Yamaha YBR250 2007 Manuals

Yamaha YBR250 2007 Manuals

Manuals and User Guides for Yamaha YBR250 2007. We have 1 Yamaha YBR250 2007 manual available for free PDF download: Service Manual

Yamaha YBR250 2007 Service Manual

Yamaha YBR250 2007 Service Manual (361 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.07 MB

Table of Contents

Table of Contents

7
- Chassis
  6
- Electrical System
  6
- Engine
  6
- Fuel Injection System
  6
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Table of Contents
    7
  - Gen Info
    9
- Chapter 1
  9
- Model Label
  9
- Vehicle Identification
  9
- Vehicle Identification Number
  9
- Features
  10
  - Fi System
    11
- Important Information
  12
  - Preparation for Removal and Disassembly
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers, Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking the Connections
  14
- Special Tools
  16
Chapter 2 Specifications

18
- General Specifications
  19
- Spec
  19
- Engine Specifications
  20
- Chassis Specifications
  29
- Electrical Specifications
  32
- Conversion Table
  34
- General Tightening Torque Specification
  34
- Tightening Torques
  35
  - Engine Tightening Torques
    35
- Lubrication Points and Lubricant Types
  39
  - Engine
    39
  - Chassis
    40
- Oil Cooling System Diagram
  41
- Lubrication Flow
  42
- Lubrication System Diagrams
  43
- Cable Routing
  47
Chapter 3 Periodic Checks and Adjustments

55
- Chk Adj
  57
- Introduction
  57
- Periodic Maintenance and Lubrication Table
  57
- Cowling and Side Covers
  59
  - Side Covers
    59
- Fuel Tank
  60
  - Removing the Fuel Tank
    61
  - Removing the Fuel Pump
    61
  - Installing the Fuel Pump
    62
  - Installing the Fuel Hose
    62
- Engine
  63
- Chassis
  83
- Eletrical System
  99
  - Checking and Charging the Battery
    99
  - Checking the Fuses
    105
  - Replacing the Headlight Bulb
    106
  - Replacing the Headlight Auxiliary Bulb
    107
  - Adjusting the Headlight Beam
    107
  - Adjusting the Digital Clock
    107
Chapter 4 Chassis

108
- Chas
  110
  - Front Wheel and Brake Disc
    110
- Front Wheel
  111
- Checking the Front Wheel
  112
- Removing the Front Wheel
  112
- Checking the Front Brake Disc
  115
- Installing the Front Wheel
  116
- Adjusting the Front Wheel Static Balancing
  117
- Rear Wheel, Brake Disc and Rear Wheel Sprocket
  120
  - Rear Wheel
    120
  - Brake Shoe Plate and Rear Wheel Sprocket
    121
  - Wheel
    122
  - Brake Shoe Plate
    123
  - Removing the Rear Wheel
    124
  - Checking the Rear Wheel
    125
  - Checking and Replacing the Sprocket
    126
  - Checking the Rear Wheel Drive Hub
    126
  - Removing the Rear Brake Lining
    127
  - Assembling the Rear Brake
    129
  - Installing the Rear Wheel
    131
  - Rear Wheel Static Balance
    132
- Front Brake
  133
  - Front Brake Pads
    133
  - Replacing the Front Brake Pads
    134
  - Front Brake Master Cylinder
    137
  - Disassembling the Front Brake Master Cylinder
    139
  - Checking the Brake Master Cylinder
    140
  - Assembling and Installing the Brake Master Cylinder
    140
  - Front Brake Calipers
    143
  - Removing the Front Brake Caliper
    145
  - Checking the Brake Caliper
    145
  - Assembling the Brake Caliper
    147
  - Installing the Brake Caliper
    148
- Front Fork
  150
  - Removing the Front Fork Legs
    154
  - Disassembling the Front Fork Legs
    154
  - Checking the Front Fork Legs
    156
  - Assembling the Front Fork Legs
    157
  - Installing the Front Fork Legs
    161
- Handlebar
  163
  - Removing the Handlebar
    165
  - Checking the Handlebar
    165
  - Installing the Handlebar
    165
- Steering Head
  169
  - Removing the Lower Bracket
    171
  - Checking the Steering Head
    171
  - Installing the Steering Head
    172
- Rear Shock Absorber Assembly
  174
- Swingarm and Drive Chain
  180
  - Removing the Swingarm
    182
  - Checking the Swingarm
    183
  - Removing the Sprocket
    184
  - Removing the Drive Chain
    184
  - Checking the Drive Chain
    184
  - Installing the Swingarm
    187
Chapter 5 Engine

189
- Eng
  191
- Muffler and Exhaust Pipe
  191
- Removing the Engine
  191
- Leads, Cables, Hoses and Ignition Coil
  192
- Engine
  194
- Installing the Engine
  195
- Cylinder Head
  197
  - Removing the Cylinder Head
    199
  - Checking the Cylinder Head
    200
  - Checking the Tappet Covers and Camshaft
    201
  - Sprocket Cover
    201
  - Checking the Timing Chain Tensioner
    201
  - Checking the Camshaft Sprocket
    201
  - Installing the Cylinder Head
    202
- Rocker Arms and Camshaft
  206
- Valves and Valve Springs
  211
  - Removing the Valves
    213
  - Checking the Valves and Valve Guides
    214
  - Checking the Valve Seat
    216
  - Checking the Valve Springs
    218
  - Installing the Valves
    219
- Cylinder and Piston
  221
  - Removing the Cylinder and Piston
    221
  - Checking the Cylinder and Piston
    221
  - Checking the Piston Rings
    223
  - Checking the Piston Pin
    224
  - Installing the Cylinder and Piston
    225
- Clutch
  227
  - Clutch Cover
    227
  - Pull Lever Shaft
    228
  - Clutch
    228
  - Removing the Clutch
    231
  - Checking the Primary Drive Gear
    232
  - Checking the Friction Plates
    232
  - Checking the Clutch Plates
    232
  - Checking the Clutch Springs
    233
  - Checking the Clutch Housing
    233
  - Checking the Pressure Plate
    234
  - Checking the Push Lever Shaft and Push Rod
    234
  - Installing the Clutch
    234
- Oil Pump and Balancer Gear
  238
  - Oil Pump
    240
  - Checking the Oil Pump
    241
  - Checking the Oil Delivery Hoses and Pipes
    242
  - Assembling the Oil Pump
    242
  - Installing the Oil Pump
    243
  - Removing the Balancer Gear
    244
  - Checking the Balancer Gear
    244
  - Assembling the Balancer Gear
    245
  - Balancer Gear Timing with the Drive Gear
    245
- Oil Cooler
  246
  - Checking the Oil Cooler
    248
  - Assembling the Oil Cooler
    249
- Shift Shaft
  250
  - Shift Shaft and Stopper Lever
    250
  - Disassembling the Shift Shaft
    251
  - Checking the Shift Shaft
    251
  - Installing the Shift Shaft
    251
- Starter Clutch and Ac Magneto
  253
  - Removing the Ac Magneto
    255
  - Checking the Starter Clutch (One Way)
    256
  - Assembling the Ac Magneto
    256
- Crankshaft and Crankcases
  259
  - Disassembling the Crankcases
    261
  - Removing the Balancer and Crankshaft Assembly
    262
  - Checking the Crankshaft
    262
  - Checking the Crankcases
    263
  - Checking the Timing Chain Guide and Timing Chain
    263
  - Assembling the Crankshaft
    264
  - Installing the Crankshaft Assembly
    264
- Transmission
  268
  - Main Axle/ Drive Axle
    268
  - Removing the Transmission
    270
  - Checking Shift Drum and Shift Forks
    270
  - Checking the Transmission
    271
  - Installing the Transmission
    272
Chapter 6 Fuel Injection System

273
- Electrical Circuit Diagram
  275
- Ecu's Self-Diagnostic Function
  276
- Self-Diagnostic Function Table
  278
- Troubleshooting Method
  280
  - Diagnostic Mode
    281
- Troubleshooting Details
  287
- Throttle Body
  300
  - Removing the Fuel Hose
    303
  - Removing the Fuel Pump
    303
  - Checking the Fuel Injector
    304
  - Checking the Throttle Body
    304
  - Installing the Throttle Body
    304
  - Checking the Fuel Pump
    305
  - Installing the Fuel Pump
    306
  - Installing the Fuel Hose
    306
  - Checking the Fid (Fast Idle Solenoid) System
    307
- Air Induction System
  308
  - Air Induction System Diagram
    308
  - Air Injection
    309
  - Checking the Air Induction System
    309
Chapter 7 Electrical System

310
- Elec
  311
- Electrical Components
  311
- Checking Switch Continuity
  313
- Checking the Switches
  314
- Checking the Bulbs and Bulb Sockets
  315
  - Types of Bulbs
    315
  - Checking the Condition of the Bulbs
    316
- Ignition System
  321
  - Circuit Diagram
    323
  - Troubleshooting
    325
- Starter Motor
  328
  - Checking the Starter Motor
    330
  - Assembling the Starter Motor
    332
- Charging System
  334
  - Circuit Diagram
    336
  - Troubleshooting
    337
- Signaling System
  341
  - Circuit Diagram
    341
  - Troubleshooting
    342
  - Checking the Signaling System
    343
- Chapter 8 Troubleshooting
  352
- Starting Failures
  352
- Incorrect Engine Idling Speed
  353
- Faulty Clutch
  354
- Faulty Gear Shifting
  354
- Poor Medium-And-High-Speed Performance
  354
- Overheating
  355
- Poor Braking Performance
  355
- Faulty Front Fork Legs
  356
- Unstable Handling
  356
- Trbl Shtg
  357
  - Faulty Lighting or Signaling System
    357

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