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Yamaha Manuals
Motorcycle
WR250FM 2021
Owner's service manual
Yamaha WR250FM 2021 Owner's Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety Information
For Safety, be Sure to Obey the Following
Location of Important Labels
Description
Identification
Vehicle Identification Number
Engine Serial Number
Vehicle Emission Control Information Label
Included Parts
Nipple Wrench
Handlebar Protector
Fuel Hose Joint Cover
Coupler for Connecting Optional Part
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Basic Service Information
Electrical System
Special Tools
Instrument and Control Functions
Warning Lights
Engine Stop Switch
Start Switch
Shift Pedal
Front Brake Lever
Rear Brake Pedal
Sidestand
Starter Knob
Fuel Tank Cap
Multi-Function Display
Description
Basic Mode
Changeover to Basic Mode/Race Mode
Race Mode
Function Diagram
Starting and Break-In
Fuel
Handling Note
Starting a Cold Engine
Starting a Warm Engine
Break-In Procedures
Shifting
Maintenance after Break-In
Major Maintenance
Air Filter Maintenance
Torque-Check Points
Motorcycle Care and Storage
Care
Storage
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Cable Routing Diagram
Periodic Checks and Adjustments
Periodic Maintenance
General Maintenance and Lubrication Chart
Introduction
Periodic Maintenance Chart for the Emission Control System
Maintenance Intervals for Competition Use
Pre-Operation Inspection and Maintenance
General Inspection and Maintenance
Engine
Adjusting the Valve Clearance
Valve Clearance Shim Chart
Checking the Engine Idling Speed
Checking the Throttle Grip
Checking the Spark Plug
Checking the Engine Oil Level
Changing the Engine Oil
Adjusting the Clutch Lever Free Play
Cleaning the Air Filter Element
Checking the Throttle Body Joint
Checking the Fuel Line
Checking the Cylinder Head Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Chassis
Adjusting the Front Disc Brake
Adjusting the Rear Disc Brake
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Front Brake Hose
Checking the Rear Brake Hose
Checking the Brake Operation
Bleeding the Hydraulic Brake System
Drive Chain Slack
Lubricating the Drive Chain
Checking and Adjusting the Steering Head
Lubricating the Steering Head
Checking the Front Fork Legs
Adjusting the Front Fork Legs
Checking the Rear Shock Absorber Assembly
Adjusting the Rear Shock Absorber Assembly
Checking the Swingarm Operation
Lubricating the Swingarm Pivot
Checking the Connecting Arm and Relay Arm
Checking the Tires
Checking and Tightening the Spokes
Checking the Wheels
Checking the Wheel Bearings
Checking the Chassis Fasteners
Checking and Lubricating the Cables
Lubricating the Brake Lever
Lubricating the Clutch Lever
Lubricating the Pedal
Checking the Sidestand
Lubricating the Sidestand
Electrical System
Checking and Charging the Battery
Checking the Fuses
Checking the Ignition Timing
Replacing the Headlight Bulb
Chassis
General Chassis
Removing the Seat
Installing the Air Scoop
Removing the Side Cover
Installing the Side Cover
Front Wheel
Removing the Front Wheel
Checking the Front Wheel Sensor and Sensor Rotor
Disassembling the Front Wheel
Checking the Front Wheel
Assembling the Front Wheel
Installing the Front Wheel
Rear Wheel
Removing the Rear Wheel
Disassembling the Rear Wheel
Checking the Rear Wheel
Checking and Replacing the Rear Wheel Sprocket
Assembling the Rear Wheel
Installing the Rear Wheel
Front Brake
Introduction
Checking the Front Brake Disc
Replacing the Front Brake Pads
Removing the Front Brake Caliper
Disassembling the Front Brake Caliper
Checking the Front Brake Caliper
Assembling the Front Brake Caliper
Installing the Front Brake Caliper
Removing the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Removing the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Installing the Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Chain Drive
Removing the Drive Chain
Checking the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Sprocket
Installing the Drive Chain
Engine
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Engine Removal
Removing the Engine
Installing the Engine
Installing the Exhaust Pipe and Muffler
Camshaft
Removing the Camshaft
Checking the Camshaft
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Tensioners
Checking the Decompression System
Installing the Camshafts
Cylinder Head
Removing the Cylinder Head
Checking the Timing Chain Guide (Intake Side)
Checking the Cylinder Head
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Lifters
Installing the Valves
Cylinder and Piston
Removing the Piston
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Installing the Piston and Cylinder
Generator
Removing the Generator
Checking the Generator
Checking the Woodruff Key
Installing the Generator
Starter Clutch
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Push Lever Shaft
Checking the Push Rods
Checking the Primary Drive Gear
Checking the Primary Driven Gear
Installing the Clutch
Shift Shaft
Removing the Segment
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Oil Pump
Removing the Balancer
Checking the Oil Pump
Assembling the Oil Pump
Installing the Oil Pump
Crankcase
Disassembling the Crankcase
Checking the Timing Chain Guide (Exhaust Side)
Checking the Crankcase
Assembling the Crankcase
Crankshaft and Balancer Shaft
Removing the Crankshaft
Checking the Crankshaft
Installing the Crankshaft
Transmission
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Installing the Transmission
Cooling System
Cooling System Diagrams
Radiator
Checking the Radiator
Installing the Radiator
Water Pump
Disassembling the Water Pump
Checking the Water Pump
Assembling the Water Pump
Fuel System
Fuel Tank
Fuel Tank
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Removing the Fuel Pump
Removing the Fuel Tank
Installing the Fuel Pump
Installing the Fuel Tank
Throttle Body
Checking the Fuel Pressure
Checking the Injector
Checking the Throttle Body
Adjusting the Throttle Position Sensor
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2021
OWNER'S SERVICE MANUAL
WR250F
Read this manual carefully before operating this vehicle.
WR250FM
LIT-11626-34-56
BAK-2819U-11
Table of
Contents
Previous
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Page
1
2
3
4
5
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Chapters
Table of Contents
9
Specifications
53
Periodic Checks and Adjustments
87
Chassis
125
Engine
199
Cooling System
279
Fuel System
289
Electrical System
299
Troubleshooting
373
Tuning
389
Table of Contents
Troubleshooting
TROUBLESHOOTING
304
TROUBLESHOOTING
310
TROUBLESHOOTING
314
TROUBLESHOOTING
318
TROUBLESHOOTING
322
TROUBLESHOOTING
326
TROUBLESHOOTING METHOD
331
TROUBLESHOOTING DETAILS (FAULT CODE)
334
TROUBLESHOOTING
356
TROUBLESHOOTING
373
TROUBLESHOOTING
374
TROUBLESHOOTING OF CLUTCH
377
TROUBLESHOOTING OF TRANSMISSION
379
TROUBLESHOOTING OF COOLING SYSTEM
380
TROUBLESHOOTING OF BRAKE
381
TROUBLESHOOTING OF STEERING/HANDLING
383
TROUBLESHOOTING OF CHARGING SYSTEM
384
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