Yamaha WR250FM 2021 Off-Road Motorcycle Manuals

Manuals and User Guides for Yamaha WR250FM 2021 Off-Road Motorcycle. We have 1 Yamaha WR250FM 2021 Off-Road Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha WR250FM 2021 Owner's Service Manual

Yamaha WR250FM 2021 Owner's Service Manual (404 pages)

Brand: Yamaha | Category: Motorcycle | Size: 25.47 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
- Included Parts
  19
  - Nipple Wrench
    19
  - Handlebar Protector
    19
  - Fuel Hose Joint Cover
    19
  - Coupler for Connecting Optional Part
    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
  33
  - Warning Lights
    33
  - Engine Stop Switch
    33
  - Start Switch
    33
  - Shift Pedal
    33
  - Front Brake Lever
    34
  - Rear Brake Pedal
    34
  - Sidestand
    34
  - Starter Knob
    34
  - Fuel Tank Cap
    34
- Multi-Function Display
  36
  - Description
    36
  - Basic Mode
    36
  - Changeover to Basic Mode/Race Mode
    38
  - Race Mode
    39
  - Function Diagram
    42
- Starting and Break-In
  43
  - Fuel
    43
  - Handling Note
    43
  - Starting a Cold Engine
    43
  - Starting a Warm Engine
    44
  - Break-In Procedures
    44
  - Shifting
    44
- Maintenance after Break-In
  46
  - Major Maintenance
    46
  - Air Filter Maintenance
    46
- Torque-Check Points
  47
- Motorcycle Care and Storage
  49
  - Care
    49
  - Storage
    50
Specifications

53
- General Specifications
  54
- Engine Specifications
  55
- Chassis Specifications
  60
- Electrical Specifications
  61
  - Tightening Torques
    63
- General Tightening Torque Specifications
  63
  - Engine Tightening Torques
    64
  - Chassis Tightening Torques
    67
- Cable Routing Diagram
  70
Periodic Checks and Adjustments

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

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

199
- Lubrication System Chart and Diagrams
  
  201
  - Engine Oil Lubrication Chart
    201
  - Lubrication Diagrams
    202
- Engine Removal
  
  206
  - Removing the Engine
    211
  - Installing the Engine
    211
  - Installing the Exhaust Pipe and Muffler
    212
  - Camshaft
    214
  - Removing the Camshaft
    216
  - Checking the Camshaft
    217
  - Checking the Timing Chain and Camshaft Sprocket
    218
  - Checking the Timing Chain Tensioners
    218
  - Checking the Decompression System
    218
  - Installing the Camshafts
    218
- Cylinder Head
  
  221
- Valves and Valve Springs
  
  227
  - Removing the Valves
    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
  - Removing the Piston
    234
  - Checking the Cylinder and Piston
    234
  - Checking the Piston Rings
    235
  - Checking the Piston Pin
    235
  - Installing the Piston and Cylinder
    236
  - Generator
    238
  - Removing the Generator
    239
  - Checking the Generator
    239
  - Checking the Woodruff Key
    239
  - Installing the Generator
    239
- Starter Clutch
  
  241
  - Removing the Starter Clutch
    242
  - Checking the Starter Clutch
    242
  - Installing the Starter Clutch
    242
- Electric Starter
  
  244
  - Checking the Starter Motor
    246
  - Assembling the Starter Motor
    246
- Clutch
  
  248
  - Removing the Clutch
    251
  - Checking the Friction Plates
    251
  - Checking the Clutch Plates
    251
  - Checking the Clutch Springs
    251
  - Checking the Clutch Housing
    251
  - Checking the Clutch Boss
    252
  - Checking the Pressure Plate
    252
  - Checking the Push Lever Shaft
    252
  - Checking the Push Rods
    252
  - Checking the Primary Drive Gear
    252
  - Checking the Primary Driven Gear
    252
  - Installing the Clutch
    252
- Shift Shaft
  
  256
  - Removing the Segment
    257
  - Checking the Shift Shaft
    257
  - Checking the Stopper Lever
    257
  - Installing the Shift Shaft
    257
- Oil Pump
  
  260
  - Removing the Balancer
    262
  - Checking the Oil Pump
    262
  - Assembling the Oil Pump
    262
  - Installing the Oil Pump
    263
- Crankcase
  
  266
  - Disassembling the Crankcase
    268
  - Checking the Timing Chain Guide (Exhaust Side)
    268
  - Checking the Crankcase
    268
  - Assembling the Crankcase
    269
- Crankshaft and Balancer Shaft
  
  270
  - Removing the Crankshaft
    271
  - Checking the Crankshaft
    271
  - Installing the Crankshaft
    272
- Transmission
  
  273
  - Removing the Transmission
    274
  - Checking the Shift Forks
    274
  - Checking the Shift Drum Assembly
    274
  - Checking the Transmission
    274
  - Installing the Transmission
    275
Cooling System

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

289
- Fuel Tank
  290
- 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
- Ignition System
  
  302
  - Circuit Diagram
    302
  - Troubleshooting
    304
- Electric Starting System
  
  306
  - Circuit Diagram
    306
  - Starting Circuit Cut-Off System Operation
    308
  - Troubleshooting
    310
- Charging System
  
  312
  - Circuit Diagram
    312
  - Troubleshooting
    314
- Signaling System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Lighting System
  
  320
  - Circuit Diagram
    320
  - Troubleshooting
    322
- Cooling System
  
  324
  - Circuit Diagram
    324
  - Troubleshooting
    326
- Fuel Injection System
  
  328
  - Circuit Diagram
    328
  - Ecu Self-Diagnostic Function
    330
  - Troubleshooting Method
    331
  - Yamaha Diagnostic Tool
    332
  - Connecting the Yamaha Diagnostic Tool
    332
  - Troubleshooting Details (Fault Code)
    334
- Fuel Pump System
  
  354
  - Circuit Diagram
    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 Spark Gap
    366
  - Checking the Spark Plug Cap
    366
  - Checking the Ignition Coil
    366
  - Checking the Crankshaft Position Sensor
    367
  - Checking the Lean Angle Sensor
    368
  - Checking the Starter Motor Operation
    368
  - Checking the Stator Coil
    368
  - Checking the Rectifier/Regulator
    368
  - Checking the Speed Sensor
    369
  - Checking the Fuel Sender
    369
  - Checking the Resistor
    369
  - Checking the Radiator Fan Motor
    370
  - Checking the Coolant Temperature Sensor
    370
  - Checking the Throttle Position Sensor Input Voltage
    371
  - Checking the Intake Air Temperature Sensor
    371
  - Checking the Gear Position Switch
    372
  - Checking the Injector
    372
Troubleshooting

373
- Troubleshooting
  
  374
- Self-Diagnostic Function and Diagnostic Code Table
  
  385
Tuning

389
- Chassis
  390
- Drive and Rear Wheel Sprockets Setting Parts
  390
- Front Fork Setting
  390
- Selection of the Secondary Reduction Ratio (Sprocket)
  390
- Tire Pressure
  390
- Change in Amount and Characteristics of Fork Oil
  391
- Setting of Spring after Replacement
  391
- Choosing Set Length
  392
- Front Fork Setting Parts
  392
- Rear Suspension Setting
  392
- Setting of Spring after Replacement
  393
- Rear Shock Absorber Setting Parts
  394
- Suspension Setting (Front Fork)
  395
- Suspension Setting (Rear Shock Absorber)
  396

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