Yamaha WR250FF Manuals

Manuals and User Guides for Yamaha WR250FF. We have 1 Yamaha WR250FF manual available for free PDF download: Owner's Service Manual

Yamaha WR250FF Owner's Service Manual

Yamaha WR250FF Owner's Service Manual (430 pages)

2015

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

Table of Contents

Table of Contents

11
- Important Manual Information
  6
- Safety Information
  7
- How to Use this Manual
  8
- 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
  - Features
    20
    
    Outline of the Fi System
    20
    
    Fi System
    21
  - Included Parts
    22
    
    Spark Plug Wrench
    22
    
    Nipple Wrench
    22
    
    Handlebar Protector
    22
    
    Fuel Hose Joint Cover
    22
    
    Coupler for Connecting Optional Part
    22
  - Important Information
    23
    
    Preparation for Removal and Disassembly
    23
    
    Replacement Parts
    23
    
    Gaskets, Oil Seals and O-Rings
    24
    
    Lock Washers/Plates and Cotter Pins
    24
    
    Bearings and Oil Seals
    24
    
    Circlips
    24
  - Basic Service Information
    25
    
    Electrical System
    25
  - Special Tools
    29
  - Control Functions
    35
    
    Indicator Lights and Warning Lights
    35
    
    Engine Stop Switch
    35
    
    Start Switch
    35
    
    Clutch Lever
    35
    
    Shift Pedal
    36
    
    Kickstarter Lever
    36
    
    Throttle Grip
    36
    
    Front Brake Lever
    36
    
    Rear Brake Pedal
    36
    
    Sidestand
    37
    
    Starter Knob/Idle Adjusting Screw
    37
    
    Fuel Tank Cap
    37
  - Multi-Function Display
    38
    
    Description
    38
    
    Basic Mode
    38
    
    Changeover to Basic Mode/Race Mode
    39
    
    Race Mode
    40
    
    Function Diagram
    44
  - Starting and Break-In
    46
    
    Fuel
    46
    
    Handling Note
    46
    
    Air Filter Maintenance
    46
    
    Starting a Cold Engine
    46
    
    Starting a Warm Engine
    47
    
    Break-In Procedures
    48
  - Maintenance after Break-In
    49
    
    Major Maintenance
    49
  - Torque-Check Points
    50
  - Motorcycle Care and Storage
    52
    
    Care
    52
    
    Storage
    53
Specifications

55
- General Specifications
  56
- Engine Specifications
  57
- Chassis Specifications
  63
- Electrical Specifications
  66
- Tightening Torques
  68
- Lubrication Points and Lubricant Types
  76
  - Engine
    76
  - Chassis
    77
- Lubrication System Chart and Diagrams
  80
  - Lubrication Diagrams
    80
- Cable Routing Diagram
  88
Periodic Checks and Adjustments

103
- Periodic Maintenance
  
  105
- Pre-Operation Inspection and Maintenance
  
  113
  - General Inspection and Maintenance
    113
- Engine
  
  114
  - Checking the Coolant Level
    114
  - Checking the Cooling System
    114
  - Changing the Coolant
    114
  - Checking the Radiator Cap
    115
  - Checking the Radiator Cap Opening Pressure
    115
  - Checking the Coolant Circulatory System for Leaks
    116
  - Adjusting the Clutch Lever Free Play
    116
  - Adjusting the Throttle Grip Free Play
    117
  - Lubricating the Throttle Cable
    117
  - Cleaning the Air Filter Element
    118
  - Checking the Throttle Body Joint
    119
  - Checking the Breather Hoses
    119
  - Checking the Exhaust System
    119
  - Checking the Fuel Line
    120
  - Checking the Engine Oil Level
    120
  - Changing the Engine Oil
    121
  - Adjusting the Engine Idling Speed
    122
  - Adjusting the Valve Clearance
    123
  - Cleaning the Spark Arrester
    127
- Chassis
  
  128
  - Bleeding the Brake System
    128
  - Checking the Brake Hose
    129
  - Adjusting the Front Brake
    129
  - Adjusting the Rear Brake
    130
  - Checking the Front Brake Pads
    130
  - Checking the Rear Brake Pads
    132
  - Checking the Rear Brake Pad Insulator
    133
  - Checking the Brake Fluid Level
    133
  - Adjusting the Drive Chain Slack
    134
  - Checking the Front Fork Legs
    135
  - Checking the Front Fork Protector Guide
    135
  - Cleaning the Front Fork Oil Seal and Dust Seal
    135
  - Air Bleeding from Front Fork
    135
  - Adjusting the Front Fork Legs
    136
  - Checking the Swingarm Operation
    137
  - Checking the Rear Suspension
    137
  - Adjusting the Rear Shock Absorber Assembly
    137
  - Checking the Tires
    139
  - Checking and Tightening the Spokes
    139
  - Checking the Wheels
    140
  - Checking the Wheel Bearings
    140
  - Checking and Adjusting the Steering Head
    140
  - Checking and Lubricating the Cables
    141
  - Lubricating the Levers
    141
  - Lubricating the Pedal
    141
  - Lubricating the Drive Chain
    142
  - Lubricating the Sidestand
    142
  - Checking the Chassis Fasteners
    142
- Electrical System
  
  143
  - Checking the Spark Plug
    143
  - Checking the Ignition Timing
    143
  - Checking and Charging the Battery
    144
  - Replacing the Headlight Bulb
    144
Tuning

147
- Chassis
  148
  - Selection of the Secondary Reduction Ratio (Sprocket)
    148
  - Drive and Rear Wheel Sprockets Setting Parts
    148
  - Tire Pressure
    148
  - Front Fork Setting
    149
  - Change in Amount and Characteristics of Fork Oil
    149
  - Setting of Spring after Replacement
    149
  - Front Fork Setting Parts
    150
  - Rear Suspension Setting
    150
  - Choosing Set Length
    150
  - Setting of Spring after Replacement
    151
  - Rear Shock Absorber Setting Parts
    151
  - Suspension Setting (Front Fork)
    153
  - Suspension Setting (Rear Shock Absorber)
    154
Chassis

157
- General Chassis
  
  161
  - Removing the Left Side Cover
    161
  - Removing the Seat
    161
- Front Wheel
  
  162
  - Removing the Front Wheel
    163
  - Checking the Front Wheel
    163
  - Disassembling the Front Wheel
    164
  - Assembling the Front Wheel
    164
  - Installing the Front Wheel
    165
- Rear Wheel
  
  167
  - Removing the Rear Wheel
    168
  - Checking the Rear Wheel
    168
  - Disassembling the Rear Wheel
    168
  - Checking and Replacing the Rear Wheel Sprocket
    168
  - Assembling the Rear Wheel
    169
  - Installing the Rear Wheel
    169
- Front Brake
  
  171
- Rear Brake
  
  181
- Handlebar
  
  193
  - Removing the Handlebar
    193
  - Checking the Handlebar
    193
  - Installing the Handlebar
    193
- Front Fork
  
  198
  - Removing the Front Fork Legs
    200
  - Disassembling the Front Fork Legs
    200
  - Checking the Front Fork Legs
    201
  - Assembling the Front Fork Legs
    202
  - Installing the Front Fork Legs
    208
- Steering Head
  
  211
  - Removing the Lower Bracket
    212
  - Checking the Steering Head
    212
  - Installing the Steering Head
    212
- Rear Shock Absorber Assembly
  
  215
- Swingarm
  
  222
  - Removing the Swingarm
    223
  - Removing the Bearing
    223
  - Checking the Swingarm
    223
  - Installing the Swingarm
    224
- Chain Drive
  
  225
  - Removing the Drive Chain
    226
  - Checking the Drive Chain
    226
  - Checking the Drive Sprocket
    227
  - Checking the Rear Wheel Sprocket
    227
  - Installing the Drive Chain
    227
Engine

229
- Engine Removal
  
  232
  - Removing the Drive Sprocket
    237
  - Removing the Exhaust Pipe 2
    237
  - Removing the Silencer
    237
  - Cleaning the Spark Arrester
    238
  - Removing the Engine
    238
  - Checking the Silencer and Exhaust Pipe
    239
  - Installing the Engine
    239
  - Installing the Brake Pedal
    240
  - Installing the Drive Sprocket
    240
  - Installing the Exhaust Pipe and Muffler
    240
- Camshaft
  
  242
  - Removing the Camshaft
    244
  - Checking the Camshaft
    245
  - Checking the Timing Chain and Camshaft Sprocket
    246
  - Checking the Timing Chain Tensioners
    246
  - Checking the Decompression System
    247
  - Installing the Camshafts
    247
- Cylinder Head
  
  250
- Valves and Valve Springs
  
  254
  - Removing the Valves
    254
  - Checking the Valves and Valve Guides
    255
  - Checking the Valve Seats
    257
  - Checking the Valve Springs
    258
  - Checking the Valve Lifters
    259
  - Installing the Valves
    259
- Cylinder and Piston
  
  262
  - Removing the Piston
    262
  - Checking the Cylinder and 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
- Clutch
  
  274
  - Removing the Clutch
    274
  - Checking the Friction Plates
    274
  - Checking the Clutch Plates
    274
  - Checking the Clutch Springs
    274
  - Checking the Clutch Housing
    275
  - Checking the Clutch Boss
    275
  - Checking the Pressure Plate
    275
  - Checking the Push Lever Shaft
    275
  - Checking the Clutch Push Rods
    275
  - Checking the Primary Drive Gear
    275
  - Checking the Primary Driven Gear
    276
  - Installing the Oil Seal
    276
  - Installing the Right Crankcase Cover
    276
  - Installing the Clutch
    276
  - Installing the Kickstarter Lever
    279
- Kickstater
  
  281
- Shift Shaft
  
  283
  - Removing the Shift Guide and Shift Lever Assembly
    284
  - Removing the Segment
    284
  - Checking the Shift Shaft
    284
  - Checking the Shift Guide and Shift Lever Assembly
    284
  - Checking the Stopper Lever
    284
  - Installing the Stopper Lever
    285
  - Installing the Segment
    285
  - Installing the Shift Guide and Shift Lever Assembly
    285
  - Installing the Shift Shaft
    286
  - Installing the Shift Pedal
    286
- Oil Pump and Balancer Gear
  
  288
- Generator and Starter Clutch
  
  295
  - Removing the Generator
    295
  - Checking the Starter Clutch
    295
  - Installing the Starter Clutch
    296
  - Installing the Generator
    296
- Crankcase
  
  299
  - Disassembling the Crankcase
    302
  - Removing the Crankcase Bearing
    302
  - Checking the Timing Chain, Timing Chain Guide, Oil Strainer
    302
  - Checking the Crankcase
    302
  - Installing the Oil Seal
    303
  - Assembling the Crankcase
    303
- Crankshaft Assembly and Balancer Shaft
  
  304
- Transmission
  
  307
  - Removing the Transmission
    308
  - Checking the Shift Forks
    308
  - Checking the Shift Drum Assembly
    309
  - Checking the Transmission
    309
  - Installing the Transmission
    309
  - Cooling System
    313
    
    Water Pump
    319
Fuel System

321
- Fuel Tank
  
  322
  - Checking the Fuel Pump Body
    324
  - Installing the Fuel Pump
    324
  - Removing the Fuel Pump
    324
  - Removing the Fuel Tank
    324
  - Checking the Fuel Sender
    325
  - Installing the Fuel Sender
    325
  - Installing the Fuel Tank
    325
  - Removing the Fuel Sender
    325
  - Checking the Damper
    326
  - Checking the Fuel Pressure
    326
  - Checking and Replacing the Protector
    327
- Throttle Body
  
  328
  - Checking the Injector
    331
  - Checking the Throttle Body
    331
  - Checking the Throttle Body Joint
    331
  - Adjusting the Throttle Position Sensor
    332
Electrical System

333
- Ignition System
  
  336
  - Circuit Diagram
    336
  - Troubleshooting
    338
- Electric Starting System
  
  340
  - Circuit Diagram
    340
  - Starting Circuit Cut-Off System Operation
    342
  - Troubleshooting
    344
- Charging System
  
  346
  - Circuit Diagram
    346
  - Troubleshooting
    348
- Lighting System
  
  350
  - Circuit Diagram
    350
  - Troubleshooting
    352
- Signaling System
  
  354
  - Circuit Diagram
    354
  - Troubleshooting
    356
- Cooling System
  
  358
  - Circuit Diagram
    358
  - Troubleshooting
    360
- Fuel Injection System
  
  362
  - Circuit Diagram
    362
  - Ecu Self-Diagnostic Function
    364
  - Troubleshooting Method
    365
  - Yamaha Diagnostic Tool
    366
  - Troubleshooting Details
    369
- Fuel Pump System
  
  390
  - Circuit Diagram
    390
  - Troubleshooting
    392
- Electrical Components
  
  394
  - Checking the Switches
    398
  - Checking the Bulbs and Bulb Sockets
    401
  - Checking the Fuses
    402
  - Checking and Charging the Battery
    403
  - Checking the Relays
    406
  - Checking the Diode
    407
  - Checking the Ignition Spark Gap
    407
  - Checking the Spark Plug Cap
    407
  - Checking the Ignition Coil
    408
  - Checking the Crankshaft Position Sensor
    408
  - Checking the Lean Angle Sensor
    409
  - Checking the Starter Motor Operation
    409
  - Checking the Stator Coil
    410
  - Checking the Rectifier/Regulator
    410
  - Checking the Speed Sensor
    411
  - Checking the Fuel Sender
    411
  - Checking the Resister
    411
  - Checking the Radiator Fan Motor
    412
  - Checking the Coolant Temperature Sensor
    412
  - Checking the Throttle Position Sensor
    413
  - Checking the Throttle Position Sensor Input Voltage
    413
  - Checking the Intake Air Pressure Sensor
    414
  - Checking the Intake Air Temperature Sensor
    414
  - Checking the Fuel Injector
    415
Troubleshooting

417
- General Information
  417
- Troubleshooting
  
  418
  - General Information
    418
  - Starting Failures
    418
  - Incorrect Engine Idling Speed
    418
  - Poor Medium-And-High-Speed Performance
    419
  - Shifting Is Difficult
    419
  - Shift Pedal Does Not Move
    419
  - Jumps out of Gear
    419
  - Clutch Slips
    419
  - Clutch Drags
    419
  - Overheating
    419
  - Overcooling
    420
  - Poor Braking Performance
    420
  - Front Fork Oil Leaking
    420
  - Faulty Front Fork Legs
    420
  - Unstable Handling
    420
  - Headlight Does Not Come on
    421
  - Headlight Bulb Burnt out
    421
  - Taillight Does Not Come on
    421
- List of Self-Diagnostic and Fail-Safe Actions
  
  422

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