Yamaha WR250F 2023 Owner's Manual
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Yamaha WR250F 2023 Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
USO E MANUTENZIONE
MANUAL DEL PROPIETARIO
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Leggere attentamente questo manuale prima di utilizzare questo veicolo.
Lea este manual atentamente antes de utilizar este vehículo.
2023
WR250F
WR250F
WR250FP
BAK-28199-52

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  • Page 1 2023 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG USO E MANUTENZIONE MANUAL DEL PROPIETARIO WR250F Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo.
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2023 OWNER’S MANUAL WR250F Read this manual carefully before operating this vehicle. WR250F WR250FP BAK-28199-52-E0...
  • Page 4 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada in addition to notifying Yamaha Motor Canada Ltd, Canada. If Transport Canada receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 5 EAM20080 WR250F WR250FP OWNER’S MANUAL ©2023 by Yamaha Motor Co., Ltd. First edition, July 2022 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
  • Page 6 EAM20081 IMPORTANT Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

  • Page 9: General Information

    GENERAL INFORMATION SAFETY INFORMATION..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING: ......1-1 LOCATION OF IMPORTANT LABELS ............1-4 DESCRIPTION....................1-7 IDENTIFICATION....................1-8 VEHICLE IDENTIFICATION NUMBER ............1-8 ENGINE SERIAL NUMBER ...............1-8 VEHICLE EMISSION CONTROL INFORMATION LABEL......1-8 INCLUDED PARTS...................1-9 NIPPLE WRENCH..................1-9 HANDLEBAR PROTECTOR ..............1-9 FUEL HOSE JOINT COVER ..............1-9 POWER TUNER (Except for Canada) ............1-9 COUPLER FOR CONNECTING OPTIONAL PART (For Canada) ..1-10...
  • Page 10 BREAK-IN PROCEDURES ..............1-23 SHIFTING....................1-23 MAINTENANCE AFTER BREAK-IN ..............1-25 MAJOR MAINTENANCE................1-25 AIR FILTER MAINTENANCE ..............1-25 TORQUE-CHECK POINTS................1-26 MOTORCYCLE CARE AND STORAGE ............1-28 CARE......................1-28 STORAGE ....................1-29...

  • Page 11: Safety Information

    Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
  • Page 12 1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
  • Page 13 SAFETY INFORMATION Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...

  • Page 14: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 1, 2, 3 4, 5, 6 7, 8 9, 10, 11...
  • Page 15 LOCATION OF IMPORTANT LABELS...
  • Page 16 LOCATION OF IMPORTANT LABELS AUS, NZL, ZAF...

  • Page 17: Description

    DESCRIPTION EAM20086 DESCRIPTION 3, 4 13.Fuel tank 1. Clutch lever 14.Headlight 2. Multi-function display 15.Radiator 3. Engine trouble warning light “ ” 16.Coolant drain bolt 4. Fuel level warning light “ ” 17.Oil level check window 5. Front brake lever 18.Rear brake pedal 6.

  • Page 18: Identification

    There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive identi- fication of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.

  • Page 19: Specifications

    INCLUDED PARTS EAM20088 EWA20460 INCLUDED PARTS WARNING • Do not operate the engine in a closed area. EAM30005 The exhaust gas is poisonous. NIPPLE WRENCH • Never let flames near the servicing area. The nipple wrench “1” is used to tighten the spoke.

  • Page 20: Coupler For Connecting Optional Part (For Canada)

    INCLUDED PARTS pressed or while the engine is running (the CCU is activated), input the CCU serial num- ber into your smartphone and establish a wireless connection. 3. Activate the Power Tuner app. If the CCU wireless network cannot be detected, operate the start switch again.

  • Page 21: Important Information

    YAMAHA genuine Refer to “CARE” on page 1-28. parts and recommended parts.

  • Page 22: Instrument And Control Functions

    ” This warning light comes on or flashes if a prob- lem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the vehicle. The electrical circuit of the warning light can be checked by pushing the start switch.

  • Page 23: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS Shift up points You can use the Power Tuner app to adjust the 1st  2nd map settings. 20 km/h (12 mph) When the mode switch “1” is illuminated, map 2 2nd  3rd is selected. 30 km/h (19 mph) 3rd ...

  • Page 24: Sidestand

    INSTRUMENT AND CONTROL FUNCTIONS EAM30190 SIDESTAND • To remove the fuel tank cap cover, insert fin- This sidestand “1” is used to support only the gers under part “a”, and then use both hands to machine when standing. lift it up towards the rear of the vehicle. EWA18980 •...

  • Page 25: Multi-Function Display

    MULTI-FUNCTION DISPLAY EAM20150 MULTI-FUNCTION DISPLAY EWA19000 WARNING Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the 3 4 5 6 7 following: • Speedometer • Clock Changing the display item •...
  • Page 26 MULTI-FUNCTION DISPLAY • Starting measurement consists of the following two starts, either of which can be selected. Manual start: Starting measurement by the rider himself op- erating the button. Auto start: Starting timer measurement automatically on detection of the movement of the machine. (When long pushing the A button and B button simultaneously, the measurement will become Auto start...

  • Page 27: Setting Mode

    MULTI-FUNCTION DISPLAY 3. Push the A button and B button simultane- Setting the backlight brightness ously once again to restart the measurement. 1. Push the B button and adjust the brightness. 2. When the B button is pushed, the number of segments will increase one by one as the me- ter brightness increases.
  • Page 28 MULTI-FUNCTION DISPLAY 2. Push the A button to set the hour, and then Setting the unit change shift to the minute setting. 1. Push the B button to change the units of the speedometer and fuel. The unit display will change in the following order: Except for U.K.
  • Page 29 MULTI-FUNCTION DISPLAY 1. Push the B button to adjust the setting. A long push on the button will fast-forward the setting value. • The initial setting value of the accumulated fuel consumption correction is set as 100 %. • Pushing the B button at a setting value of 110 % will return the setting to 90 %.

  • Page 30: Function Diagram

    MULTI-FUNCTION DISPLAY EAM30330 FUNCTION DIAGRAM The following diagram illustrates the multi-function display regarding the direction and operation condi- tion involved in each of its functions. A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions.
  • Page 31 MULTI-FUNCTION DISPLAY A. A short push on the button changes the oper- ation in the arrowed direction. B. A short push on the button changes the oper- ation in both arrowed directions. C. A long push on the button changes the oper- ation in the arrowed direction.

  • Page 32: Starting And Break-In

    Your Yamaha engine has been designed to use unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 95 or higher.

  • Page 33: Starting A Warm Engine

    STARTING AND BREAK-IN 1. After warming up the engine, drive it for about 20 minutes at a throttle opening of 1/2 or less. This model is equipped with an engine auto-stop system. The engine stops automatically if left idling for 7 minutes. If the engine stops, push the start switch to restart the engine.
  • Page 34 STARTING AND BREAK-IN 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. Recommended shift points The recommended shift points during accelera- tion and deceleration are shown in the table be- low. Shift up points 1st ...

  • Page 35: Maintenance After Break-In

    Pour the specified amount of the recom- AIR FILTER MAINTENANCE mended oil. Apply the Yamaha foam air filter oil or other qual- • Generator ity foam air filter oil to the element. (Excess oil in Check for looseness in mounted areas of the the element may adversely affect engine start- generator rotor and the stator coil assembly.

  • Page 36: Torque-Check Points

    TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Fuel tank to frame Frame to rear frame Frame to engine protector Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame...
  • Page 37 TORQUE-CHECK POINTS Shift pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover...

  • Page 38: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE any longer than instructed. Also, thorough- EAM20126 MOTORCYCLE CARE AND STOR- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- tion spray. • Improper cleaning can damage plastic EAM30200 CARE parts (such as cowlings, panels, wind- While the open design of a motorcycle reveals...

  • Page 39: Storage

    Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
  • Page 40 MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “CARE” on page 1-28. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
  • Page 41 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-4 ELECTRICAL SPECIFICATIONS ..............2-7 TIGHTENING TORQUES .................2-8 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-8 ENGINE TIGHTENING TORQUES............2-9 CHASSIS TIGHTENING TORQUES............2-12...

  • Page 42: Specifications

    GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model BAKF (AUS, NZL, ZAF) BAKH (CAN) BAKJ (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR) Dimensions Overall length 2175 mm (85.6 in) Overall width 825 mm (32.5 in)

  • Page 43: Engine Specifications

    ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 250 cm³ Number of cylinders Single cylinder Bore  stroke 77.0  53.6 mm (3.03  2.11 in) Compression ratio 13.8 : 1 Starting system Electric starter Fuel...
  • Page 44 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Idling condition Engine idling speed 1900–2100 r/min Exhaust gas sampling point Sampling port on the exhaust pipe 70–80 C (158–176 F)

  • Page 45: Chassis Specifications

    CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 27.2  Caster angle Trail 116 mm (4.6 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 Rear wheel Wheel type Spoke wheel Rim size 18 x 2.15 Front tire Type With tube Size 80/100-21 51M (CAN)
  • Page 46 Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 496.0 cm³ (16.77 US oz, 17.49 Imp.oz) Quantity (right) 496.0 cm³ (16.77 US oz, 17.49 Imp.oz)
  • Page 47 CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size Chain type Sealed type Number of links...

  • Page 48: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAM20130 ELECTRICAL SPECIFICATIONS Battery Model YTZ7S(F) Voltage, capacity 12 V, 6.0 Ah (10 HR) Headlight Bulb type Halogen bulb Bulb wattage Headlight HS1, 35.0 W/35.0 W Brake/tail light Meter lighting EL (Electroluminescent) Indicator light Fuel level warning light Engine trouble warning light Fuse(s) Main fuse...

  • Page 49: Tightening Torques

    TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 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- tern and progressive stages until the specified tightening torque is reached.
  • Page 50 TIGHTENING TORQUES EAM30203 ENGINE TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head stud bolt (exhaust 7 N·m (0.7 kgf·m, 5.2 lb·ft) pipe)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Clutch cable locknut (clutch cable 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) adjuster) Clutch cable locknut (engine side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Exhaust pipe nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe protector screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Exhaust pipe bracket bolt...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Generator rotor nut 65 N·m (6.5 kgf·m, 48 lb·ft) Stator coil screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) Crankshaft position sensor bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Stator coil assembly lead holder bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft)
  • Page 53 TIGHTENING TORQUES EAM30204 CHASSIS TIGHTENING TORQUES - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q’ty Tightening torques Remarks size Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft)  Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) ...
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Front brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Rear brake disc bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) / Footrest bracket bolt 55 N·m (5.5 kgf·m, 41 lb·ft) Sidestand bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Rear brake pedal bolt...
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torques Remarks size Drive chain tensioner bolt (lower 16 N·m (1.6 kgf·m, 12 lb·ft) side) Bolt (drive chain support) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain support nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain guide bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Fuel tank bolt (front side)
  • Page 56 TIGHTENING TORQUES 2-15...
  • Page 57 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 MAINTENANCE INTERVALS FOR COMPETITION USE ......3-3 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-6 GENERAL INSPECTION AND MAINTENANCE........3-6 ENGINE ......................3-7 ADJUSTING THE VALVE CLEARANCE ...........3-7 CHECKING THE ENGINE IDLING SPEED ..........3-8 CHECKING THE THROTTLE GRIP............3-8...
  • Page 58 CHECKING AND TIGHTENING THE SPOKES........3-29 CHECKING THE WHEELS ..............3-29 CHECKING THE CHASSIS FASTENERS ..........3-29 CHECKING AND LUBRICATING THE CABLES ........3-29 LUBRICATING THE BRAKE LEVER ............3-30 LUBRICATING THE CLUTCH LEVER.............3-30 LUBRICATING THE PEDAL ..............3-30 CHECKING THE SIDESTAND..............3-30 LUBRICATING THE SIDESTAND............3-30 ELECTRICAL SYSTEM..................3-31 CHECKING AND CHARGING THE BATTERY........3-31 CHECKING THE FUSES .................3-31 REPLACING THE HEADLIGHT BULB.............3-31...

  • Page 59: Periodic Maintenance

    • From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 60 • Replace if necessary. Rear suspension • Apply molybdenum disulfide grease lightly.   18 * link pivots • Apply Yamaha chain and cable lube or engine oil    19 * Control cables 10W-30 thoroughly. • Check operation and free play.

  • Page 61: Maintenance Intervals For Competition Use

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 62 PERIODIC MAINTENANCE Every Every After Every Item Routine third race fifth race break-in race required (or 500 km) (or 1000 km) • Inspect score marks.  • Inspect wear. 11 * Cylinder  • Replace. • Inspect housing, friction plate, ...
  • Page 63 PERIODIC MAINTENANCE Every Every After Every Item Routine third race fifth race break-in race required (or 500 km) (or 1000 km)   • Inspect and adjust. 30 * Front fork(s) • Replace oil.   • Replace oil seal. ...

  • Page 64: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...

  • Page 65: Engine

    Turn the crankshaft counterclockwise with sic knowledge and skill concerning the servic- a wrench. ing of Yamaha motorcycles (e.g., Yamaha b. Align the top dead center (TDC) mark “a” dealers, service engineers, etc.). Those who on the generator rotor with the alignment have little knowledge and skill concerning ser- mark “b”...

  • Page 66: Checking The Engine Idling Speed

    1. Start the engine, and warm this up until the oil has reached the specified temperature. 2. Measure the coolant temperature using the Yamaha diagnostic tool. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03264 FI diagnostic tool sub–lead...

  • Page 67: Checking The Spark Plug

    ENGINE 2. Adjust: 2. Remove: • Throttle grip free play • Holder • Spark plug cap a. Loosen the locknut “1”. b. Turn the adjuster “2” until the specified • Spark plug throttle grip free play is obtained. ECA24410 NOTICE c.

  • Page 68: Checking The Engine Oil Level

    ENGINE ECA24290 NOTICE • Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. • Do not allow foreign material to enter the crankcase. Recommended brand YAMALUBE 7.
  • Page 69 ENGINE d. Install the oil strainer. Oil strainer bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Install: • Gasket • Drain bolt Drain bolt 20 N·m (2.0 kgf·m, 15 lb·ft) 4. If the oil filter element is also to be replaced, 7.

  • Page 70: Adjusting The Clutch Lever Free Play

    ENGINE EWA19120 WARNING When the engine is started with the check bolt removed, oil will spout; therefore, al- ways loosen it before the checkup. 2. Adjust: 1 1 1 • Clutch lever free play Handlebar side a. Turn the adjuster “1” until the specified clutch lever free play is obtained.

  • Page 71: Cleaning The Air Filter Element

    • Air filter element Damage  Replace. 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil a. Put the air filter element into a plastic bag and drip the filter oil into the bag.

  • Page 72: Checking The Throttle Body Joint

    ENGINE ter case. • Check that the air filter element is turned up be- tween the air filter guide and air filter case and that there is no gap. Gap  Reinstall. 10.Install: • Fuel tank cap cover EAM30335 CHECKING THE THROTTLE BODY JOINT 1.

  • Page 73: Checking The Cylinder Head Breather Hose

    ENGINE 2. Remove: • Exhaust pipe protector 3. Check: • Exhaust pipe 1 • Exhaust pipe 2 • Silencer Crack/damage  Replace. 4. Check: • Spark arrester Carbon deposits  Clean. 5. Clean: 3. Install: • Spark arrester • Fuel tank a.

  • Page 74: Checking The Coolant Level

    ENGINE Exhaust pipe nut “1” Tap the spark arrester lightly, then use a wire 10 N·m (1.0 kgf·m, 7.4 lb·ft) brush to remove any carbon deposits. Exhaust pipe clamp bolt “2” 12 N·m (1.2 kgf·m, 8.9 lb·ft) f. Install the spark arrester gasket (new gas- Exhaust pipe clamp bolt “3”...

  • Page 75: Checking The Cooling System

    ENGINE 1. Stand the vehicle upright on a level surface. 2. Check: 2. Remove: • Radiator • Radiator cap “1” • Radiator hose Crack/damage  Replace. 3. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30212 CHANGING THE COOLANT EWA13030...
  • Page 76 ENGINE • Coolant drain bolt Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine Radiator (including all routes) 0.93 L (0.98 US qt, 0.82 Imp.qt) Coolant mixing ratio 1:1 (Coolant:Water) EWA13040...

  • Page 77: Chassis

    CHASSIS system. Air in the brake system will consid- EAM20136 CHASSIS erably reduce braking performance. ECA13490 EAM30479 ADJUSTING THE FRONT DISC BRAKE NOTICE After adjusting the brake lever position, There should be no free play at the brake lever make sure there is no brake drag. end.

  • Page 78: Checking The Front Brake Pads

    CHASSIS Specified brake fluid DOT 4 EAM30232 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. A. Front brake 1. Operate the brake. B. Rear brake 2. Check: • Rear brake pad EWA13090 Wear indicator grooves “1” almost disap- WARNING •...

  • Page 79: Checking The Brake Operation

    CHASSIS 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • Brake hose Brake fluid leakage  Replace the damaged hose. EAM30499 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly  Check the brake system.

  • Page 80: Drive Chain Slack

    CHASSIS Bleed screw Drive chain slack (Maintenance 5 N·m (0.5 kgf·m, 3.7 lb·ft) Stand) 50.0–60.0 mm (1.97–2.36 in) j. Pour brake fluid to the reservoir up to the specified level. Adjusting the drive chain slack Refer to “CHECKING THE BRAKE FLUID EWA13120 WARNING LEVEL”...

  • Page 81: Checking And Adjusting The Steering Head

    CHASSIS clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings.

  • Page 82: Lubricating The Steering Head

    Unsmooth operation  Correct or replace. Refer to “FRONT FORK” on page 4-16. If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 5. Check: • Protector guide “1”...

  • Page 83: Adjusting The Front Fork Legs

    CHASSIS EAM30239 ADJUSTING THE FRONT FORK LEGS EWA19180 WARNING • Always adjust the left and right front forks evenly. If this is not done, the vehicle may have poor stability. • Securely support the vehicle so that there is no danger of it falling over. Rebound damping ECA24340 Compression damping...

  • Page 84: Checking The Rear Shock Absorber Assembly

    CHASSIS 3. Check: • Rear shock absorber assembly smooth ac- tion • Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly. Unsmooth operation ...
  • Page 85 CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 30 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 11 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “a”...

  • Page 86: Checking The Swingarm Operation

    CHASSIS Fast compression damping Slow compression damping Minimum (soft) Minimum (soft) 2 turn(s) in direction “b”* 20 click(s) in direction “b”* Standard Standard 1-3/4 turn(s) in direction “b”* 11 click(s) in direction “b”* Maximum (hard) Maximum (hard) 0 turn(s) in direction “b”* 0 click(s) in direction “b”* * With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-...

  • Page 87: Checking And Tightening The Spokes

    CHASSIS Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi) Rear 100 kPa (1.00 kgf/cm², 15 psi) • Check the tire while it is cold. • Because if the bead stopper tightening nut is loose when the tire pressure is low, the tire could slip off the rim, thus be sure to check and Spoke nipple wrench (6–7) 90890-01521...

  • Page 88: Lubricating The Brake Lever

    CHASSIS place damaged outer cable and inner cables Recommended lubricant as soon as possible. Lithium-soap-based grease 1. Check: • Outer cable Damage  Replace. 2. Check: • Cable operation Rough movement  Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit-...

  • Page 89: Electrical System

    ELECTRICAL SYSTEM EAM20137 ELECTRICAL SYSTEM EAM30256 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-4. EAM30505 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 7-3. 4. Install: EAM30339 • Headlight bulb REPLACING THE HEADLIGHT BULB Fasten the new headlight bulb with the head- EWA13320 light bulb holder.
  • Page 90 ELECTRICAL SYSTEM 3-32...
  • Page 91 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT ................4-1 INSTALLING THE AIR SCOOP ..............4-1 REMOVING THE SIDE COVER..............4-1 INSTALLING THE SIDE COVER ...............4-1 FRONT WHEEL....................4-3 REMOVING THE FRONT WHEEL.............4-3 INSTALLING THE FRONT WHEEL ............4-3 REAR WHEEL ....................4-5 REMOVING THE REAR WHEEL ...............4-5 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ....4-5 INSTALLING THE REAR WHEEL..............4-5 FRONT BRAKE ....................4-7...
  • Page 92 CHAIN DRIVE....................4-32 REMOVING THE DRIVE CHAIN..............4-32 CHECKING THE DRIVE CHAIN ..............4-32 CHECKING THE DRIVE SPROCKET............4-33 CHECKING THE REAR WHEEL SPROCKET.........4-33 INSTALLING THE DRIVE CHAIN ............4-33...

  • Page 93: General Chassis

    GENERAL CHASSIS EAM20094 GENERAL CHASSIS EAM30016 REMOVING THE SEAT d d d The fuel tank cap cover and the seat are coupled with each other with a plastic band. When removing the seat, always remove the fuel tank cap cover beforehand. 1.
  • Page 94 GENERAL CHASSIS a a a a. Projection b. Slot c. Rib (side cover) d. Rib (rear fender)

  • Page 95: Front Wheel

    FRONT WHEEL sensor. Foreign materials cause damage to EAM20095 FRONT WHEEL the front wheel sensor rotor and front wheel sensor. EAM30017 REMOVING THE FRONT WHEEL ECA22340 When installing the front wheel sensor, check NOTICE the wheel sensor lead for twists. •...
  • Page 96 FRONT WHEEL 6. Measure: • Distance “a” (between the wheel sensor rotor “1” and front wheel sensor “2”) Out of specification  Check the wheel bear- ing for looseness, and the front wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®...

  • Page 97: Rear Wheel

    REAR WHEEL EAM20096 REAR WHEEL EAM30022 REMOVING THE REAR WHEEL 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: b.
  • Page 98 REAR WHEEL drive chain. Drive chain slack (Maintenance Stand) 50.0–60.0 mm (1.97–2.36 in) Refer to “DRIVE CHAIN SLACK” on page 3-22. 3. Install: • Drive chain puller (left) “1” • Rear wheel axle “2” • Install the drive chain puller (left), and insert the 6.

  • Page 99: Front Brake

    FRONT BRAKE EAM20097 FRONT BRAKE Brake pad lining thickness limit 1.0 mm (0.04 in) EAM30519 REPLACING THE FRONT BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1.
  • Page 100 FRONT BRAKE e. Install the brake caliper “4” and tighten the pad pin “5”. Bolt (brake caliper) 28 N·m (2.8 kgf·m, 21 lb·ft) Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) f. Install the pad pin plug “6”. Pad pin plug 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4.

  • Page 101: Rear Brake

    REAR BRAKE EAM20098 REAR BRAKE Brake pad lining thickness limit 1.0 mm (0.04 in) EAM30523 REPLACING THE REAR BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1.
  • Page 102 REAR BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. e. Install the brake caliper “5” and the rear wheel “6”. f. Tighten the pad pin “7”. Pad pin 17 N·m (1.7 kgf·m, 13 lb·ft) g. Install the pad pin plug “8” and the protector “9”.

  • Page 103: Handlebar

    HANDLEBAR EAM20099 HANDLEBAR EAM30052 REMOVING THE HANDLEBAR 1. Stand the vehicle upright on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Clutch switch “1” EAM30053 CHECKING THE HANDLEBAR 1.
  • Page 104 HANDLEBAR ECA14250 NOTICE • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
  • Page 105 HANDLEBAR • Clamp “3” Engine stop switch screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) Screw (mode switch) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) • The engine stop switch “1” and the mode switch “2” should be installed according to the dimensions shown.
  • Page 106 HANDLEBAR Apply the lithium-soap-based grease on the throttle grip sliding surface. 11.Install: • Throttle cable “1” Slightly coat the end of throttle cable and inside of throttle grip with lithium-soap-based grease. Then, mount the throttle grip onto the handlebar. 13.Install: •...
  • Page 107 HANDLEBAR 15.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-8. Throttle grip free play 3.0–6.0 mm (0.12–0.24 in) 4-15...

  • Page 108: Front Fork

    FRONT FORK EAM20100 FRONT FORK • While compressing the inner tube “2”, set the cap bolt ring wrench “4” between the inner tube EAM30055 and locknut “3”. REMOVING THE FRONT FORK LEGS • Hold the locknut and remove the adjuster. 1.

  • Page 109: Checking The Front Fork Legs

    FRONT FORK dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Check: • Outer tube Scratches/wear/damage  Replace. 3. Measure: • Fork spring free length “a” 5. Remove: Out of specification ...

  • Page 110: Assembling The Front Fork Legs

    1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 7. Check: 216 cm³ (7.30 US oz, 7.62 Imp.oz) • Adjuster “1”...
  • Page 111 FRONT FORK 4. Measure: 6. Loosen: • Oil level (left and right) “a” • Compression damping force adjuster “1” Out of specification  Regulate. • Before loosening the damping force adjuster, Standard oil level record the setting position. 145–148 mm (5.71–5.83 in) •...
  • Page 112 FRONT FORK Base valve 28 N·m (2.8 kgf·m, 21 lb·ft) Hold the damper assembly with the cap bolt ring wrench “2” and use the cap bolt wrench “3” to tighten the base valve. Cap bolt wrench 90890-01500 Cap bolt wrench 12.Allow the overflowing oil to escape at the hole YM-01500 “a”...
  • Page 113 FRONT FORK • Apply the lithium-soap-based grease on the dust seal lip and oil seal lip. • Apply the fork oil on the inner tube. • Install the scraper to the inner tube as shown in the illustration. • When installing the oil seal, use vinyl seat “a” with fork oil applied to protect the oil seal lip.
  • Page 114 FRONT FORK Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 22.Measure: • Distance “a” Out of specification  Turn the locknut to specification. Distance “a” 19.Install: 16 mm (0.63 in) or more • Stopper ring “1” Between the damper assembly “1”...
  • Page 115 FRONT FORK ECA24560 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube. Be careful not to dam- age the inner tube. 27.Measure: • Gap “a” between the adjuster “1” and the locknut “2”...

  • Page 116: Installing The Front Fork Legs

    55 N·m (5.5 kgf·m, 41 lb·ft) LOCTITE® 32.Install: • Protector guide “1” 30.Fill: • Front fork leg Recommended oil Yamaha Suspension Oil S1 Standard oil amount 290 cm³ (9.80 US oz, 10.23 EAM30059 INSTALLING THE FRONT FORK LEGS Imp.oz) 1. Install: Extent of adjustment •...
  • Page 117 FRONT FORK Cap bolt ring wrench 90890-01501 Cap bolt ring wrench YM-01501 5. Install: • Speed sensor lead “1” • Front brake hose “2” • Plate “3” (to the left front fork protector) 3. Adjust: Plate bolt • Front fork top end “a” 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Front fork top end (standard) “a”...
  • Page 118 FRONT FORK 8. Adjust: • Compression damping force Turn in the damping adjuster “1” finger-tight and then turn out to the originally set position. 4-26...

  • Page 119: Steering Head

    STEERING HEAD c. Install a new bearing race. EAM20101 STEERING HEAD ECA14270 NOTICE EAM30060 If the bearing race is not installed properly, REMOVING THE LOWER BRACKET the steering head pipe could be damaged. 1. Use a maintenance stand to raise the front wheel off the ground.
  • Page 120 STEERING HEAD 2. Install: • Bearing race • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
  • Page 121 STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...

  • Page 122: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY absorber assembly. EAM20102 REAR SHOCK ABSORBER AS- • Spring SEMBLY Damage/wear  Replace. • Spring guide Damage/wear  Replace. EAM30065 REMOVING THE REAR SHOCK ABSORBER • Bearing ASSEMBLY Damage/wear  Replace. 1. Use a maintenance stand to raise the rear •...

  • Page 123: Swingarm

    SWINGARM EAM20103 SWINGARM EAM30071 REMOVING THE SWINGARM 1. Use a maintenance stand to raise the rear wheel off the ground. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Measure: • Swingarm side play •...

  • Page 124: Chain Drive

    CHAIN DRIVE EAM20104 CHAIN DRIVE EAM30075 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. Place the vehicle on a maintenance stand so that the rear wheel is elevated.

  • Page 125: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive sprocket EAM30078 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-5. EAM30079 INSTALLING THE DRIVE CHAIN 1. Install: 4. Check: • Drive chain •...
  • Page 126 CHAIN DRIVE ECA24590 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its.
  • Page 127 ENGINE EXHAUST SYSTEM ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER.........5-1 CLUTCH ......................5-3 REMOVING THE CLUTCH ................5-3 CHECKING THE FRICTION PLATES............5-3 CHECKING THE CLUTCH PLATES ............5-3 CHECKING THE CLUTCH SPRINGS............5-3 CHECKING THE CLUTCH HOUSING ............5-3 CHECKING THE CLUTCH BOSS..............5-4 CHECKING THE PRESSURE PLATE ............5-4 CHECKING THE PUSH LEVER SHAFT............5-4 CHECKING THE PUSH RODS ..............5-4 CHECKING THE PRIMARY DRIVE GEAR..........5-4...

  • Page 128: Exhaust System

    EXHAUST SYSTEM EAM20199 EXHAUST SYSTEM 2 mm (0.08 in) EAM30167 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket • Exhaust pipe 1 “1” • Nut (exhaust pipe 1) “2” 3. Install: Nut (exhaust pipe 1) • Clamp 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
  • Page 129 EXHAUST SYSTEM joints are inserted in position. • Make sure that the exhaust pipe clamp “1” does not ride on the projection “a” on the ex- haust pipe “2” or silencer “3”. Be sure to insert the projection “b” into the slot in the exhaust pipe (or silencer).

  • Page 130: Clutch

    CLUTCH EAM20111 CLUTCH Friction plate 1 thickness 2.70–2.90 mm (0.106–0.114 in) Wear limit EAM30108 REMOVING THE CLUTCH 2.60 mm (0.102 in) 1. Straighten the clutch boss nut rib “a”. Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in) Wear limit 2.62 mm (0.103 in) EAM30110 CHECKING THE CLUTCH PLATES 1.

  • Page 131: Checking The Clutch Boss

    CLUTCH ratic clutch operation. EAM30484 CHECKING THE PUSH RODS 1. Check: • Push rod 1 “1” • Bearing/Washer “2” • Push rod 2 “3” • Ball “4” Cracks/damage/wear  Replace. 1 1 1 EAM30113 CHECKING THE CLUTCH BOSS 1. Check: •...
  • Page 132 CLUTCH Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Right crankcase cover “1” • Right crankcase cover bolt “2” Right crankcase cover bolt 5. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Conical washer “1” •...
  • Page 133 CLUTCH (to the push rod 1 “4”) Apply the engine oil on the bearing, washer and push rod 1. 8. Install: • Push rod 2 “1” • Ball “2” • Push rod 1 “3” Apply the engine oil on the push rod 1, 2 and 6.
  • Page 134 CLUTCH 10.Install: • Clutch spring • Clutch spring bolt Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross pattern. 11.Install: • Gasket “1” 12.Install: • Clutch cover • Clutch cover bolt Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten the bolts in stages and in a crisscross...
  • Page 135 FUEL SYSTEM FUEL TANK ......................6-1 REMOVING THE FUEL TANK ..............6-1 INSTALLING THE FUEL TANK..............6-1...
  • Page 136 FUEL TANK EAM20140 FUEL TANK EAM30263 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose coupler EWA19370 WARNING Cover the fuel hose connection with a cloth when disconnecting it.
  • Page 137 FUEL TANK 3. Connect: • Fuel pump coupler 4. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 138 FUEL TANK...
  • Page 139 ELECTRICAL SYSTEM FUEL INJECTION SYSTEM................7-1 ECU SELF-DIAGNOSTIC FUNCTION............7-1 ELECTRICAL COMPONENTS.................7-3 CHECKING THE BULBS AND BULB SOCKETS ........7-3 CHECKING THE FUSES ................7-3 CHECKING AND CHARGING THE BATTERY..........7-4...

  • Page 140: Fuel Injection System

    FUEL INJECTION SYSTEM EAM20145 FUEL INJECTION SYSTEM EAM30352 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 141 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor 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 142: Electrical Components

    Check each bulb socket for continuity in the c. If the fuse immediately blows again, have same manner as described in the bulb section; a Yamaha dealer check the electrical sys- however, note the following. tem. a. Install a good bulb into the bulb socket.

  • Page 143: Checking And Charging The Battery

    ELECTRICAL COMPONENTS ing a fuse with the wrong amperage rating charging method. If the battery is over- may cause extensive damage to the electri- charged, the electrolyte level will drop con- cal system, cause the lighting and ignition siderably. Therefore, take special care systems to malfunction and could possibly when charging the battery.
  • Page 144 ELECTRICAL COMPONENTS charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted.
  • Page 145 ELECTRICAL COMPONENTS the standard charging current written on after leaving the battery unused for more the battery. than 30 minutes. 12.8 V or more --- Charging is complete. If the current is lower than the standard charging 12.7 V or less --- Recharging is required. current written on the battery, set the charging Under 12.0 V --- Replace the battery.
  • Page 146 ELECTRICAL COMPONENTS...

  • Page 147: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ................8-1 TROUBLESHOOTING OF ENGINE (fault code not detected)....8-1 TROUBLESHOOTING OF CLUTCH............8-4 TROUBLESHOOTING OF TRANSMISSION ..........8-6 TROUBLESHOOTING OF COOLING SYSTEM ........8-7 TROUBLESHOOTING OF BRAKE ............8-8 TROUBLESHOOTING OF SUSPENSION..........8-8 TROUBLESHOOTING OF STEERING/HANDLING ........8-10 TROUBLESHOOTING OF CHARGING SYSTEM ........8-11 TROUBLESHOOTING OF LIGHTING SYSTEM........8-11 TROUBLESHOOTING OF SIGNALING SYSTEM ........8-11 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ...8-12...

  • Page 148: Troubleshooting

    • The following guide for troubleshooting represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motor- cycle properly.
  • Page 149 Low fuel pressure Clogged fuel pump Clean or replace the fuel pump. Cracks or damage in fuel pump Replace the fuel pump. Have a Yamaha dealer check the Fuel pump malfunction electrical system. Failed or clogged fuel injector Replace the fuel injector.
  • Page 150 TROUBLESHOOTING Symptom Possible cause Actions Worn camshaft lobe Replace the camshaft. Water or foreign material in fuel, Change fuel. degraded fuel Contaminated throttle body or Clean the throttle body. clogged internal passage Incorrectly adjusted throttle cable Adjust the throttle grip free play. Incorrectly adjusted idling speed Adjust the idle screw.

  • Page 151: Troubleshooting Of Clutch

    TROUBLESHOOTING Symptom Possible cause Actions Replace the piston and piston Worn or damaged piston ring rings as a set. Replace the piston and piston Worn or damaged piston rings as a set. Replace the piston and piston pin Worn piston (piston pin hole) as a set.
  • Page 152 TROUBLESHOOTING Symptom Possible cause Actions Replace the clutch springs as a Faulty clutch spring set. Warped pressure plate Replace the pressure plate. Replace the friction plates as a Swollen friction plate set. Warped clutch plate Replace the clutch plates as a set. Bent pull rod (outer pull type) Replace the pull rod.

  • Page 153: Troubleshooting Of Transmission

    TROUBLESHOOTING EAM30511 TROUBLESHOOTING OF TRANSMISSION Symptom Possible cause Actions Clutch drags Refer to “Clutch drags”. Adjust the shift rod installation Improperly adjusted shift rod length. Bent shift shaft Replace the shift shaft. Foreign object in a shift drum Remove foreign object from shift groove drum groove.

  • Page 154: Troubleshooting Of Cooling System

    Clogged radiator fin Clean the radiator fin. Repair the radiator fin or replace Bent or damaged radiator fin the radiator. Have a Yamaha dealer check the Overheating Faulty radiator fan motor electrical system. Damaged or faulty water pump Replace the water pump.

  • Page 155: Troubleshooting Of Brake

    TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
  • Page 156 TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...

  • Page 157: Troubleshooting Of Steering/Handling

    TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.

  • Page 158: Troubleshooting Of Charging System

    EAM30516 TROUBLESHOOTING OF CHARGING SYSTEM Symptom Possible cause Actions Battery is not charged Have a Yamaha dealer check the electrical system. EAM30525 TROUBLESHOOTING OF LIGHTING SYSTEM Symptom Possible cause Actions Headlight does not come on Have a Yamaha dealer check the electrical system.

  • Page 159: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAM20174 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAM30497 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) Fault code Item Crankshaft position sensor: no normal signals are received from the crankshaft position sen- sor. Intake air pressure sensor: open or short circuit detected. Intake air pressure sensor: hose system malfunction (clogged or detached hose).
  • Page 160 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8-13...

  • Page 161: Tuning

    TUNING CHASSIS ......................9-1 SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) ....................9-1 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ....9-1 TIRE PRESSURE..................9-1 FRONT FORK SETTING................9-1 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL....9-2 SETTING OF SPRING AFTER REPLACEMENT ........9-2 FRONT FORK SETTING PARTS...............9-3 REAR SUSPENSION SETTING ..............9-3 CHOOSING SET LENGTH ................9-3 SETTING OF SPRING AFTER REPLACEMENT ........9-4...

  • Page 162: Chassis

    CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 5GS-25448-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 5TJ-25450-80 REDUCTION RATIO (SPROCKET) (STD) BAK-25451-00 Secondary reduction ratio = Number of 5TJ-25452-80 rear wheel sprocket teeth/Number of drive sprocket teeth Secondary reduction ratio 3.923 (51/13) <Requirement for selection of secondary gear reduction ratio>...

  • Page 163: Change In Amount And Characteristics Of Fork Oil

    SETTING OF SPRING AFTER REPLACEMENT Recommended oil As the front fork setting can be easily affected by Yamaha Suspension Oil S1 the rear suspension, take care so that the front Standard oil amount and the rear are balanced (in position etc.) when 290 cm³...

  • Page 164: Front Fork Setting Parts

    CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring STD Spring rate N/mm 2.

  • Page 165: Setting Of Spring After Replacement

    CHASSIS EAM30177 EAM30178 SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS REPLACEMENT • Rear shock spring “1” After replacement, be sure to adjust the spring to STD Spring rate the set length [sunken length 90–100 mm (3.5– N/mm 3.9 in)] and set it. Spring 1.
  • Page 166 CHASSIS • Spring preload adjusting positions Spring preload adjusting positions Minimum Position in which the spring is turned in 1.5 mm (0.06 in) from its free length. Standard Position in which the spring is turned in 8.0 mm (0.31 in) from its free length.

  • Page 167: Suspension Setting (Front Fork)

    CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

  • Page 168: Suspension Setting (Rear Shock Absorber)

    CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend-   ing to lower front Set sunken length for 95–100 posture Balance with rear...
  • Page 169 CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force   damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
  • Page 170 CHASSIS...
  • Page 171 15. CCU (Communication Control Black/White Unit) (Except for Canada) Black/Yellow 16. Resistor Br/W Brown/White 17. Diode 2 Green/Black 18. Yamaha diagnostic tool cou- Green/White pler Green/Yellow 19. ECU (Engine Control Unit) Blue/Black 20. Ignition coil Blue/Green 21. Spark plug Blue/Red 22.
  • Page 172 PRINTED IN JAPAN...
  • Page 174 Original instructions Notice originale Originalbetriebsanleitung Istruzioni originali Manual original PRINTED IN JAPAN 2022.07-0.4×1 ! (E, F, G, H, S)
  • Page 175 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO R R R Br/W Br Br B B B R R R/L Br Br Br Br/W (Gy) B/L Gy Gy B (Gy) R,R/W R,R/Y...
  • Page 176 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 WR250F/WR250FP 2023 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO (Gy) (Gy) PUSH FREE (Dl)

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