Yamaha WR250F 2023 Page 147 Owner'S Manual Download

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TROUBLESHOOTING

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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

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SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION

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Summary of Contents for WR250F 2023

Page 1: ...lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie das Fahrzeug in Betrieb nehmen Leggere attentamente questo manuale prima di utilizzare questo veicolo WR250F WR250FP WR250F 2023 WR250F W...

Page 2: ...attentamente questo manuale prima di utilizzare questo veicolo Questo manuale dovrebbe accompagnare il veicolo se viene venduto Q Bitte lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie...

Page 3: ...Read this manual carefully before operating this vehicle 2023 OWNER S MANUAL WR250F WR250F WR250FP BAK 28199 52 E0...

Page 4: ...Canada Ltd Canada To contact Transport Canada you may call Defect Investigations and Recall Division at 819 994 3328 or toll free 1 800 333 0510 go to www tc gc ca or email mvs sa tc gc ca or write t...

Page 5: ...0FP OWNER S MANUAL 2023 by Yamaha Motor Co Ltd First edition July 2022 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibi...

Page 6: ...manual is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill conce...

Page 7: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8 TUNING 9 EAM10003 TABLE OF CONTENTS...

Page 8: ......

Page 9: ...R FOR CONNECTING OPTIONAL PART For Canada 1 10 IMPORTANT INFORMATION 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS 1 11 INSTRUMENT AND CONTROL FUNCTIONS 1 12 WARNING LIGHTS 1 12...

Page 10: ...REAK IN PROCEDURES 1 23 SHIFTING 1 23 MAINTENANCE AFTER BREAK IN 1 25 MAJOR MAINTENANCE 1 25 AIR FILTER MAINTENANCE 1 25 TORQUE CHECK POINTS 1 26 MOTORCYCLE CARE AND STORAGE 1 28 CARE 1 28 STORAGE 1 2...

Page 11: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 12: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 13: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Page 14: ...LOCATION OF IMPORTANT LABELS 1 4 EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CAN 9 10 11 7 8 13 12 1 2 3 4 5 6...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 5...

Page 16: ...LOCATION OF IMPORTANT LABELS 1 6 AUS NZL ZAF EUR...

Page 17: ...18 2 3 4 1 5 10 11 13 12 9 8 7 6 19 1 Clutch lever 2 Multi function display 3 Engine trouble warning light 4 Fuel level warning light 5 Front brake lever 6 Throttle grip 7 Start switch 8 Radiator cap...

Page 18: ...ehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into t...

Page 19: ...the engine in a closed area The exhaust gas is poisonous Never let flames near the servicing area NOTICE ECA26050 This application is designed for adjusting the settings on a standard vehicle In case...

Page 20: ...erform the operation again 1 Turn on the smartphone 2 For two minutes after the start switch is pressed or while the engine is running the CCU is activated input the CCU serial num ber into your smart...

Page 21: ...t to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the like 6 If coolant is left adhered to the chassis paint and plating will be damaged Therefore rinse it out with wate...

Page 22: ...circuit of the warning light can be checked by pushing the start switch The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the sta...

Page 23: ...e shown in the table be low EAM30188 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti vate the front brake EAM30189 REAR BRAKE PEDAL The...

Page 24: ...IP When operating the throttle grip in the closing di rection the starter knob 1 moves in the direc tion b as shown and returns to its original position WARNING EWA20470 While handling the starter kno...

Page 25: ...er km h Accumulated fuel consumption meter indica tor L For U K Speedometer MPH Accumulated fuel consumption meter indica tor GAL Changing the display item TIP The odometer will lock at 199999 The tri...

Page 26: ...A button and B button simultane ously to stop the timer measurement TIP Long pushing the A button for 1 second and more while the timer measurement is being stopped will reset the value 3 Push the A b...

Page 27: ...ven if the set tings are not finished and the setting mode dis play will disappear The display has been turned off The vehicle has been moved A communication error has occurred Setting the backlight b...

Page 28: ...Push the B button to change the units of the speedometer and fuel The unit display will change in the following order Except for U K Accumulated fuel consumption meter L GAL L Speedometer km h MPH km...

Page 29: ...s set as 100 Pushing the B button at a setting value of 110 will return the setting to 90 2 Push the A button to set the fuel consumption correction value The correction value will then be kept and th...

Page 30: ...the setting mode A button Odometer ODO TRIP A TRIP B Clock Timer Accumulated fuel consumption Setting the timer Putting measurement on standby A button B button Auto start Manual start A button Measu...

Page 31: ...2 ODO 3 TRIP A 4 TRIP B 5 Clock 6 Timer 7 Accumulated fuel consumption 8 SETTING MODE 9 Setting the backlight brightness 10 Setting the clock time hour 11 Setting the clock time minute 12 Setting the...

Page 32: ...ar ea The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area NOTICE ECA25910 If the throttle is open...

Page 33: ...left idling for 7 minutes If the engine stops push the start switch to restart the engine 2 Make a pit stop and check mounted areas for looseness oil leaks or other problems 3 Then drive it for about...

Page 34: ...ansmission into second gear Make sure not to shift the transmission into the neutral position 6 Open the throttle part way and gradually re lease the clutch lever 7 Follow the same procedure when shif...

Page 35: ...and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the brac...

Page 36: ...frame Link to rear shock absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tighten...

Page 37: ...t pedal Shift pedal to shift shaft Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rea...

Page 38: ...y rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter l...

Page 39: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 40: ...rk plug and then install the spark plug and the spark plug cap WARNING To pre vent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricat...

Page 41: ...NERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 4 ELECTRICAL SPECIFICATIONS 2 7 TIGHTENING TORQUES 2 8 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 8 ENGINE TIGHTENING TORQUE...

Page 42: ...mm 32 5 in Overall height 1270 mm 50 0 in Seat height 955 mm 37 6 in Wheelbase 1480 mm 58 3 in Ground clearance 320 mm 12 60 in Weight Curb weight 115 kg 254 lb Shift up points 1st 2nd 20 km h 12 mph...

Page 43: ...L 0 77 US qt 0 64 Imp qt With oil filter removal 0 75 L 0 79 US qt 0 66 Imp qt Quantity disassembled 0 95 L 1 00 US qt 0 84 Imp qt Cooling system Coolant quantity Radiator including all routes 0 93 L...

Page 44: ...0 815 22 27 Secondary reduction ratio 3 923 51 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Idlin...

Page 45: ...CAN Rear tire Type With tube Size 110 100 18 64M CAN 140 80 18 70R AUS AUT BEL CHE CYP CZE DEU DNK ESP FIN FRA GBR GRC HRV HUN IRL ITA NLD NOR NZL POL PRT SVK SVN SWE TUR ZAF Manufacturer model DUNLO...

Page 46: ...from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock a...

Page 47: ...nt Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 11 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Nu...

Page 48: ...y 12 V 6 0 Ah 10 HR Headlight Bulb type Halogen bulb Bulb wattage Headlight HS1 35 0 W 35 0 W Brake tail light LED Meter lighting EL Electroluminescent Indicator light Fuel level warning light LED Eng...

Page 49: ...o avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi...

Page 50: ...8 kgf m 28 lb ft Timing chain guide stopper plate exhaust side M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner cap bolt M6 1 6 N m 0 6 kgf m 4 4 lb ft Timing chain tensioner bolt M6 2 10 N m 1...

Page 51: ...screw M14 1 6 N m 0 6 kgf m 4 4 lb ft Drive sprocket cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Crankcase bearing cover plate screw M8 4 22 N m 2 2 kgf m 16 lb ft Bearing plate cover bolt left side of...

Page 52: ...oth sides of the lock washers Generator rotor nut M12 1 65 N m 6 5 kgf m 48 lb ft Stator coil screw M5 3 10 N m 1 0 kgf m 7 4 lb ft Crankshaft position sensor bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stat...

Page 53: ...screw front fork M5 2 1 3 N m 0 13 kgf m 0 95 lb ft Front fork protector bolt M6 6 5 N m 0 5 kgf m 3 7 lb ft Speed sensor bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Plate bolt M5 2 3 8 N m 0 38 kgf m 2 8 lb...

Page 54: ...25 kgf m 1 8 lb ft Bolt rear brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt upper side M10 2 45 N m 4 5 kgf m 33...

Page 55: ...eat bolt M8 2 22 N m 2 2 kgf m 16 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Air...

Page 56: ...TIGHTENING TORQUES 2 15...

Page 57: ...THE CYLINDER HEAD BREATHER HOSE 3 15 CHECKING THE EXHAUST SYSTEM 3 15 CHECKING THE COOLANT LEVEL 3 16 CHECKING THE COOLING SYSTEM 3 17 CHANGING THE COOLANT 3 17 CHASSIS 3 19 ADJUSTING THE FRONT DISC...

Page 58: ...NG AND LUBRICATING THE CABLES 3 29 LUBRICATING THE BRAKE LEVER 3 30 LUBRICATING THE CLUTCH LEVER 3 30 LUBRICATING THE PEDAL 3 30 CHECKING THE SIDESTAND 3 30 LUBRICATING THE SIDESTAND 3 30 ELECTRICAL S...

Page 59: ...l Odometer readings 600 mi 1000 km or 1 month 1800 mi 3000 km or 3 months 3000 mi 5000 km or 6 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check conditio...

Page 60: ...Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every ride 12 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease ever...

Page 61: ...runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data a...

Page 62: ...vel and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses 22 Outside nuts and bolts Retighten 23 Air filter Clean and lubricate Replace 24 Oil filter Replace 25 Engine...

Page 63: ...Swingarm Inspect lube and retighten 37 Relay arm connect ing rod Inspect lube and retighten 38 Sidestand Lubricate 39 Steering head Inspect free play and retighten Clean and lubricate Replace bearing...

Page 64: ...ar brake 3 19 3 19 3 19 3 20 3 20 3 20 3 20 3 21 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 22 4 32 4 32 4 33 4 33 4 33 Wheels Check for exce...

Page 65: ...t Side cover left right Air scoop left right Fuel tank Refer to FUEL TANK on page 6 1 ECU Engine Control Unit 2 Remove Spark plug Cylinder head cover 3 Remove Timing mark accessing screw 1 Crankshaft...

Page 66: ...3 Install Digital tachometer TIP Get the high tension cord 1 of the ignition coil pinched in the detector a of the digital tachom eter 4 Measure Engine idling speed Out of specification Regulate 5 Adj...

Page 67: ...to pull the hose TIP Remove the fuel tank turn this 180 clockwise and put it in the frame 2 as shown 2 Remove Holder Spark plug cap Spark plug NOTICE ECA24410 In order not to allow the dirt accumulat...

Page 68: ...the clutch the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign material to enter the crankcase EAM30225 CHANGING THE ENGINE OI...

Page 69: ...ing 2 d Install the oil strainer 6 Install Gasket Drain bolt 7 Pour the specified amount of engine oil into the oil filler cap hole 8 Install Oil filler cap 9 Check Oil level Refer to CHECKING THE ENG...

Page 70: ...ssure again e Tighten the oil pressure check bolt EAM30216 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar...

Page 71: ...ement when squeezing the element 5 Check Air filter element Damage Replace 6 Apply Yamaha foam air filter oil or other quality foam air filter oil a Put the air filter element into a plastic bag and d...

Page 72: ...d into the two edges b on the air fil ter case Be sure to carefully align the two ribs c locat ed on the left and right sides of the air filter case cover with the projections d on the air scoop and t...

Page 73: ...t pipe and muffler are cool before cleaning the spark arrester Do not start the engine when cleaning the exhaust system 1 Remove Exhaust pipe 1 Exhaust pipe 2 Refer to EXHAUST SYSTEM on page 5 1 2 Rem...

Page 74: ...adiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a t...

Page 75: ...Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 EAM30212 CHANGING THE COOLANT WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gi...

Page 76: ...e concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them w...

Page 77: ...STING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting nut 2 until the brake pedal is in the correct position c Tighten the locknut WARNING EWA19150 A soft...

Page 78: ...the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 7 EAM30232 CHECKING THE R...

Page 79: ...ficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 2 Bleed the brake system a Fill the reservoir...

Page 80: ...ack WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 1 Adjust Drive chain slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn the adjusting b...

Page 81: ...gle to the steering nut wrench Move the steering to the left and right a couple of times to check that it moves smoothly c Turn the front fork to the right and left a few times and make sure that the...

Page 82: ...he handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 16 TIP If any damage is found or the front fork does not op...

Page 83: ...1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly matc...

Page 84: ...orber assembly smooth ac tion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly...

Page 85: ...necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Tur...

Page 86: ...ld be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth a...

Page 87: ...reak in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARN...

Page 88: ...ting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHE...

Page 89: ...the headlight unit bolts lift and remove the headlight unit 2 Remove Headlight coupler 1 Bulb cover 2 3 Remove Headlight bulb 1 4 Install Headlight bulb Fasten the new headlight bulb with the head lig...

Page 90: ...ELECTRICAL SYSTEM 3 32...

Page 91: ...4 9 REPLACING THE REAR BRAKE PADS 4 9 HANDLEBAR 4 11 REMOVING THE HANDLEBAR 4 11 CHECKING THE HANDLEBAR 4 11 INSTALLING THE HANDLEBAR 4 11 FRONT FORK 4 16 REMOVING THE FRONT FORK LEGS 4 16 DISASSEMBLI...

Page 92: ...CHAIN DRIVE 4 32 REMOVING THE DRIVE CHAIN 4 32 CHECKING THE DRIVE CHAIN 4 32 CHECKING THE DRIVE SPROCKET 4 33 CHECKING THE REAR WHEEL SPROCKET 4 33 INSTALLING THE DRIVE CHAIN 4 33...

Page 93: ...ilter case in serting the grooves c into the ribs d of the air filter case and inserting the projection e into the slot f in the air filter case install the air scoop and secure it with the bolts EAM3...

Page 94: ...GENERAL CHASSIS 4 2 a Projection b Slot c Rib side cover d Rib rear fender a a a 1 1 c c b b d d...

Page 95: ...he brake disc 1 between the brake pads 2 correctly 2 Install Front wheel sensor Front wheel sensor bracket NOTICE ECA21020 Make sure there are no foreign materials in the front wheel sensor rotor and...

Page 96: ...by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front w...

Page 97: ...1 4 tooth wear a Replace the rear wheel sprocket and the drive sprocket as a set Bent tooth Replace the rear wheel sprock et and the drive sprocket as a set 2 Replace Rear wheel sprocket a Remove the...

Page 98: ...ear wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK...

Page 99: ...specification Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw and...

Page 100: ...fer to CHECKING THE BRAKE FLUID LEVEL on page 3 19 5 Check Brake lever operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 Bolt brake c...

Page 101: ...of specification Replace the brake pads as a set 3 Install Brake pad a Connect the plastic hose 1 to the bleed screw 2 and place a container under the end of the plastic hose b Loosen the bleed screw...

Page 102: ...fluid level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 19 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 2...

Page 103: ...aken it EAM30054 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1...

Page 104: ...wer handlebar holder nut 4 Install Clutch lever holder 1 Clutch lever 2 Clutch switch 3 TIP The clutch lever holder 1 should be installed according to the dimensions shown 5 Install Engine stop switch...

Page 105: ...ard 7 Install Clutch cable 1 TIP Before installation apply the lithium soap based grease to the clutch cable end 8 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3...

Page 106: ...le grip 3 moves smoothly If it does not retighten the screws for adjustment 13 Install Rubber cover 1 Cover throttle cable housing 2 14 Install Start switch 1 Front brake master cylinder assembly 2 Fr...

Page 107: ...HANDLEBAR 4 15 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 8 Throttle grip free play 3 0 6 0 mm 0 12 0 24 in 2 5 1 4 3 4...

Page 108: ...emove Front fork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between t...

Page 109: ...erously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage R...

Page 110: ...er tube bushing Slide metal Oil seal Copper washer Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE...

Page 111: ...ion Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after installation 7 Install Base valve 1 to the damper assembly 2 TIP First bring the damper...

Page 112: ...e damper assem bly 12 Allow the overflowing oil to escape at the hole a in the damper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tig...

Page 113: ...ct the oil seal lip 15 Install Piston metal 1 TIP Install the piston metal onto the slot on inner tube 16 Install Outer tube 1 to the inner tube 2 17 Install Slide metal 1 Washer 2 to the outer tube T...

Page 114: ...t the steps 14 to 20 22 Measure Distance a Out of specification Turn the locknut to specification 23 Install Upper spring seat 1 Fork spring 2 to the damper assembly 3 TIP Install the upper spring sea...

Page 115: ...the damper assembly 4 TIP While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damp er assembly 27 Measure...

Page 116: ...ghten the damper assembly 32 Install Protector guide 1 EAM30059 INSTALLING THE FRONT FORK LEGS 1 Install Front fork 1 TIP Temporarily tighten the lower bracket pinch bolts Do not tighten the upper bra...

Page 117: ...fork protector 6 Install Protector 1 Bolt protector 2 7 Adjust Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Cap bolt ring wre...

Page 118: ...FRONT FORK 4 26 8 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 1 1...

Page 119: ...itting Replace 3 Replace Bearing Bearing race a Remove the bearing race from the steer ing head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and...

Page 120: ...teering ring nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 23 5 Check the steering...

Page 121: ...teering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If tor...

Page 122: ...1 TIP While removing the rear shock absorber assem bly lower bolt hold the swingarm so that it does not drop down 3 Remove Rear shock absorber assembly upper bolt Rear shock absorber assembly EAM30067...

Page 123: ...al movement a Measure the tightening torque of the pivot shaft nut b Check the swingarm side play a by mov ing the swingarm from side to side If the swingarm has side to side play check the bushings t...

Page 124: ...ner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location eac...

Page 125: ...OCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 5 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP I...

Page 126: ...dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 22 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital...

Page 127: ...E FRICTION PLATES 5 3 CHECKING THE CLUTCH PLATES 5 3 CHECKING THE CLUTCH SPRINGS 5 3 CHECKING THE CLUTCH HOUSING 5 3 CHECKING THE CLUTCH BOSS 5 4 CHECKING THE PRESSURE PLATE 5 4 CHECKING THE PUSH LEVE...

Page 128: ...silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2 3 Install Clamp Silencer 1 Bolt silencer 2 TIP Install and temporarily tighten the silencer so that its joint is posi...

Page 129: ...t the exhaust pipe clamp 1 does not ride on the projection a on the ex haust pipe 2 or silencer 3 Be sure to insert the projection b into the slot in the exhaust pipe or silencer A Exhaust pipe 1 and...

Page 130: ...Out of specification Replace the clutch plates as a set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of...

Page 131: ...cation Replace EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the...

Page 132: ...CE ECA24660 Make sure to tighten to specification other wise it may damage the other part that is fas tened together TIP Install the conical washer on the main axle with the OUT mark a facing away fro...

Page 133: ...ification color orange 6 and friction plate 1 identifi cation color black 1 Apply the engine oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TIP...

Page 134: ...s in stages and in a crisscross pattern 11 Install Gasket 1 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stages and in a crisscross pattern Clutch spring bolt 10 N m 1 0 kgf m 7...

Page 135: ...1 2 3 4 5 6 7 8 9 10 FUEL SYSTEM FUEL TANK 6 1 REMOVING THE FUEL TANK 6 1 INSTALLING THE FUEL TANK 6 1...

Page 136: ...the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few cloths in the area under where it will be removed To prevent sand dust and other foreign m...

Page 137: ...FUEL TANK 6 2 3 Connect Fuel pump coupler 4 Install Air scoop left right Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 1 a...

Page 138: ...FUEL TANK 6 3...

Page 139: ...7 8 9 10 ELECTRICAL SYSTEM FUEL INJECTION SYSTEM 7 1 ECU SELF DIAGNOSTIC FUNCTION 7 1 ELECTRICAL COMPONENTS 7 3 CHECKING THE BULBS AND BULB SOCKETS 7 3 CHECKING THE FUSES 7 3 CHECKING AND CHARGING THE...

Page 140: ...gine trouble warning light Engine trouble warning light indication and fuel injection system operation The engine trouble warning light flashes when any one of the following conditions is present and...

Page 141: ...g light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified...

Page 142: ...place the bulb socket EAM30290 CHECKING THE FUSES The following procedure applies to all of the fus es 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check Main fuse 1 Radiator fan motor fuse 2...

Page 143: ...rate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery sh...

Page 144: ...comes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illu...

Page 145: ...ure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charging current written on the battery this type of battery char...

Page 146: ...ELECTRICAL COMPONENTS 7 7...

Page 147: ...SSION 8 6 TROUBLESHOOTING OF COOLING SYSTEM 8 7 TROUBLESHOOTING OF BRAKE 8 8 TROUBLESHOOTING OF SUSPENSION 8 8 TROUBLESHOOTING OF STEERING HANDLING 8 10 TROUBLESHOOTING OF CHARGING SYSTEM 8 11 TROUBLE...

Page 148: ...ngine will not start or is difficult to start but it cranks Symptom Possible cause Actions Starter motor does not operate Have a Yamaha dealer check the electrical system Starter motor operates but th...

Page 149: ...g Replace the piston and piston rings as a set Seized or damaged piston Replace the piston and piston rings as a set Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set...

Page 150: ...element Clean or replace the air filter ele ment Incorrect oil level high Adjust the oil level to the specified level Symptom Possible cause Actions Noise heard from around cylinder head Incorrect va...

Page 151: ...ve gear Replace the balancer drive gear and balancer shaft as a set Worn or damaged big end bearing Replace the big end bearing Worn or damaged crankshaft jour nal bearing Replace the crankshaft journ...

Page 152: ...bushing Replace the clutch housing Improperly installed pull lever Align the match mark on the pull lever before installation Incorrect oil level Adjust the engine oil level to the specified level Inc...

Page 153: ...ransmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission...

Page 154: ...radiator Faulty radiator fan motor Have a Yamaha dealer check the electrical system Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly conne...

Page 155: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Page 156: ...er rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged c...

Page 157: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 158: ...lace the swingarm bearing Damaged or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions Battery is not charged Have a Yamaha dealer check the elec...

Page 159: ...or stuck throttle position sensor is detected 21 Coolant temperature sensor open or short circuit detected 22 Intake air temperature sensor open or short circuit detected 30 The vehicle has overturned...

Page 160: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8 13...

Page 161: ...E 9 1 FRONT FORK SETTING 9 1 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 9 2 SETTING OF SPRING AFTER REPLACEMENT 9 2 FRONT FORK SETTING PARTS 9 3 REAR SUSPENSION SETTING 9 3 CHOOSING SET LENGTH 9...

Page 162: ...line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other...

Page 163: ...ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the...

Page 164: ...he rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bol...

Page 165: ...ng force WARNING EWA19200 When using a rear shock absorber other than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never...

Page 166: ...BER AS SEMBLY on page 3 26 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 8...

Page 167: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to s...

Page 168: ...unt Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Ba...

Page 169: ...enger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 170: ...CHASSIS 9 9...

Page 171: ...sure sensor 32 Speed sensor 33 Engine stop switch 34 Gear position switch 35 Mode switch Except for Cana da 36 Diode 1 37 Starting circuit cut off relay 38 Clutch switch 39 Start switch 40 Diode 4 41...

Page 172: ...PRINTED IN JAPAN E...

Page 173: ...attentamente questo manuale prima di utilizzare questo veicolo Questo manuale dovrebbe accompagnare il veicolo se viene venduto Q Bitte lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie...

Page 174: ...lesen Sie diese Bedienungsanleitung sorgf ltig durch bevor Sie das Fahrzeug in Betrieb nehmen Leggere attentamente questo manuale prima di utilizzare questo veicolo WR250F WR250FP WR250F 2023 WR250F W...

Page 175: ...r R W Br R L R L R L R L B L B L B L B L B L B L B L B L B L B L B L R L B L B L B B B L B B R L Br B L B L W L B B B B Br W L L L L L L L L L R L R L R L R L R L B L B L B L B L B L B L B L L L L L B...

Page 176: ...B PUSH FREE ON OFF ON OFF B B WR250F WR250FP 2023 WIRING DIAGRAM WR250F WR250FP 2023 SCH MA DE C BLAGE WR250F WR250FP 2023 SCHALTPLAN WR250F WR250FP 2023 SCHEMA ELETTRICO WR250F WR250FP 2023 DIAGRAMA...

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