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WR250FM 2021
Yamaha WR250FM 2021 Manuals
Manuals and User Guides for Yamaha WR250FM 2021. We have
1
Yamaha WR250FM 2021 manual available for free PDF download: Owner's Service Manual
Yamaha WR250FM 2021 Owner's Service Manual (404 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 25.47 MB
Table of Contents
Table of Contents
9
Safety Information
13
For Safety, be Sure to Obey the Following
13
Location of Important Labels
16
Description
17
Identification
18
Vehicle Identification Number
18
Engine Serial Number
18
Vehicle Emission Control Information Label
18
Included Parts
19
Nipple Wrench
19
Handlebar Protector
19
Fuel Hose Joint Cover
19
Coupler for Connecting Optional Part
19
Important Information
20
Preparation for Removal and Disassembly
20
Replacement Parts
20
Gaskets, Oil Seals and O-Rings
20
Lock Washers/Plates and Cotter Pins
21
Bearings and Oil Seals
21
Circlips
21
Basic Service Information
22
Electrical System
22
Special Tools
26
Instrument and Control Functions
33
Warning Lights
33
Engine Stop Switch
33
Start Switch
33
Shift Pedal
33
Front Brake Lever
34
Rear Brake Pedal
34
Sidestand
34
Starter Knob
34
Fuel Tank Cap
34
Multi-Function Display
36
Description
36
Basic Mode
36
Changeover to Basic Mode/Race Mode
38
Race Mode
39
Function Diagram
42
Starting and Break-In
43
Fuel
43
Handling Note
43
Starting a Cold Engine
43
Starting a Warm Engine
44
Break-In Procedures
44
Shifting
44
Maintenance after Break-In
46
Major Maintenance
46
Air Filter Maintenance
46
Torque-Check Points
47
Motorcycle Care and Storage
49
Care
49
Storage
50
Specifications
53
General Specifications
54
Engine Specifications
55
Chassis Specifications
60
Electrical Specifications
61
Tightening Torques
63
General Tightening Torque Specifications
63
Engine Tightening Torques
64
Chassis Tightening Torques
67
Cable Routing Diagram
70
Periodic Checks and Adjustments
87
Periodic Maintenance
89
General Maintenance and Lubrication Chart
89
Introduction
89
Periodic Maintenance Chart for the Emission Control System
89
Maintenance Intervals for Competition Use
91
Pre-Operation Inspection and Maintenance
94
General Inspection and Maintenance
94
Engine
95
Adjusting the Valve Clearance
95
Valve Clearance Shim Chart
98
Checking the Engine Idling Speed
100
Checking the Throttle Grip
100
Checking the Spark Plug
101
Checking the Engine Oil Level
102
Changing the Engine Oil
102
Adjusting the Clutch Lever Free Play
104
Cleaning the Air Filter Element
104
Checking the Throttle Body Joint
106
Checking the Fuel Line
106
Checking the Cylinder Head Breather Hose
106
Checking the Exhaust System
107
Checking the Coolant Level
108
Checking the Cooling System
109
Changing the Coolant
109
Chassis
111
Adjusting the Front Disc Brake
111
Adjusting the Rear Disc Brake
111
Checking the Brake Fluid Level
112
Checking the Front Brake Pads
112
Checking the Rear Brake Pads
112
Checking the Front Brake Hose
112
Checking the Rear Brake Hose
113
Checking the Brake Operation
113
Bleeding the Hydraulic Brake System
113
Drive Chain Slack
114
Lubricating the Drive Chain
115
Checking and Adjusting the Steering Head
115
Lubricating the Steering Head
116
Checking the Front Fork Legs
116
Adjusting the Front Fork Legs
117
Checking the Rear Shock Absorber Assembly
118
Adjusting the Rear Shock Absorber Assembly
118
Checking the Swingarm Operation
120
Lubricating the Swingarm Pivot
120
Checking the Connecting Arm and Relay Arm
120
Checking the Tires
121
Checking and Tightening the Spokes
121
Checking the Wheels
121
Checking the Wheel Bearings
121
Checking the Chassis Fasteners
122
Checking and Lubricating the Cables
122
Lubricating the Brake Lever
122
Lubricating the Clutch Lever
122
Lubricating the Pedal
122
Checking the Sidestand
122
Lubricating the Sidestand
122
Electrical System
123
Checking and Charging the Battery
123
Checking the Fuses
123
Checking the Ignition Timing
123
Replacing the Headlight Bulb
123
Chassis
125
General Chassis
130
Removing the Seat
130
Installing the Air Scoop
130
Removing the Side Cover
130
Installing the Side Cover
130
Front Wheel
132
Removing the Front Wheel
133
Checking the Front Wheel Sensor and Sensor Rotor
133
Disassembling the Front Wheel
133
Checking the Front Wheel
134
Assembling the Front Wheel
134
Installing the Front Wheel
136
Rear Wheel
139
Removing the Rear Wheel
139
Disassembling the Rear Wheel
139
Checking the Rear Wheel
139
Checking and Replacing the Rear Wheel Sprocket
139
Assembling the Rear Wheel
140
Installing the Rear Wheel
140
Front Brake
143
Introduction
146
Checking the Front Brake Disc
146
Replacing the Front Brake Pads
146
Removing the Front Brake Caliper
148
Disassembling the Front Brake Caliper
148
Checking the Front Brake Caliper
148
Assembling the Front Brake Caliper
148
Installing the Front Brake Caliper
149
Removing the Front Brake Master Cylinder
150
Checking the Front Brake Master Cylinder
150
Assembling the Front Brake Master Cylinder
150
Installing the Front Brake Master Cylinder
151
Rear Brake
153
Introduction
157
Checking the Rear Brake Disc
157
Replacing the Rear Brake Pads
157
Removing the Rear Brake Caliper
159
Disassembling the Rear Brake Caliper
159
Checking the Rear Brake Caliper
159
Assembling the Rear Brake Caliper
159
Installing the Rear Brake Caliper
160
Removing the Rear Brake Master Cylinder
160
Checking the Rear Brake Master Cylinder
161
Assembling the Rear Brake Master Cylinder
161
Installing the Rear Brake Master Cylinder
162
Removing the Handlebar
164
Checking the Handlebar
164
Installing the Handlebar
164
Front Fork
169
Removing the Front Fork Legs
171
Disassembling the Front Fork Legs
171
Checking the Front Fork Legs
172
Assembling the Front Fork Legs
173
Installing the Front Fork Legs
179
Steering Head
182
Removing the Lower Bracket
183
Checking the Steering Head
183
Installing the Steering Head
183
Rear Shock Absorber Assembly
186
Handling the Rear Shock Absorber
189
Disposing of a Rear Shock Absorber
189
Removing the Rear Shock Absorber Assembly
189
Checking the Rear Shock Absorber Assembly
189
Checking the Connecting Arm and Relay Arm
190
Installing the Relay Arm
190
Installing the Rear Shock Absorber Assembly
190
Swingarm
192
Removing the Swingarm
193
Checking the Swingarm
193
Installing the Swingarm
193
Chain Drive
195
Removing the Drive Chain
196
Checking the Drive Chain
196
Checking the Drive Sprocket
197
Checking the Rear Wheel Sprocket
197
Installing the Drive Chain
197
Engine
199
Lubrication System Chart and Diagrams
201
Engine Oil Lubrication Chart
201
Lubrication Diagrams
202
Engine Removal
206
Removing the Engine
211
Installing the Engine
211
Installing the Exhaust Pipe and Muffler
212
Camshaft
214
Removing the Camshaft
216
Checking the Camshaft
217
Checking the Timing Chain and Camshaft Sprocket
218
Checking the Timing Chain Tensioners
218
Checking the Decompression System
218
Installing the Camshafts
218
Cylinder Head
221
Removing the Cylinder Head
223
Checking the Timing Chain Guide (Intake Side)
223
Checking the Cylinder Head
223
Installing the Cylinder Head
223
Valves and Valve Springs
227
Removing the Valves
227
Checking the Valves and Valve Guides
228
Checking the Valve Seats
229
Checking the Valve Springs
230
Checking the Valve Lifters
231
Installing the Valves
231
Cylinder and Piston
233
Removing the Piston
234
Checking the Cylinder and Piston
234
Checking the Piston Rings
235
Checking the Piston Pin
235
Installing the Piston and Cylinder
236
Generator
238
Removing the Generator
239
Checking the Generator
239
Checking the Woodruff Key
239
Installing the Generator
239
Starter Clutch
241
Removing the Starter Clutch
242
Checking the Starter Clutch
242
Installing the Starter Clutch
242
Electric Starter
244
Checking the Starter Motor
246
Assembling the Starter Motor
246
Clutch
248
Removing the Clutch
251
Checking the Friction Plates
251
Checking the Clutch Plates
251
Checking the Clutch Springs
251
Checking the Clutch Housing
251
Checking the Clutch Boss
252
Checking the Pressure Plate
252
Checking the Push Lever Shaft
252
Checking the Push Rods
252
Checking the Primary Drive Gear
252
Checking the Primary Driven Gear
252
Installing the Clutch
252
Shift Shaft
256
Removing the Segment
257
Checking the Shift Shaft
257
Checking the Stopper Lever
257
Installing the Shift Shaft
257
Oil Pump
260
Removing the Balancer
262
Checking the Oil Pump
262
Assembling the Oil Pump
262
Installing the Oil Pump
263
Crankcase
266
Disassembling the Crankcase
268
Checking the Timing Chain Guide (Exhaust Side)
268
Checking the Crankcase
268
Assembling the Crankcase
269
Crankshaft and Balancer Shaft
270
Removing the Crankshaft
271
Checking the Crankshaft
271
Installing the Crankshaft
272
Transmission
273
Removing the Transmission
274
Checking the Shift Forks
274
Checking the Shift Drum Assembly
274
Checking the Transmission
274
Installing the Transmission
275
Cooling System
279
Cooling System Diagrams
280
Radiator
281
Checking the Radiator
283
Installing the Radiator
283
Water Pump
285
Disassembling the Water Pump
286
Checking the Water Pump
286
Assembling the Water Pump
286
Fuel System
289
Fuel Tank
290
Fuel Tank
290
Checking the Fuel Pump Body
291
Checking the Fuel Pump Operation
291
Removing the Fuel Pump
291
Removing the Fuel Tank
291
Installing the Fuel Pump
292
Installing the Fuel Tank
292
Throttle Body
293
Checking the Fuel Pressure
296
Checking the Injector
296
Checking the Throttle Body
296
Adjusting the Throttle Position Sensor
297
Electrical System
299
Ignition System
302
Circuit Diagram
302
Troubleshooting
304
Electric Starting System
306
Circuit Diagram
306
Starting Circuit Cut-Off System Operation
308
Troubleshooting
310
Charging System
312
Circuit Diagram
312
Troubleshooting
314
Signaling System
316
Circuit Diagram
316
Troubleshooting
318
Lighting System
320
Circuit Diagram
320
Troubleshooting
322
Cooling System
324
Circuit Diagram
324
Troubleshooting
326
Fuel Injection System
328
Circuit Diagram
328
Ecu Self-Diagnostic Function
330
Troubleshooting Method
331
Yamaha Diagnostic Tool
332
Connecting the Yamaha Diagnostic Tool
332
Troubleshooting Details (Fault Code)
334
Fuel Pump System
354
Circuit Diagram
354
Troubleshooting
356
Electrical Components
357
Checking the Switches
358
Checking the Bulbs and Bulb Sockets
360
Checking the Fuses
360
Checking and Charging the Battery
361
Checking the Relays
363
Checking the Relay Unit (Diode)
365
Checking the Ignition Spark Gap
366
Checking the Spark Plug Cap
366
Checking the Ignition Coil
366
Checking the Crankshaft Position Sensor
367
Checking the Lean Angle Sensor
368
Checking the Starter Motor Operation
368
Checking the Stator Coil
368
Checking the Rectifier/Regulator
368
Checking the Speed Sensor
369
Checking the Fuel Sender
369
Checking the Resistor
369
Checking the Radiator Fan Motor
370
Checking the Coolant Temperature Sensor
370
Checking the Throttle Position Sensor Input Voltage
371
Checking the Intake Air Temperature Sensor
371
Checking the Gear Position Switch
372
Checking the Injector
372
Troubleshooting
373
Troubleshooting
374
TROUBLESHOOTING of ENGINE (Fault Code Not Detected)
374
Troubleshooting of Clutch
377
Troubleshooting of Transmission
379
Troubleshooting of Cooling System
380
Troubleshooting of Brake
381
Troubleshooting of Suspension
381
Troubleshooting of Steering/Handling
383
Troubleshooting of Charging System
384
Troubleshooting of Lighting System
384
Troubleshooting of Signaling System
384
Self-Diagnostic Function and Diagnostic Code Table
385
Self-Diagnostic Function Table (for Fuel Injection System)
385
Diagnostic Code: Sensor Operation Table
385
Diagnostic Code: Actuator Operation Table
387
Tuning
389
Chassis
390
Drive and Rear Wheel Sprockets Setting Parts
390
Front Fork Setting
390
Selection of the Secondary Reduction Ratio (Sprocket)
390
Tire Pressure
390
Change in Amount and Characteristics of Fork Oil
391
Setting of Spring after Replacement
391
Choosing Set Length
392
Front Fork Setting Parts
392
Rear Suspension Setting
392
Setting of Spring after Replacement
393
Rear Shock Absorber Setting Parts
394
Suspension Setting (Front Fork)
395
Suspension Setting (Rear Shock Absorber)
396
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