Yamaha WR250FN1 2022 Manuals

Manuals and User Guides for Yamaha WR250FN1 2022. We have 1 Yamaha WR250FN1 2022 manual available for free PDF download: Owner's Service Manual

Yamaha WR250FN1 2022 Owner's Service Manual

Yamaha WR250FN1 2022 Owner's Service Manual (404 pages)

Brand: Yamaha | Category: Motorcycle | Size: 26.98 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
- Coupler for Connecting Optional Part
  19
- Fuel Hose Joint Cover
  19
- Handlebar Protector
  19
- Nipple Wrench
  19
- Included Parts
  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
  32
- Warning Lights
  32
- Engine Stop Switch
  32
- Start Switch
  32
- Shift Pedal
  32
- Front Brake Lever
  33
- Rear Brake Pedal
  33
- Sidestand
  33
- Starter Knob
  33
- Fuel Tank Cap
  33
- Multi-Function Display
  36
- 20.Setting the Timer
  43
- 10.Setting Mode
  43
- Starting and Break-In
  44
- Fuel
  44
- Handling Note
  44
- Starting a Cold Engine
  44
- Starting a Warm Engine
  45
- Break-In Procedures
  45
- Shifting
  45
- Maintenance after Break-In
  47
- Major Maintenance
  47
- Air Filter 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
  61
- General Tightening Torque Specifications
  63
- Tightening Torques
  63
- Engine Tightening Torques
  64
- Chassis Tightening Torques
  67
- Cable Routing Diagram
  70
Periodic Checks and Adjustments

87
- General Maintenance and Lubrication Chart
  89
- Introduction
  89
- Periodic Maintenance
  89
- Periodic Maintenance Chart for the Emission Control System
  89
- Maintenance Intervals for Competition Use
  91
- General Inspection and Maintenance
  94
- Pre-Operation Inspection and Maintenance
  94
- Adjusting the Valve Clearance
  95
- Engine
  95
- Valve Clearance Shim Chart
  98
- Checking the Engine Idling Speed
  100
- Checking the Throttle Grip
  100
- Checking the Spark Plug
  101
- Changing the Engine Oil
  102
- Checking the Engine Oil Level
  102
- Adjusting the Clutch Lever Free Play
  104
- Cleaning the Air Filter Element
  104
- Checking the Cylinder Head Breather Hose
  106
- Checking the Fuel Line
  106
- Checking the Throttle Body Joint
  106
- Checking the Exhaust System
  107
- Checking the Coolant Level
  108
- Changing the Coolant
  109
- Checking the Cooling System
  109
- Adjusting the Front Disc Brake
  111
- Adjusting the Rear Disc Brake
  111
- Chassis
  111
- Checking the Brake Fluid Level
  111
- Checking the Front Brake Hose
  112
- Checking the Front Brake Pads
  112
- Checking the Rear Brake Hose
  112
- Checking the Rear Brake Pads
  112
- Bleeding the Hydraulic Brake System
  113
- Checking the Brake Operation
  113
- Drive Chain Slack
  114
- Checking and Adjusting the Steering Head
  115
- Lubricating the Drive Chain
  115
- Checking the Front Fork Legs
  116
- Lubricating the Steering Head
  116
- Adjusting the Front Fork Legs
  117
- Adjusting the Rear Shock Absorber Assembly
  118
- Checking the Rear Shock Absorber Assembly
  118
- Checking the Connecting Arm and Relay Arm
  120
- Checking the Swingarm Operation
  120
- Lubricating the Swingarm Pivot
  120
- Checking and Tightening the Spokes
  121
- Checking the Tires
  121
- Checking the Wheel Bearings
  121
- Checking the Wheels
  121
- Checking and Lubricating the Cables
  122
- Checking the Chassis Fasteners
  122
- Checking the Sidestand
  122
- Lubricating the Brake Lever
  122
- Lubricating the Clutch Lever
  122
- Lubricating the Pedal
  122
- Lubricating the Sidestand
  122
- Checking and Charging the Battery
  123
- Checking the Fuses
  123
- Checking the Ignition Timing
  123
- Electrical System
  123
- Replacing the Headlight Bulb
  123
Chassis

125
- General Chassis
  130
- Installing the Air Scoop
  130
- Installing the Side Cover
  130
- Removing the Seat
  130
- Removing the Side Cover
  130
- Front Wheel
  132
- Checking the Front Wheel Sensor and Sensor Rotor
  133
- Disassembling the Front Wheel
  133
- Removing the Front Wheel
  133
- Assembling the Front Wheel
  134
- Checking the Front Wheel
  134
- Installing the Front Wheel
  136
- Rear Wheel
  138
- Checking and Replacing the Rear Wheel Sprocket
  139
- Checking the Rear Wheel
  139
- Disassembling the Rear Wheel
  139
- Removing the Rear Wheel
  139
- Assembling the Rear Wheel
  140
- Installing the Rear Wheel
  140
- Front Brake
  143
- Checking the Front Brake Disc
  146
- Introduction
  146
- Replacing the Front Brake Pads
  146
- Assembling the Front Brake Caliper
  148
- Checking the Front Brake Caliper
  148
- Disassembling the Front Brake Caliper
  148
- Removing the Front Brake Caliper
  148
- Installing the Front Brake Caliper
  149
- Assembling the Front Brake Master Cylinder
  150
- Checking the Front Brake Master Cylinder
  150
- Removing the Front Brake Master Cylinder
  150
- Installing the Front Brake Master Cylinder
  151
- Rear Brake
  153
- Checking the Rear Brake Disc
  157
- Introduction
  157
- Replacing the Rear Brake Pads
  157
- Assembling the Rear Brake Caliper
  159
- Checking the Rear Brake Caliper
  159
- Disassembling the Rear Brake Caliper
  159
- Removing the Rear Brake Caliper
  159
- Installing the Rear Brake Caliper
  160
- Removing the Rear Brake Master Cylinder
  160
- Assembling the Rear Brake Master Cylinder
  161
- Checking the Rear Brake Master Cylinder
  161
- Installing the Rear Brake Master Cylinder
  162
- Checking the Handlebar
  164
- Installing the Handlebar
  164
- Removing the Handlebar
  164
- Front Fork
  169
- Disassembling the Front Fork Legs
  171
- Removing 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
- Checking the Steering Head
  183
- Installing the Steering Head
  183
- Removing the Lower Bracket
  183
- Rear Shock Absorber Assembly
  186
- Checking the Rear Shock Absorber Assembly
  189
- Disposing of a Rear Shock Absorber
  189
- Handling the Rear Shock Absorber
  189
- Removing the Rear Shock Absorber Assembly
  189
- Checking the Connecting Arm and Relay Arm
  190
- Installing the Rear Shock Absorber Assembly
  190
- Installing the Relay Arm
  190
- Swingarm
  192
- Checking the Swingarm
  193
- Installing the Swingarm
  193
- Removing the Swingarm
  193
- Chain Drive
  195
- Checking the Drive Chain
  196
- Removing the Drive Chain
  196
- Checking the Drive Sprocket
  197
- Checking the Rear Wheel Sprocket
  197
- Installing the Drive Chain
  197
Engine

199
- Engine Oil Lubrication Chart
  202
- Lubrication System Chart and Diagrams
  202
- Lubrication Diagrams
  203
- Engine Removal
  207
- Installing the Engine
  211
- Removing the Engine
  211
- Installing the Exhaust Pipe and Muffler
  212
- Camshaft
  214
- Removing the Camshaft
  216
- Checking the Camshaft
  217
- Checking the Decompression System
  218
- Checking the Timing Chain and Camshaft Sprocket
  218
- Checking the Timing Chain Tensioners
  218
- Installing the Camshafts
  218
- Cylinder Head
  221
- Checking the Cylinder Head
  223
- Checking the Timing Chain Guide (Intake Side)
  223
- Installing the Cylinder Head
  223
- Removing the Cylinder Head
  223
- Removing the Valves
  227
- Valves and Valve Springs
  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
- Checking the Cylinder and Piston
  234
- Removing the Piston
  234
- Checking the Piston Pin
  235
- Checking the Piston Rings
  235
- Installing the Piston and Cylinder
  236
- Generator
  238
- Checking the Generator
  239
- Checking the Woodruff Key
  239
- Installing the Generator
  239
- Removing the Generator
  239
- Starter Clutch
  241
- Checking the Starter Clutch
  242
- Installing the Starter Clutch
  242
- Removing the Starter Clutch
  242
- Electric Starter
  244
- Assembling the Starter Motor
  246
- Checking the Starter Motor
  246
- Clutch
  248
- Checking the Clutch Housing
  251
- Checking the Clutch Plates
  251
- Checking the Clutch Springs
  251
- Checking the Friction Plates
  251
- Removing the Clutch
  251
- Checking the Clutch Boss
  252
- Checking the Pressure Plate
  252
- Checking the Primary Drive Gear
  252
- Checking the Primary Driven Gear
  252
- Checking the Push Lever Shaft
  252
- Checking the Push Rods
  252
- Installing the Clutch
  252
- Shift Shaft
  256
- Checking the Shift Shaft
  257
- Checking the Stopper Lever
  257
- Installing the Shift Shaft
  257
- Removing the Segment
  257
- Oil Pump
  260
- Assembling the Oil Pump
  262
- Checking the Oil Pump
  262
- Removing the Balancer
  262
- Installing the Oil Pump
  263
- Crankcase
  266
- Checking the Crankcase
  268
- Checking the Timing Chain Guide (Exhaust Side)
  268
- Disassembling the Crankcase
  268
- Assembling the Crankcase
  269
- Crankshaft and Balancer Shaft
  270
- Checking the Crankshaft
  271
- Removing the Crankshaft
  271
- Installing the Crankshaft
  272
- Transmission
  273
- Checking the Shift Forks
  274
- Removing the Transmission
  274
Cooling System

279
- Cooling System Diagrams
  280
- Radiator
  281
- Checking the Radiator
  283
- Installing the Radiator
  283
- Water Pump
  285
- Assembling the Water Pump
  286
- Checking the Water Pump
  286
- Disassembling the Water Pump
  286
Fuel System

289
- 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
- Circuit Diagram
  302
- Ignition System
  302
- Troubleshooting
  304
- Circuit Diagram
  306
- Electric Starting System
  306
- Starting Circuit Cut-Off System Operation
  308
- Troubleshooting
  310
- Charging System
  312
- Circuit Diagram
  312
- Troubleshooting
  314
- Circuit Diagram
  316
- Signaling System
  316
- Troubleshooting
  318
- Circuit Diagram
  320
- Lighting System
  320
- Troubleshooting
  322
- Circuit Diagram
  324
- Cooling System
  324
- Troubleshooting
  326
- Circuit Diagram
  328
- Fuel Injection System
  328
- Ecu Self-Diagnostic Function
  330
- Troubleshooting Method
  331
- Connecting the Yamaha Diagnostic Tool
  332
- Yamaha Diagnostic Tool
  332
- Troubleshooting Details (Fault Code)
  334
- Circuit Diagram
  354
- Fuel Pump System
  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 Coil
  366
- Checking the Ignition Spark Gap
  366
- Checking the Spark Plug Cap
  366
- Checking the Crankshaft Position Sensor
  367
- Checking the Lean Angle Sensor
  368
- Checking the Rectifier/Regulator
  368
- Checking the Starter Motor Operation
  368
- Checking the Stator Coil
  368
- Checking the Fuel Sender
  369
- Checking the Resistor
  369
- Checking the Speed Sensor
  369
- Checking the Coolant Temperature Sensor
  370
- Checking the Radiator Fan Motor
  370
- Checking the Intake Air Temperature Sensor
  371
- Checking the Throttle Position Sensor Input Voltage
  371
- Checking the Gear Position Switch
  372
- Checking the Injector
  372
Troubleshooting

373
Tuning

389
- Chassis
  390
- Drive and Rear Wheel Sprockets Setting Parts
  390
- Selection of the Secondary Reduction Ratio (Sprocket)
  390
- Tire Pressure
  390
- Change in Amount and Characteristics of Fork Oil
  391
- Front Fork Setting
  391
- Setting of Spring after Replacement
  391
- Choosing Set Length
  392
- Front Fork Setting Parts
  392
- Rear Suspension Setting
  392
- Rear Shock Absorber Setting Parts
  393
- Setting of Spring after Replacement
  393
- Suspension Setting (Front Fork)
  395
- Suspension Setting (Rear Shock Absorber)
  396

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