Yamaha Wr250r 2008 Manual
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ELECTRICAL COMPONENTS 8-80 sor shaft, check that the throttle position sen- sor voltage is within the specified range. The voltage does not change or it changes abruptly → Replace the throttle position sen- sor. EAS28360 CHECKING THE EXUP SERVO MOTOR 1. Check: EXUP servo motor operation Out of specification → Replace. a. Disconnect the EXUP cables from the EXUP servo motor pulley. b. Disconnect the EXUP servo motor coupler from the wire harness. c. Connect the battery leads to the EXUP servo motor coupler as shown. d. Check that the EXUP servo motor pulley ro- tates several times. CAUTION: ECA14390 To prevent damaging the EXUP servomotor, perform this test within a few seconds of connecting the battery. EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: Intake air pressure sensor output voltage Out of specification → Replace. a. Connect the pocket tester (DC 20 V) to the in- take air pressure sensor coupler (wire har- ness side) as shown. b. Set the main switch to “ON”. c. Measure the intake air pressure sensor out- put voltage. EAS28420 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: Intake air temperature sensor (from the air filter case.) WARNING EWA14110 Handle the intake air temperature sensor with special care. Never subject the intake air temperature Throttle position sensor output voltage 0.6 – 5.0 V Positive battery lead Black/Green “ 1 ” Negative battery lead Black/Red “ 2 ” 12 Intake air pressure sensor output voltage 3.75 – 4.25V Digital circuit tester 90890 – 03174 Model 88 Multimeter with ta- chometer YU-A1927 Positive tester probe Pink/White “ 1 ” Negative tester probe Black/Blue “ 2 ” 12
ELECTRICAL COMPONENTS 8-81 sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: Intake air temperature sensor resistance Out of specification → Replace. a. Connect the pocket tester ( Ω × 1k) to the in- take air temperature sensor terminal as shown. EAS32D1013 CHECKING THE INTAKE SOLENOID 1. Check: Intake solenoid resistance Out of specification → Replace. a. Disconnect the intake solenoid coupler from the wire harness. b. Connect the pocket tester ( Ω × 10) to the in- take solenoid terminal as shown.c. Measure the intake solenoid resistance. Intake air temperature sensor re- sistance 2.21 – 2.69 k Ω 20 ° C Digital circuit tester 90890 – 03174 Model 88 Multimeter with ta- chometer YU-A1927 Positive tester probe Brown/White “ 1 ” Negative tester probe Black/Blue “ 2 ” Intake solenoid resistance 42 – 48 Ω 20 ° C 12 Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive lead Red/White “ 1 ” Tester negative lead Brown/Black “ 2 ” 12
1 2 3 4 5 6 7 8 9 TROUBLESHOOTING TROUBLESHOOTING ...................................................................................9-1 GENERAL INFORMATION ......................................................................9-1 STARTING FAILURES.............................................................................9-1 INCORRECT ENGINE IDLING SPEED ...................................................9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ..........................9-2 FAULTY GEAR SHIFTING.......................................................................9-2 SHIFT PEDAL DOES NOT MOVE ...........................................................9-2 JUMPS OUT OF GEAR ...........................................................................9-2 FAULTY CLUTCH ....................................................................................9-2 OVERHEATING .......................................................................................9-2 OVERCOOLING.......................................................................................9-3 POOR BRAKING PERFORMANCE.........................................................9-3 FAULTY FRONT FORK LEGS.................................................................9-3 UNSTABLE HANDLING ...........................................................................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .......................................9-3
TROUBLESHOOTING 9-1 EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, adjustments, and replace- ment of parts. EAS28470 STARTING FAILURES Engine 1. Cylinder (s) and cylinder head (s) Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve 2. Piston (s) and piston ring (s) Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston 3. Air filter Improperly installed air filter Clogged air filter element 4. Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft Fuel system 1. Fuel tank Empty fuel tank Deteriorated or contaminated fuel 2. Fuel pump Faulty fuel pump 3. Fuel cock Clogged or damaged fuel hose 4. Throttle body Clogged pilot air passage Electrical system 1. Battery Discharged battery Faulty battery 2. Fuse (s) Blown, damaged or incorrect fuse Improperly installed fuse 3. Spark plug (s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4. Ignition coil (s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5. Ignition system ECU failure. Faulty crankshaft position sensor Broken generator rotor woodruff key 6. Switches and wiring Defective lean angle sensor Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections 7. Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder (s) and cylinder head (s) Incorrect valve clearance Damaged valve train components 2. Air filter Clogged air filter element Fuel system 1. Throttle body Air intake in throttle body joint Improper throttle cable free play Faulty air induction system Electrical system 1. Battery Discharged battery Faulty battery 2. Spark plug (s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator
TROUBLESHOOTING 9-2 Faulty spark plug cap 3. Ignition coil (s) Faulty ignition coil Cracked or broken ignition coil 4. Ignition system ECU failure. Faulty crankshaft position sensor EAS28520 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES” on page 9-1. Engine 1. Air filter Clogged air filter element Fuel system 1. Fuel pump Faulty fuel pump 2. Throttle body Defective throttle body 3. ECU ECU failure. EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to “Clutch drags”. EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1. Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2. Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil Clutch drags 1. Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Broken clutch boss Burnt primary driven gear bushing 2. Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil EAS28590 OVERHEATING Engine 1. Cylinder head (s) and piston (s) Heavy carbon buildup 2. Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Cooling system 1. Coolant Low coolant level 2. Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin 3. Water pump Damaged or faulty water pump Faulty thermostat Damaged fan motor or disconnected coupler Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe Fuel system 1. Throttle body Air intake in throttle body joint 2. Air filter
TROUBLESHOOTING 9-3 Clogged air filter element Chassis 1. Brake (s) Dragging brake Electrical system 1. Spark plug (s) Incorrect spark plug gap Incorrect spark plug heat range 2. Ignition system ECU failure Faulty radiator fan motor relay Faulty coolant temperature sensor EAS28610 OVERCOOLING Cooling system 1. Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Defective master cylinder kit Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent, damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O-ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28690 UNSTABLE HANDLING 1. Handlebar Bent or improperly installed handlebar 2. Steering head components Improperly installed upper bracket Improperly installed lower bracket (improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing race 3. Front fork leg (s) Uneven oil levels (both front fork legs) Unevenly tensioned fork spring (both front fork legs) Broken fork spring Bent or damaged inner tube Bent or damaged outer tube 4. Swingarm Worn bearing or bushing Bent or damaged swingarm 5. Rear shock absorber assembly (-ies) Faulty rear shock absorber spring Leaking oil or gas 6. Tire (s) Uneven tire pressures (front and rear) Incorrect tire pressure Uneven tire wear 7. Wheel (s) Incorrect wheel balance Broken or loose spoke Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8. Frame Bent frame Damaged steering head pipe Improperly installed bearing race EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Fuse open circuit Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit
TROUBLESHOOTING 9-4 Faulty main switch Headlight bulb life expired Tail/brake light does not come on Too many electrical accessories Incorrect connection Turn signal does not come on Fuse open circuit Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown, damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal relay Burnt-out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt-out turn signal bulb Horn does not sound Improperly adjusted horn Damaged or faulty horn (Coil open circuit or damaged terminal) Faulty main switch Faulty horn switch Faulty battery Blown, damaged or incorrect fuse Faulty wire harness
EAS28740 WIRING DIAGRAM WR250R(X)/WR250X(X) 2008 WIRING DIAGRAM 1.AC magneto 2.Rectifier/regulator 3.Main switch 4.Battery 5.Main fuse 6.Starter relay 7.Starter motor 8.Right handlebar switch 9.Engine stop switch 10.Start switch 11.Relay unit 12.Sidestand switch 13.Neutral switch 14.Clutch switch 15.Fuel pump 16.ECU (electronic control unit) 17.Ignition coil 18.Spark plug 19.Intake solenoid 20.Fuel injector 21.Air induction solenoid 22.Intake air temperature sensor 23.Coolant temperature sensor 24.Speed sensor 25.Throttle position sensor 26.Intake air pressure sensor 27.Lean angle sensor 28.EXUP servo motor 29.Meter assembly 30.Neutral indicator light 31.Coolant temperature warning light 32.Engine trouble warning light 33.Fuel level warning light 34.High beam indicator light 35.Turn signal indicator light 36.Turn signal relay 37.Turn signal switch 38.Rear right turn signal light 39.Front right turn signal/posi- tion light 40.Front left turn signal/position light 41.Rear left turn signal light 42.Headlight relay 43.Dimmer switch 44.Headlight 45.Horn 46.Horn switch47.Left handlebar switch 48.Rear brake switch 49.Front brake light switch 50.Tail/brake light 51.License plate light 52.Radiator fan motor relay 53.Radiator fan motor 54.Headlight fuse 55.Signal fuse 56.Ignition fuse 57.Radiator fan fuse 58.Fuel injection system fuse 59.Backup fuse EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B/G Black/Green B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White G/B Green/Black G/R Green/Red G/W Green/White G/Y Green/Yellow Gy/G Gray/Green Gy/R Gray/Red Gy/Y Gray/Yellow L/B Blue/Yellow L/R Blue/Red L/W Blue/White L/Y Blue/Yellow O/B Orange/Black P/W Pink/White R/B Red/Black R/G Red/Green R/L Red/Blue R/W Red/White R/Y Red/Yellow Sb/W Sky blue/White W/B White/Black W/R White/Red W/Y White/Yellow Y/B Yellow/Black Y/G Yellow/Green Y/L Yellow/Blue Y/R Yellow/Red