YAMAHA WR250R Manuals

Manuals and User Guides for YAMAHA WR250R. We have 3 YAMAHA WR250R manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha WR250R Service Manual (364 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18 MB

Table of Contents

7
- How to Use this Manual
  5
- Symbols
  6
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Multi-Function Display
    13
  - Important Information
    17
  - Preparation for Removal and Disassembly
    17
    
    Replacement Parts
    17
    
    Gaskets, Oil Seals and O-Rings
    17
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    17
    
    Circlips
    18
  - Checking the Connections
    19
  - Special Tools
    20
Specifications

25
- General Specifications
  26
- Engine Specifications
  27
- Chassis Specifications
  34
- Electrical Specifications
  37
- Tightening Torques
  40
- Lubrication Points and Lubricant Types
  46
  - Engine
    46
  - Chassis
    47
- Lubrication System Chart and Diagrams
  50
  - Lubrication Diagrams
    50
- Cooling System Diagrams
  54
- Cable Routing
  56
- Front Rear Brake Hose
  64
- Throttle Body
  66
- Canister (for California)
  68
Periodic Checks and Adjustments

71
- Periodic Maintenance
  
  73
  - Introduction
    73
  - Periodic Maintenance Chart for the Emission Control System
    73
- Engine
  
  76
- Chassis
  
  92
  - Adjusting the Front Disc Brake
    92
    
    Adjusting the Rear Disc Brake
    92
    
    Checking the Brake Fluid Level
    93
    
    Checking the Front Brake Pads
    93
    
    Checking the Rear Brake Pads
    94
    
    Checking the Front Brake Hose
    94
    
    Checking the Rear Brake Hose
    94
    
    Adjusting the Rear Brake Light Switch
    94
    
    Bleeding the Hydraulic Brake System
    95
    
    Adjusting the Drive Chain Slack
    96
    
    Lubricating the Drive Chain
    96
    
    Checking and Adjusting the Steering Head
    97
    
    Checking the Front Fork
    98
    
    Adjusting the Front Fork Legs
    98
    
    Air Bleeding from Front Fork
    99
    
    Adjusting the Rear Shock Absorber Assembly
    99
    
    Checking the Tires
    101
    
    Checking the Wheels
    103
    
    Checking and Tightening the Spokes
    103
    
    Checking and Lubricating the Cables
    103
    
    Lubricating the Levers
    103
  - Spoke Nipple Wrench (8–9)
    103
    
    Lubricating the Pedal
    104
    
    Lubricating the Sidestand
    104
Chassis

109
- Front Wheel
  
  112
  - Removing the Front Wheel
    114
  - Checking the Front Wheel
    114
  - Disassembling the Front Wheel
    115
  - Assembling the Front Wheel
    115
  - Installing the Front Wheel (Disc)
    115
- Rear Wheel
  
  117
  - Removing the Rear Wheel
    119
  - Disassembling the Rear Wheel
    119
  - Checking the Rear Wheel
    119
  - Checking and Replacing the Rear Wheel Sprocket
    119
  - Assembling the Rear Wheel
    120
  - Installing the Rear Wheel (Disc)
    120
- Front Brake
  
  121
- Rear Brake
  
  133
  - Introduction
    138
  - Checking the Rear Brake Disc
    138
  - Replacing the Rear Brake Pads
    138
  - Removing the Rear Brake Caliper
    139
  - Disassembling the Rear Brake Caliper
    139
  - Checking the Rear Brake Caliper
    140
  - Assembling the Rear Brake Caliper
    140
  - Installing the Rear Brake Caliper
    140
  - Removing the Rear Brake Master Cylinder
    141
  - Checking the Rear Brake Master Cylinder
    141
  - Assembling the Rear Brake Master Cylinder
    142
  - Installing the Rear Brake Master Cylinder
    142
  - Handlebar
    144
  - Removing the Handlebars
    146
  - Checking the Handlebar
    146
  - Installing the Handlebar
    146
- Front Fork
  
  149
  - Removing the Front Fork Legs
    152
  - Disassembling the Front Fork Legs
    152
  - Checking the Front Fork Legs
    153
  - Assembling the Front Fork Legs
    153
  - Installing the Front Fork Legs
    157
- Steering Head
  
  159
  - Removing the Lower Bracket
    161
  - Checking the Steering Head
    161
  - Installing the Steering Head
    161
- Rear Shock Absorber Assembly
  
  163
- Swingarm
  
  166
  - Removing the Swingarm
    167
  - Checking the Swingarm
    167
  - Installing the Swingarm
    167
- Chain Drive
  
  169
  - Removing the Drive Chain
    170
  - Checking the Drive Chain
    170
  - Checking the Drive Sprocket
    171
  - Checking the Rear Wheel Sprocket
    171
  - Installing the Drive Chain
    171
Engine

173
- Engine Removal
  
  175
  - Installing the Engine
    179
    
    Installing the Shift Pedal
    179
- Camshaft
  
  180
  - Removing the Camshaft
    182
  - Checking the Camshaft
    182
  - Checking the Timing Chain and Camshaft Sprocket
    184
  - Checking the Timing Chain Tensioners
    184
  - Checking the Decompression System
    185
  - Installing the Camshafts
    185
  - Cylinder Head
    188
- Removing the Cylinder Head
  
  189
  - Checking the Cylinder Head
    189
  - Installing the Cylinder Head
    189
- Valves and Valve Springs
  
  192
  - Removing the Valves
    192
  - Checking the Valves and Valve Guides
    193
  - Checking the Valve Seats
    194
  - Checking the Valve Springs
    196
  - Checking the Valve Lifters
    197
  - Installing the Valves
    197
- Cylinder and Piston
  
  199
  - Removing the Piston
    200
  - Checking the Cylinder and Piston
    200
  - Checking the Piston Rings
    201
  - Checking the Piston Pin
    201
  - Installing the Piston and Cylinder
    202
- Starter Motor
  
  204
  - Checking the Starter Motor
    206
  - Assembling the Starter Motor
    207
- Clutch
  
  208
  - Removing the Clutch
    212
  - Checking the Friction Plates
    212
  - Checking the Clutch Plates
    212
  - Checking the Clutch Springs
    213
  - Checking the Clutch Housing
    213
  - Checking the Clutch Boss
    213
  - Checking the Pressure Plate
    213
  - Checking the Clutch Push Rods
    213
  - Checking the Primary Drive Gear
    214
  - Checking the Primary Driven Gear
    214
  - Installing the Clutch
    214
  - Checking the Shift Shaft
    218
  - Checking the Stopper Lever
    218
  - Installing the Shift Shaft
    218
- Oil Pump and Balancer Gear
  
  219
  - Removing the Oil Pump
    221
  - Checking the Oil Pump
    221
  - Assembling the Oil Pump
    221
  - Installing the Oil Pump and Balancer Gear
    222
- Generator and Starter Clutch
  
  224
  - Removing the Generator
    227
  - Checking the Starter Clutch
    227
  - Installing the Starter Clutch
    228
  - Installing the Generator
    228
- Crankcase
  
  230
- Crankshaft Assembly and Balancer Shaft
  
  235
- Transmission
  
  238
  - Checking the Shift Forks
    241
  - Checking the Shift Drum Assembly
    241
  - Checking the Transmission
    241
  - Installing the Shift Forks and Shift Drum Assembly
    242
  - Installing the Transmission
    243
Cooling System

245
- Radiator
  
  246
  - Checking the Radiator
    247
  - Installing the Radiator
    247
- Thermostat
  
  249
  - Checking the Thermostat
    250
  - Installing the Thermostat Assembly
    250
- Water Pump
  
  251
  - Checking the Water Pump
    252
  - Assembling the Water Pump
    252
Fuel System

255
- Fuel Tank
  
  256
  - Installing the Fuel Pump
    257
  - Installing the Fuel Tank
    257
  - Removing the Fuel Pump
    257
  - Removing the Fuel Tank
    257
  - Pressure Gauge
    261
    
    Adjusting the Throttle Position Sensor
    262
- Throttle Bodies
  
  261
  - Checking the Injectors
    261
  - Checking the Throttle Bodies
    261
  - Checking the Pressure Regulator
    261
  - Checking the Pressure Regulator Operation
    261
- Air Induction System
  
  264
  - Checking the Air Induction System
    267
  - Canister (for California)
    268
Electrical System

269
- Ignition System
  
  272
  - Circuit Diagram
    272
  - Troubleshooting
    274
- Electric Starting System
  
  276
  - Circuit Diagram
    276
  - Starting Circuit Cut-Off System Operation
    278
  - Troubleshooting
    280
- Charging System
  
  282
  - Circuit Diagram
    282
  - Troubleshooting
    284
- Lighting System
  
  286
  - Circuit Diagram
    286
  - Troubleshooting
    288
- Signaling System
  
  290
  - Circuit Diagram
    290
  - Troubleshooting
    292
- Cooling System
  
  296
  - Circuit Diagram
    296
  - Troubleshooting
    298
- Fuel Injection System
  
  300
  - Circuit Diagram
    300
  - Ecu Self-Diagnostic Function
    302
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    303
  - Troubleshooting Method
    305
  - Diagnostic Mode
    305
  - Troubleshooting Details
    312
- Fuel Pump System
  
  326
  - Circuit Diagram
    326
  - Trouble Shooting
    328
- Electrical Components
  
  330
  - Checking the Switches
    334
  - Checking the Bulbs and Bulb Sockets
    337
  - Checking the Fuses
    338
  - Checking and Charging the Battery
    339
  - Checking the Relays
    342
  - Checking the Diode
    344
  - Checking the Ignition Spark Gap
    345
  - Checking the Ignition Coil
    345
  - Checking the Crankshaft Position Sensor
    346
  - Checking the Lean Angle Sensor
    346
  - Checking the Stator Coil
    347
  - Checking the Rectifier/Regulator
    347
  - Checking the Horn
    348
  - Checking the Speed Sensor
    348
  - Checking the Fuel Sender (Fuel Pump)
    349
  - Checking the Coolant Temperature Sensor
    349
  - Checking the Radiator Fan Motor
    350
  - Checking the Throttle Position Sensor
    350
  - Checking the Exup Servo Motor
    351
  - Checking the Intake Air Pressure Sensor
    351
  - Checking the Intake Air Temperature Sensor
    351
  - Checking the Intake Solenoid
    352
Troubleshooting

353
- General Information
  353
- General Information
  354
- Incorrect Engine Idling Speed
  354
- Starting Failures
  354
- Troubleshooting
  354
- Faulty Clutch
  355
- Faulty Gear Shifting
  355
- Jumps out of Gear
  355
- Overheating
  355
- Poor Medium-And-High-Speed Performance
  355
- Shift Pedal Does Not Move
  355
- Faulty Front Fork Legs
  356
- Faulty Lighting or Signaling System
  356
  - Engine
    359
- Overcooling
  356
- Poor Braking Performance
  356
- Unstable Handling
  356

Yamaha WR250R Owner's Manual (112 pages)

Brand: Yamaha | Category: Motorcycle | Size: 3 MB

Table of Contents
6
Location of Important Labels
8
Safety Information
12
Description
17
Left View
17
Right View
18
Controls and Instruments
19
Instrument and Control Functions
20
Main Switch/Steering Lock
20
Indicator Lights and Warning Lights
21
Multi-Function Display
22
Handlebar Switches
27
Clutch Lever
28
Shift Pedal
29
Brake Lever
29
Brake Pedal
29
Fuel Tank Cap
30
Fuel
30
Catalytic Converter
32
Seat
32
Helmet Holder
33
Adjusting the Front Fork
33
Front Fork Bleeding
35
Adjusting the Shock Absorber Assembly
36
EXUP System
37
Sidestand
38
Ignition Circuit Cut-Off System
38
For Your Safety - Pre-Operation Checks
40
Operation and Important Riding Points
43
Starting the Engine
43
Shifting
44
Engine Break-In
45
Parking
46
Owner's Tool Kit
48
Periodic Maintenance Chart for the Emission Control System
49
General Maintenance and Lubrication Chart
51
Removing and Installing Panels
55
Checking the Spark Plug
58
Canister (for California)
59
Engine Oil
59
Coolant
62
Cleaning the Air Filter Element and Check Hose
63
Cleaning the Spark Arrester
65
Adjusting the Engine Idling Speed
66
Checking the Throttle Grip Free Play
66
Valve Clearance
67
Tires
67
Spoke Wheels
69
Adjusting the Clutch Lever Free Play
69
Adjusting the Brake Lever Free Play
70
Checking the Shift Pedal
71
Brake Light Switches
71
Checking the Front and Rear Brake Pads
72
Checking the Brake Fluid Level
73
Changing the Brake Fluid
74
Drive Chain Slack
74
Cleaning and Lubricating the Drive Chain
75
Checking and Lubricating the Cables
76
Checking and Lubricating the Throttle Grip and Cable
76
Checking and Lubricating the Brake and Clutch Levers
77
Checking and Lubricating the Brake Pedal
77
Checking and Lubricating the Sidestand
78
Lubricating the Swingarm Pivots
78
Checking the Front Fork
78
Checking the Steering
79
Checking the Wheel Bearings
79
Battery
80
Replacing the Fuses
81
Replacing the Headlight Bulb
82
Tail/Brake Light
83
Replacing a Turn Signal Light Bulb
83
Replacing the License Plate Light Bulb
84
Supporting the Motorcycle
85
Front Wheel
85
Rear Wheel
86
Troubleshooting
87
Troubleshooting Charts
89
Motorcycle Care and Storage
91
Matte Color Caution
91
Care
91
Storage
93
Specifications
95
Consumer Information
98
Identification Numbers
98
Reporting Safety Defects
100
Motorcycle Noise Regulation
101
Maintenance Record
102
Yamaha Motor
105
Warranty
105
Yamaha Extended Service (Y.e.s.)
106
Index
108

YAMAHA WR250R Owner's Manual (98 pages)

Brand: YAMAHA | Category: Motorcycle | Size: 2 MB

Important Manual Information
4
Table of Contents
6
Safety Information

8
- Specifications
  11
Description

13
- Left View
  13
- Right View
  14
- Controls and Instruments
  15
Instrument and Control Functions

16
- Main Switch/Steering Lock
  16
- Unlock Steering
  17
- Indicator Lights and Warning Lights
  17
- Multi-Function Display
  18
  - Set Clock
    20
  - Manual Start
    21
- Handlebar Switches
  23
- Clutch Lever
  24
- Shift Pedal
  25
- Brake Lever
  25
- Brake Pedal
  25
- Fuel Tank Cap
  26
- Fuel
  26
- Catalytic Converter
  28
- Seat
  28
- Helmet Holder
  29
- Adjusting the Front Fork
  29
- Front Fork Bleeding
  31
- Adjusting the Shock Absorber Assembly
  32
- EXUP System
  33
- Sidestand
  34
- Ignition Circuit Cut-Off System
  34
For Your Safety - Pre-Operation Checks

36
Operation and Important Riding Points

39
- Starting the Engine
  39
- Shifting
  40
- Tips for Reducing Fuel Consumption
  41
- Engine Break-In
  41
- Parking
  42
Periodic Maintenance and Adjustment

43
- Owner's Tool Kit
  44
- Periodic Maintenance Chart for the Emission Control System
  45
- General Maintenance and Lubrication Chart
  46
- Removing and Installing Panels
  50
- Checking the Spark Plug
  53
- Check/Change Engine Oil Level
  54
- Engine Oil and Oil Filter Element
  54
- Coolant
  56
- Cleaning the Air Filter Element and Check Hose
  59
- Adjusting the Engine Idling Speed
  61
- Checking the Throttle Grip Free Play
  61
- Valve Clearance
  62
- Tires
  62
- Tire Air Pressure
  62
- Spoke Wheels
  64
- Adjusting the Clutch Lever Free Play
  64
- Adjusting the Brake Lever Free Play
  65
- Checking the Shift Pedal
  66
- Brake Light Switches
  66
- Checking the Front and Rear Brake Pads
  67
- Checking the Brake Fluid Level
  67
- Changing the Brake Fluid
  68
- Drive Chain Slack
  69
- Cleaning and Lubricating the Drive Chain
  70
- Checking and Lubricating the Cables
  71
- Checking and Lubricating the Throttle Grip and Cable
  71
- Checking and Lubricating the Brake and Clutch Levers
  71
- Checking and Lubricating the Brake Pedal
  72
- Checking and Lubricating the Sidestand
  72
- Lubricating the Swingarm Pivots
  73
- Checking the Front Fork
  73
- Checking the Steering
  74
- Checking the Wheel Bearings
  74
- Battery
  74
- Replacing the Fuses
  76
  - Replacing the Headlight Bulb
    77
  - Tail/Brake Light
    78
  - Replacing a Turn Signal Light Bulb
    78
  - Replacing the License Plate Light Bulb
    79
  - Replacing an Auxiliary Light Bulb
    80
  - Supporting the Motorcycle
    80
  - Front Wheel
    81
  - Rear Wheel
    82
  - Troubleshooting
    83
  - Troubleshooting Charts
    85
Motorcycle Care and Storage

87
- Matte Color Caution
  87
- Care
  87
- Storage
  89
Specifications

91
Consumer Information

94
- Identification Numbers
  94

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YAMAHA WR250R Manuals

Yamaha WR250R Service Manual (364 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshaft

Removing the Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Starter Motor

Clutch

Oil Pump and Balancer Gear

Generator and Starter Clutch

Crankcase

Crankshaft Assembly and Balancer Shaft

Transmission

Cooling System

Radiator

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Bodies

Air Induction System

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

Electrical Components

Troubleshooting

Yamaha WR250R Owner's Manual (112 pages)

Table of Contents

YAMAHA WR250R Owner's Manual (98 pages)

Table of Contents

Safety Information

Description

Instrument and Control Functions

For Your Safety - Pre-Operation Checks

Operation and Important Riding Points

Periodic Maintenance and Adjustment

Motorcycle Care and Storage

Specifications

Consumer Information

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YAMAHA Categories