Yamaha WR250FG 2016 Manuals

Manuals and User Guides for Yamaha WR250FG 2016. We have 1 Yamaha WR250FG 2016 manual available for free PDF download: Owner's Service Manual

Yamaha WR250FG 2016 Owner's Service Manual

Yamaha WR250FG 2016 Owner's Service Manual (428 pages)

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
  - Included Parts
    20
    
    Spark Plug Wrench
    20
    
    Nipple Wrench
    20
    
    Handlebar Protector
    20
    
    Fuel Hose Joint Cover
    20
    
    Coupler for Connecting Optional Part
    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
  - Control Functions
    33
    
    Indicator Lights and Warning Lights
    33
    
    Engine Stop Switch
    33
    
    Start Switch
    33
    
    Clutch Lever
    33
    
    Shift Pedal
    34
    
    Kickstarter Lever
    34
    
    Throttle Grip
    34
    
    Front Brake Lever
    34
    
    Rear Brake Pedal
    34
    
    Sidestand
    35
    
    Starter Knob/Idle Adjusting Screw
    35
    
    Fuel Tank Cap
    35
  - Multi-Function Display
    36
    
    Description
    36
    
    Basic Mode
    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
    45
    
    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
- Tightening Torques
  65
- Lubrication Points and Lubricant Types
  73
  - Engine
    73
  - Chassis
    74
- Lubrication System Chart and Diagrams
  76
  - Lubrication Diagrams
    76
- Cable Routing Diagram
  84
Periodic Checks and Adjustments

99
- Periodic Maintenance
  
  101
- Pre-Operation Inspection and Maintenance
  
  109
  - General Inspection and Maintenance
    109
- Engine
  
  110
  - Checking the Coolant Level
    110
  - Checking the Cooling System
    110
  - Changing the Coolant
    110
  - Checking the Radiator Cap
    111
  - Checking the Radiator Cap Valve Opening Pressure
    111
  - Checking the Coolant Circulatory System for Leaks
    112
  - Adjusting the Clutch Lever Free Play
    112
  - Adjusting the Throttle Grip Free Play
    113
  - Lubricating the Throttle Cable
    113
  - Cleaning the Air Filter Element
    114
  - Checking the Throttle Body Joint
    115
  - Checking the Breather Hoses
    115
  - Checking the Exhaust System
    115
  - Checking the Fuel Line
    116
  - Checking the Engine Oil Level
    116
  - Changing the Engine Oil
    117
  - Adjusting the Engine Idling Speed
    118
  - Adjusting the Valve Clearance
    119
  - Cleaning the Spark Arrester
    123
- Chassis
  
  124
  - Bleeding the Brake System
    124
  - Checking the Brake Hose
    125
  - Adjusting the Front Brake
    125
  - Adjusting the Rear Brake
    126
  - Checking the Front Brake Pads
    126
  - Checking the Rear Brake Pads
    128
  - Checking the Rear Brake Pad Insulator
    129
  - Checking the Brake Fluid Level
    129
  - Adjusting the Drive Chain Slack
    130
  - Checking the Front Fork Legs
    131
  - Checking the Front Fork Protector Guide
    131
  - Cleaning the Front Fork Oil Seal and Dust Seal
    131
  - Air Bleeding from Front Fork
    131
  - Adjusting the Front Fork Legs
    132
  - Checking the Swingarm Operation
    133
  - Checking the Rear Suspension
    133
  - Adjusting the Rear Shock Absorber Assembly
    133
  - Checking the Tires
    135
  - Checking and Tightening the Spokes
    135
  - Checking the Wheels
    136
  - Checking the Wheel Bearings
    136
  - Checking and Adjusting the Steering Head
    136
  - Checking and Lubricating the Cables
    137
  - Lubricating the Levers
    137
  - Lubricating the Pedal
    137
  - Lubricating the Drive Chain
    138
  - Lubricating the Sidestand
    138
  - Checking the Chassis Fasteners
    138
- Electrical System
  
  139
  - Checking the Spark Plug
    139
  - Checking the Ignition Timing
    139
  - Checking and Charging the Battery
    140
  - Replacing the Headlight Bulb
    140
Tuning

143
- Chassis
  144
  - Selection of the Secondary Reduction Ratio (Sprocket)
    144
  - Drive and Rear Wheel Sprockets Setting Parts
    144
  - Tire Pressure
    144
  - Front Fork Setting
    145
  - Change in Amount and Characteristics of Fork Oil
    145
  - Setting of Spring after Replacement
    145
  - Front Fork Setting Parts
    146
  - Rear Suspension Setting
    146
  - Choosing Set Length
    146
  - Setting of Spring after Replacement
    147
  - Rear Shock Absorber Setting Parts
    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
  - Removing the Front Wheel
    159
  - Checking the Front Wheel
    159
  - Disassembling the Front Wheel
    160
  - Assembling the Front Wheel
    160
  - Installing the Front Wheel
    161
- Rear Wheel
  
  163
  - Removing the Rear Wheel
    164
  - Checking the Rear Wheel
    164
  - Disassembling the Rear Wheel
    164
  - Checking and Replacing the Rear Wheel Sprocket
    164
  - Assembling the Rear Wheel
    165
  - Installing the Rear Wheel
    165
- Front Brake
  
  167
- Rear Brake
  
  177
- Handlebar
  
  189
  - Removing the Handlebar
    189
  - Checking the Handlebar
    189
  - Installing the Handlebar
    189
- Front Fork
  
  194
  - Removing the Front Fork Legs
    196
  - Disassembling 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
  - Removing the Lower Bracket
    209
  - Checking the Steering Head
    209
  - Installing the Steering Head
    209
- Rear Shock Absorber Assembly
  
  212
- Swingarm
  
  219
  - Removing the Swingarm
    220
  - Removing the Bearing
    220
  - Checking the Swingarm
    220
  - Installing the Swingarm
    221
- Chain Drive
  
  222
  - Removing the Drive Chain
    223
  - Checking 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
    238
- Camshaft
  
  240
  - Removing the Camshaft
    242
  - Checking the Camshaft
    243
  - Checking the Timing Chain and Camshaft Sprocket
    244
  - Checking the Timing Chain Tensioners
    244
  - Checking the Decompression System
    245
  - Installing the Camshafts
    245
- Cylinder Head
  
  248
- Valves and Valve Springs
  
  252
  - Removing the Valves
    252
  - Checking the Valves and Valve Guides
    253
  - Checking the Valve Seats
    255
  - Checking the Valve Springs
    256
  - Checking the Valve Lifters
    257
  - Installing the Valves
    257
- Cylinder and Piston
  
  260
  - Removing the Piston
    260
  - Checking the Cylinder and Piston
    260
  - Checking the Piston Rings
    261
  - Checking the Piston Pin
    262
  - Installing the Piston and Cylinder
    262
- Electric Starter
  
  264
  - Checking the Starter Motor
    266
  - Assembling the Starter Motor
    267
- Clutch
  
  272
  - Removing the Clutch
    272
  - Checking the Friction Plates
    272
  - Checking the Clutch Plates
    272
  - Checking the Clutch Springs
    272
  - Checking the Clutch Housing
    273
  - Checking the Clutch Boss
    273
  - Checking the Pressure Plate
    273
  - Checking the Push Lever Shaft
    273
  - Checking the Clutch Push Rods
    273
  - Checking the Primary Drive Gear
    273
  - Checking the Primary Driven Gear
    274
  - Installing the Oil Seal
    274
  - Installing the Right Crankcase Cover
    274
  - Installing the Clutch
    274
  - Installing the Kickstarter Lever
    277
- Kickstater
  
  279
- Shift Shaft
  
  281
  - Removing the Shift Guide and Shift Lever Assembly
    282
  - Removing the Segment
    282
  - Checking the Shift Shaft
    282
  - Checking the Shift Guide and Shift Lever Assembly
    282
  - Checking the Stopper Lever
    282
  - Installing the Stopper Lever
    283
  - Installing the Segment
    283
  - Installing the Shift Guide and Shift Lever Assembly
    283
  - Installing the Shift Shaft
    284
  - Installing the Shift Pedal
    284
- Oil Pump and Balancer Gear
  
  286
- Generator and Starter Clutch
  
  293
  - Removing the Generator
    293
  - Checking the Starter Clutch
    293
  - Installing the Starter Clutch
    294
  - Installing the Generator
    294
- Crankcase
  
  297
  - Disassembling the Crankcase
    300
  - Removing the Crankcase Bearing
    300
  - Checking the Timing Chain, Timing Chain Guide, Oil Strainer
    300
  - Checking the Crankcase
    300
  - Installing the Oil Seal
    301
  - Assembling the Crankcase
    301
- Crankshaft Assembly and Balancer Shaft
  
  302
- Transmission
  
  305
  - Removing the Transmission
    306
  - Checking the Shift Forks
    306
  - Checking the Shift Drum Assembly
    307
  - Checking the Transmission
    307
  - Installing the Transmission
    307
  - Cooling System
    311
    
    Water Pump
    317
Fuel System

319
- Fuel Tank
  
  320
  - Checking the Fuel Pump Body
    322
  - Installing the Fuel Pump
    322
  - Removing the Fuel Pump
    322
  - Removing the Fuel Tank
    322
  - Checking the Fuel Sender
    323
  - Installing the Fuel Sender
    323
  - Installing the Fuel Tank
    323
  - Removing the Fuel Sender
    323
  - Checking the Damper
    324
  - Checking the Fuel Pressure
    324
  - Checking and Replacing the Protector
    325
- Throttle Body
  
  326
  - Checking the Injector
    329
  - Checking the Throttle Body
    329
  - Checking the Throttle Body Joint
    329
  - Adjusting the Throttle Position Sensor
    330
Electrical System

331
- Ignition System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Electric Starting System
  
  338
  - Circuit Diagram
    338
  - Starting Circuit Cut-Off System Operation
    340
  - Troubleshooting
    342
- Charging System
  
  344
  - Circuit Diagram
    344
  - Troubleshooting
    346
- Lighting System
  
  348
  - Circuit Diagram
    348
  - Troubleshooting
    350
- Signaling System
  
  352
  - Circuit Diagram
    352
  - Troubleshooting
    354
- Cooling System
  
  356
  - Circuit Diagram
    356
  - Troubleshooting
    358
- Fuel Injection System
  
  360
  - Circuit Diagram
    360
  - Ecu Self-Diagnostic Function
    362
  - Troubleshooting Method
    363
  - Yamaha Diagnostic Tool
    364
  - Troubleshooting Details
    367
- Fuel Pump System
  
  388
  - Circuit Diagram
    388
  - Troubleshooting
    390
- Electrical Components
  
  392
  - Checking the Switches
    396
  - Checking the Bulbs and Bulb Sockets
    399
  - Checking the Fuses
    400
  - Checking and Charging the Battery
    401
  - Checking the Relays
    404
  - Checking the Diode
    405
  - Checking the Ignition Spark Gap
    405
  - Checking the Spark Plug Cap
    405
  - Checking the Ignition Coil
    406
  - Checking the Crankshaft Position Sensor
    406
  - Checking the Lean Angle Sensor
    407
  - Checking the Starter Motor Operation
    407
  - Checking the Stator Coil
    408
  - Checking the Rectifier/Regulator
    408
  - Checking the Speed Sensor
    409
  - Checking the Fuel Sender
    409
  - Checking the Resister
    409
  - Checking the Radiator Fan Motor
    410
  - Checking the Coolant Temperature Sensor
    410
  - Checking the Throttle Position Sensor
    411
  - Checking the Throttle Position Sensor Input Voltage
    411
  - Checking the Intake Air Pressure Sensor
    412
  - Checking the Intake Air Temperature Sensor
    412
  - Checking the Fuel Injector
    413
Troubleshooting

415
- General Information
  415
- Troubleshooting
  
  416
  - General Information
    416
  - Starting Failures
    416
  - Incorrect Engine Idling Speed
    416
  - Poor Medium-And-High-Speed Performance
    417
  - Shifting Is Difficult
    417
  - Shift Pedal Does Not Move
    417
  - Jumps out of Gear
    417
  - Clutch Slips
    417
  - Clutch Drags
    417
  - Overheating
    417
  - Overcooling
    418
  - Poor Braking Performance
    418
  - Front Fork Oil Leaking
    418
  - Faulty Front Fork Legs
    418
  - Unstable Handling
    418
  - Headlight Does Not Come on
    419
  - Headlight Bulb Burnt out
    419
  - Taillight Does Not Come on
    419
- List of Self-Diagnostic and Fail-Safe Actions
  
  420

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