine Stop Switch
  33
- Indicator Lights and Warning Lights
  33
- Control Functions
  33
- Shift Pedal
  34
- Kickstarter Lever
  34
- Throttle Grip
  34
- Front Brake Lever
  34
- Rear Brake Pedal
  34
- Sidestand
  35
- Starter Knob/Idle Screw
  35
- Fuel Tank Cap
  35
- Basic Mode
  36
- Description
  36
- Multi-Function Display
  36
- Changeover to Basic Mode/Race Mode
  37
- Race Mode
  38
- Function Diagram
  42
- Starting and Break-In
  44
- Fuel
  44
- Handling Note
  44
- Air Filter Maintenance
  44
- Starting a Cold Engine
  44
- Starting a Warm Engine
  46
- Break-In Procedures
  46
- Maintenance after Break-In
  47
- Major Maintenance
  47
- Torque-Check Points
  48
- Motorcycle Care and Storage
  50
- Care
  50
- Storage
  51
Specifications

53
- General Specifications
  54
- Engine Specifications
  55
- Chassis Specifications
  60
- Electrical Specifications
  63
- General Tightening Torque Specifications
  65
- Tightening Torques
  65
- Engine Tightening Torques
  66
- Chassis Tightening Torques
  69
- Engine
  73
- Lubrication Points and Lubricant Types
  73
- Chassis
  74
- Lubrication Diagrams
  76
- Lubrication System Chart and Diagrams
  76
- Cable Routing Diagram
  84
Periodic Checks and Adjustments

99
- Introduction
  101
- Periodic Maintenance
  101
- Periodic Maintenance Chart for the Emission Control System
  101
- General Maintenance and Lubrication Chart
  102
- Maintenance Intervals for Competition Use
  104
- General Inspection and Maintenance
  109
- Pre-Operation Inspection and Maintenance
  109
- Changing the Coolant
  110
- Checking the Coolant Level
  110
- Checking the Cooling System
  110
- Engine
  110
- Checking the Radiator Cap
  111
- Checking the Radiator Cap Valve Opening Pressure
  111
- Adjusting the Clutch Lever Free Play
  112
- Checking the Coolant Circulatory System for Leaks
  112
- Adjusting the Throttle Grip Free Play
  113
- Cleaning the Air Filter Element
  114
- Lubricating the Throttle Cable
  114
- Checking the Breather Hoses
  115
- Checking the Exhaust System
  115
- Checking the Throttle Body Joint
  115
- Checking the Engine Oil Level
  116
- Checking the Fuel Line
  116
- Changing the Engine Oil
  117
- Adjusting the Engine Idling Speed
  118
- Adjusting the Valve Clearance
  119
- Cleaning the Spark Arrester
  124
- Bleeding the Brake System
  125
- Chassis
  125
- Adjusting the Front Brake
  126
- Checking the Brake Hose
  126
- Adjusting the Rear Brake
  127
- Checking the Front Brake Pads
  127
- Checking the Rear Brake Pads
  129
- Checking the Brake Fluid Level
  130
- Checking the Rear Brake Pad Insulator
  130
- Adjusting the Drive Chain Slack
  131
- Air Bleeding from Front Fork
  132
- Checking the Front Fork Legs
  132
- Checking the Front Fork Protector Guide
  132
- Cleaning the Front Fork Oil Seal and Dust Seal
  132
- Adjusting the Front Fork Legs
  133
- Adjusting the Rear Shock Absorber Assembly
  134
- Checking the Rear Suspension
  134
- Checking the Swingarm Operation
  134
- Checking and Tightening the Spokes
  136
- Checking the Tires
  136
- Checking and Adjusting the Steering Head
  137
- Checking the Wheel Bearings
  137
- Checking the Wheels
  137
- Checking and Lubricating the Cables
  138
- Lubricating the Drive Chain
  138
- Lubricating the Levers
  138
- Lubricating the Pedal
  138
- Checking the Chassis Fasteners
  139
- Lubricating the Sidestand
  139
- Checking the Ignition Timing
  140
- Checking the Spark Plug
  140
- Electrical System
  140
- Checking and Charging the Battery
  141
- Replacing the Headlight Bulb
  141
Tuning

143
- Chassis
  144
- Drive and Rear Wheel Sprockets Setting Parts
  144
- Selection of the Secondary Reduction Ratio (Sprocket)
  144
- Tire Pressure
  144
- Change in Amount and Characteristics of Fork Oil
  145
- Front Fork Setting
  145
- Setting of Spring after Replacement
  145
- Choosing Set Length
  146
- Front Fork Setting Parts
  146
- Rear Suspension Setting
  146
- Rear Shock Absorber Setting Parts
  147
- Setting of Spring after Replacement
  147
- Suspension Setting (Front Fork)
  149
- Suspension Setting (Rear Shock Absorber)
  150
Chassis

153
- General Chassis
  157
- Removing the Left Side Cover
  157
- Removing the Seat
  157
- Front Wheel
  158
- Checking the Front Wheel
  159
- Removing the Front Wheel
  159
- Assembling the Front Wheel
  160
- Disassembling the Front Wheel
  160
- Installing the Front Wheel
  161
- Rear Wheel
  163
- Checking and Replacing the Rear Wheel Sprocket
  164
- Checking the Rear Wheel
  164
- Disassembling the Rear Wheel
  164
- Removing the Rear Wheel
  164
- Assembling the Rear Wheel
  165
- Installing the Rear Wheel
  165
- Front Brake
  167
- Checking the Front Brake Disc
  171
- Disassembling the Front Brake Caliper
  171
- Introduction
  171
- Removing the Front Brake Caliper
  171
- Assembling the Front Brake Caliper
  172
- Checking the Front Brake Caliper
  172
- Installing the Brake Caliper Piston
  172
- Installing the Front Brake Caliper
  173
- Assembling the Front Brake Master Cylinder
  174
- Checking the Front Brake Master Cylinder
  174
- Removing the Front Brake Master Cylinder
  174
- Installing the Front Brake Master Cylinder
  175
- Rear Brake
  177
- Checking the Rear Brake Disc
  181
- Introduction
  181
- Assembling the Rear Brake Caliper
  182
- Checking the Rear Brake Caliper
  182
- Disassembling the Rear Brake Caliper
  182
- Removing the Rear Brake Caliper
  182
- Installing the Brake Caliper Piston
  183
- Installing the Rear Brake Caliper
  183
- Checking the Rear Brake Master Cylinder
  184
- Removing the Rear Brake Master Cylinder
  184
- Assembling the Rear Brake Master Cylinder
  185
- Installing the Rear Brake Master Cylinder
  185
- Checking the Handlebar
  189
- Handlebar
  189
- Installing the Handlebar
  189
- Removing the Handlebar
  189
- Front Fork
  194
- Disassembling the Front Fork Legs
  196
- Removing the Front Fork Legs
  196
- Checking the Front Fork Legs
  197
- Assembling the Front Fork Legs
  198
- Installing the Front Fork Legs
  204
- Steering Head
  207
- Checking the Steering Head
  209
- Installing the Steering Head
  209
- Removing the Lower Bracket
  209
- Rear Shock Absorber Assembly
  212
- Disposing of a Rear Shock Absorber
  215
- Handling the Rear Shock Absorber
  215
- Removing the Bearing
  215
- Removing the Rear Shock Absorber Assembly
  215
- Checking the Connecting Arm and Relay Arm
  216
- Checking the Rear Shock Absorber Assembly
  216
- Installing the Relay Arm
  216
- Installing the Rear Shock Absorber Assembly
  217
- Swingarm
  219
- Checking the Swingarm
  220
- Removing the Bearing
  220
- Removing the Swingarm
  220
- Installing the Swingarm
  221
- Chain Drive
  222
- Checking the Drive Chain
  223
- Removing the Drive Chain
  223
- Checking the Drive Sprocket
  224
- Checking the Rear Wheel Sprocket
  224
- Installing the Drive Chain
  224
Engine

227
- Engine Removal
  230
- Removing the Drive Sprocket
  235
- Removing the Exhaust Pipe 2
  235
- Removing the Silencer
  235
- Cleaning the Spark Arrester
  236
- Removing the Engine
  236
- Checking the Silencer and Exhaust Pipe
  237
- Installing the Engine
  237
- Installing the Brake Pedal
  238
- Installing the Drive Sprocket
  238
- Installing the Exhaust Pipe and Muffler
  239
- Camshaft
  241
- Removing the Camshaft
  243
- Checking the Camshaft
  244
- Checking the Timing Chain and Camshaft Sprocket
  245
- Checking the Timing Chain Tensioners
  245
- Checking the Decompression System
  246
- Installing the Camshafts
  246
- Cylinder Head
  249
- Checking the Cylinder Head
  251
- Checking the Timing Chain Guide (Intake Side)
  251
- Removing the Cylinder Head
  251
- Installing the Cylinder Head
  252
- Removing the Valves
  254
- Valves and Valve Springs
  254
- Checking the Valves and Valve Guides
  255
- Checking the Valve Seats
  256
- Checking the Valve Lifters
  258
- Checking the Valve Springs
  258
- Installing the Valves
  259
- Checking the Cylinder and Piston
  262
- Cylinder and Piston
  262
- Removing the Piston
  262
- Checking the Piston Rings
  263
- Checking the Piston Pin
  264
- Installing the Piston and Cylinder
  264
- Electric Starter
  266
- Checking the Starter Motor
  268
- Assembling the Starter Motor
  269
- Checking the Clutch Plates
  274
- Checking the Clutch Springs
  274
- Checking the Friction Plates
  274
- Clutch
  274
- Removing the Clutch
  274
- Checking the Clutch Boss
  275
- Checking the Clutch Housing
  275
- Checking the Clutch Push Rods
  275
- Checking the Pressure Plate
  275
- Checking the Primary Drive Gear
  275
- Checking the Push Lever Shaft
  275
- Checking the Primary Driven Gear
  276
- Installing the Clutch
  276
- Installing the Oil Seal
  276
- Installing the Right Crankcase Cover
  276
- Installing the Kickstarter Lever
  279
- Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
  281
- Checking the Kick Shaft and Ratchet Wheel
  281
- Installing the Kick Shaft Assembly
  281
- Kickstater
  281
- Removing the Kick Shaft Assembly
  281
- Installing the Kick Idle Gear
  282
- Shift Shaft
  284
- Checking the Shift Guide and Shift Lever Assembly
  285
- Checking the Shift Shaft
  285
- Checking the Stopper Lever
  285
- Installing the Stopper Lever
  285
- Removing the Segment
  285
- Removing the Shift Guide and Shift Lever Assembly
  285
- Installing the Segment
  286
- Installing the Shift Guide and Shift Lever Assembly
  286
- Installing the Shift Pedal
  287
- Installing the Shift Shaft
  287
- Oil Pump and Balancer Gear
  289
- Checking the Balancer
  291
- Checking the Oil Pump
  291
- Checking the Primary Drive Gear, Balancer Drive Gear, and Balancer Weight Gear
  291
- Removing the Balancer
  291
- Assembling the Oil Pump
  292
- Installing the Oil Pump and Balancer Gear
  292
- Checking the Starter Clutch
  297
- Generator and Starter Clutch
  297
- Installing the Starter Clutch
  297
- Removing the Generator
  297
- Installing the Generator
  298
- Crankcase
  302
- Checking the Crankcase
  304
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  304
- Disassembling the Crankcase
  304
- Removing the Crankcase Bearing
  304
- Assembling the Crankcase
  305
- Installing the Oil Seal
  305
- Crankshaft Assembly and Balancer Shaft
  307
- Checking the Crankshaft Assembly
  308
- Removing the Crankshaft Assembly
  308
- Installing the Balancer Shaft
  309
- Installing the Crankshaft Assembly
  309
- Checking the Shift Drum Assembly
  311
- Checking the Shift Forks
  311
- Removing the Transmission
  311
- Transmission
  311
- Checking the Transmission
  312
- Installing the Transmission
  312
- Cooling System
  315
Fuel System

323
- Fuel Tank
  324
- Checking the Fuel Pump Body
  326
- Installing the Fuel Pump
  326
- Removing the Fuel Pump
  326
- Removing the Fuel Tank
  326
- Checking the Fuel Sender
  327
- Installing the Fuel Sender
  327
- Installing the Fuel Tank
  327
- Removing the Fuel Sender
  327
- Checking the Fuel Pressure
  328
- Checking and Replacing the Protector
  329
- Checking the Damper
  329
- Throttle Body
  330
- Checking the Injector
  333
- Checking the Throttle Body
  333
- Checking the Throttle Body Joint
  333
- Adjusting the Throttle Position Sensor
  334
Electrical System

335
- Circuit Diagram
  338
- Ignition System
  338
- Troubleshooting
  340
- Circuit Diagram
  342
- Electric Starting System
  342
- Starting Circuit Cut-Off System Operation
  344
- Troubleshooting
  346
- Charging System
  348
- Circuit Diagram
  348
- Troubleshooting
  350
- Circuit Diagram
  352
- Lighting System
  352
- Troubleshooting
  354
- Circuit Diagram
  356
- Signaling System
  356
- Troubleshooting
  358
- Circuit Diagram
  360
- Cooling System
  360
- Troubleshooting
  362
- Circuit Diagram
  364
- Fuel Injection System
  364
- Ecu Self-Diagnostic Function
  366
- Troubleshooting Method
  367
- Yamaha Diagnostic Tool
  368
- Troubleshooting Details
  371
- Circuit Diagram
  392
- Fuel Pump System
  392
- Troubleshooting
  394
- Electrical Components
  396
- Checking the Switches
  400
- Checking the Bulbs and Bulb Sockets
  403
- Checking the Fuses
  404
- Checking and Charging the Battery
  405
- Checking the Relays
  408
- Checking the Diode
  409
- Checking the Ignition Spark Gap
  409
- Checking the Ignition Coil
  410
- Checking the Spark Plug Cap
  410
- Checking the Crankshaft Position Sensor
  411
- Checking the Lean Angle Sensor
  411
- Checking the Rectifier/Regulator
  412
- Checking the Starter Motor Operation
  412
- Checking the Stator Coil
  412
- Checking the Fuel Sender
  413
- Checking the Speed Sensor
  413
- Checking the Coolant Temperature Sensor
  414
- Checking the Radiator Fan Motor
  414
- Checking the Resister
  414
- Checking the Throttle Position Sensor
  415
- Checking the Intake Air Pressure Sensor
  416
- Checking the Intake Air Temperature Sensor
  416
- Checking the Throttle Position Sensor Input Voltage
  416
- Checking the Fuel Injector
  417
Troubleshooting

419
- General Information
  420
- Incorrect Engine Idling Speed
  420
- Starting Failures
  420
- Troubleshooting
  420
- Clutch Drags
  421
- Clutch Slips
  421
- Jumps out of Gear
  421
- Overheating
  421
- Poor Medium-And-High-Speed Performance
  421
- Shift Pedal Does Not Move
  421
- Shifting Is Difficult
  421
- Faulty Front Fork Legs
  422
- Front Fork Oil Leaking
  422
- Overcooling
  422
- Poor Braking Performance
  422
- Unstable Handling
  422
- Headlight Bulb Burnt out
  423
- Headlight Does Not Come on
  423
- Taillight Does Not Come on
  423
- List of Self-Diagnostic and Fail-Safe Actions
  424

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