Yamaha Wr250r 2008 Manual
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1 2 3 4 5 6 7 8 9 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ...........................................................................3-1 INTRODUCTION ......................................................................................3-1 Periodic maintenance chart for the emission control system ...................3-1 ENGINE ..........................................................................................................3-4 ADJUSTING THE VALVE CLEARANCE .................................................3-4 ADJUSTING THE ENGINE IDLING SPEED ............................................3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ...............................3-6 CHECKING THE SPARK PLUG ..............................................................3-8 CHECKING THE IGNITION TIMING........................................................3-8 MEASURING THE COMPRESSION PRESSURE...................................3-9 CHECKING THE ENGINE OIL LEVEL ....................................................3-10 CHANGING THE ENGINE OIL ................................................................3-11 ADJUSTING THE CLUTCH CABLE FREE PLAY....................................3-12 CLEANING THE AIR FILTER ELEMENT ................................................3-13 CHECKING THE THROTTLE BODY JOINT............................................3-14 CHECKING THE FUEL LINE ...................................................................3-14 CHECKING THE CYLINDER HEAD BREATHER HOSE ........................3-15 CHECKING THE EXHAUST SYSTEM ....................................................3-15 ADJUSTING THE EXUP CABLES ...........................................................3-15 CLEANING THE SPARK ARRESTER .....................................................3-16 CHECKING THE CANISTER (FOR CALIFORNIA ONLY).......................3-17 CHECKING THE COOLANT LEVEL........................................................3-17 CHECKING THE COOLING SYSTEM .....................................................3-17 CHANGING THE COOLANT ...................................................................3-18 CHASSIS ........................................................................................................3-20 ADJUSTING THE FRONT DISC BRAKE.................................................3-20 ADJUSTING THE REAR DISC BRAKE ...................................................3-20 CHECKING THE BRAKE FLUID LEVEL .................................................3-21 CHECKING THE FRONT BRAKE PADS .................................................3-21 CHECKING THE REAR BRAKE PADS ...................................................3-22 CHECKING THE FRONT BRAKE HOSE ................................................3-22 CHECKING THE REAR BRAKE HOSE ...................................................3-22 ADJUSTING THE REAR BRAKE LIGHT SWITCH ..................................3-22 BLEEDING THE HYDRAULIC BRAKE SYSTEM ....................................3-23 ADJUSTING THE DRIVE CHAIN SLACK ................................................3-24 LUBRICATING THE DRIVE CHAIN .........................................................3-24 CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-25 CHECKING THE FRONT FORK ..............................................................3-26 ADJUSTING THE FRONT FORK LEGS ..................................................3-26 AIR BLEEDING FROM FRONT FORK ....................................................3-27 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY...................3-27 CHECKING THE TIRES...........................................................................3-29 CHECKING THE WHEELS ......................................................................3-31 CHECKING AND TIGHTENING THE SPOKES.......................................3-31 CHECKING AND LUBRICATING THE CABLES .....................................3-31 LUBRICATING THE LEVERS ..................................................................3-31 LUBRICATING THE PEDAL ....................................................................3-32 LUBRICATING THE SIDESTAND ...........................................................3-32
ELECTRICAL SYSTEM .................................................................................3-33 CHECKING AND CHARGING THE BATTERY........................................3-33 CHECKING THE FUSES .........................................................................3-33 REPLACING THE HEADLIGHT BULB ....................................................3-33 ADJUSTING THE HEADLIGHT BEAM ....................................................3-33
PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EAS17580 Periodic maintenance chart for the emission control system * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. No. ITEM ROUTINEINITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month4000 mi (6000 km) or 6 months7000 mi (11000 km) or 12 months10000 mi (16000 km) or 18 months13000 mi (21000 km) or 24 months16000 mi (26000 km) or 30 months 1* Fuel line Check fuel hoses for cracks or damage. Replace if necessary. √√√√√ 2 Spark plug Check condition. Adjust gap and clean. Replace at 7000 mi (11000 km) or 12 months and there- after every 6000 mi (10000 km) or 12 months. √ Replace. √ Replace. √ 3 Spark arrester Clean. √√√√√ 4* Valve clearance Check and adjust valve clearance when engine is cold.Every 26600 mi (42000 km) 5* Crankcase breather system Check breather hose for cracks or damage. Replace if necessary. √√√√√ 6* Exhaust system Check for leakage. Tighten if necessary. Replace gasket(s) if neces- sary. √√√√√ 7* Evaporative emis- sion control system (For California only) Check control system for damage. Replace if necessary. √√ 8* Air induction sys- tem Check the air cut-off valve, reed valve, and hose for damage. Replace any damaged parts. √√
General maintenance and lubrication chart 3-2 EAS32164 General maintenance and lubrication chart No. ITEM ROUTINEINITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month4000 mi (6000 km) or 6 months7000 mi (11000 km) or 12 months10000 mi (16000 km) or 18 months13000 mi (21000 km) or 24 months16000 mi (26000 km) or 30 months 1* Air filter element Clean with solvent. Replace if necessary. √√√√√ 2* Clutch Check operation. Adjust or replace cable. √√√√√√ 3* Front brake Check operation, fluid level, and for fluid leakage. Adjust brake lever free play and replace brake pads if necessary. √√√√√√ 4* Rear brake Check operation, fluid level, and for fluid leakage. Replace brake pads if nec- essary. √√√√√√ 5* Brake hose Check for cracks or damage. √√√√√ Replace. Every 4 years 6* Wheels Check runout, spoke tight- ness and for damage. Tighten spokes if necessary. √√√√√ 7* Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. √√√√√ 8* Wheel bearings Check bearings for smooth operation. Replace if necessary. √√√√√ 9* Swingarm pivot bearings Check bearing assemblies for looseness. √√√√√ 10 Drive chain Check chain slack, align- ment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.Every 300 mi (500 km) and after washing the motorcycle or riding in the rain 11 * Steering bearings Check bearing assemblies for looseness. Moderately repack with lith- ium-soap-based grease. √√√√ Repack. √ 12 * Chassis fasteners Check all chassis fitting and fasteners. Correct if necessary. √√√√√ 13 Brake lever pivot shaft Apply silicone grease lightly. √√√√√ 14 Brake pedal pivot shaft Apply lithium-soap-based grease lightly. √√√√√ 15 Clutch lever pivot shaft Apply lithium-soap-based grease lightly. √√√√√
3-3 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. 16 Sidestand pivot Check operation. Apply lithium-soap-based grease lightly. √√√√√ 17 * Sidestand switch Check operation and replace if necessary. √√√√√√ 18 * Front fork Check operation and for oil leakage. Replace if necessary. √√√√√ 19 * Shock absorber assembly Check operation and for oil leakage. Replace if necessary. √√√√√ 20 * Rear suspension link pivots Check operation. Correct if necessary. √√ 21 Engine oil Change (warm engine before draining). √√√√√√ 22 Engine oil filter ele- ment Replace. √√√ 23 * Cooling system Check hoses for cracks or damage. Replace if necessary. √√√√√ Change with ethylene glycol anti-freeze coolant every 24 months.Change. 24 * Front and rear brake switches Check operation. √√√√√√ 25 * Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. √√√√√√ 26 * Throttle grip hous- ing and cable Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. √√√√√ 27 * Lights, signals and switches Check operation. Adjust headlight beam. √√√√√√ No. ITEM ROUTINEINITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month4000 mi (6000 km) or 6 months7000 mi (11000 km) or 12 months10000 mi (16000 km) or 18 months13000 mi (21000 km) or 24 months16000 mi (26000 km) or 30 months
ENGINE 3-4 EAS20471 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Seat Side cover (left/right) Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. 2. Drain: Coolant Refer to “CHANGING THE COOLANT” on page 3-20. 3. Remove: Throttle cable Clutch cable Refer to “CAMSHAFT” on page 5-6. 4. Remove: Ignition coil assembly Spark plug Refer to “CAMSHAFT” on page 5-6. 5. Remove: Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Air vent hose (Air induction) Cylinder head cover Refer to “CAMSHAFT” on page 5-6. 6. Remove: Timing mark accessing screw “1” Crankshaft end cover “2” 7. Measure: Valve clearanceOut of specification → Adjust. a. Turn the crankshaft counterclockwise. b. Align TDC mark “a” of the generator rotor with mark “b” of the generator rotor cover. c. Measure the valve clearance with a thickness gauge “1”. Out of specification → Adjust. 8. Adjust: Valve clearance a. Remove: Cam chain tensioner Camshaft cap Intake camshaft Exhaust camshaft NOTE: Refer to “CAMSHAFT” on page 5-6. 1 2 Valve clearance (cold) Intake 0.13 – 0.20 mm (0.0051 – 0.0079 in) Exhaust 0.23 – 0.30 mm (0.0091 – 0.0118 in) Special thickness gauge 90890-03180 Feeler gauge set YU-26900-9 a b 1
ENGINE 3-5 Before removing the cam chain and camshaft, connect the cam chain using a wire so that it does not drop in the crankcase. b. Remove the valve lifter “1” and the valve pad “2” with a hand valve lapper. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be in- stalled in the correct place. c. Select the proper valve pad from the follow- ing table. NOTE: The thickness of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be round- ed in order to reach the closest equivalent to the original. Remember that the replacement valve pad number is a rough value. Repeat the above procedure until you have the standard valve clearance. d. Install the new valve pad “3” and the valve lift- er “4”. NOTE: When installing the valve pad, direct the pad having a number on it toward the lifter. Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotat- ed by hand. Install the valve lifter and the valve pad in the correct place. e. Install the exhaust and intake camshafts, tim- ing chain and the camshaft caps. Valve lapper 90890-04101 Valve lapping tool YM-A8998 1 2 Valve pad range Nos. 120 – 240 Valve pad thickness120 – 240 mm (4.72 – 9.45 in) Available valve pads25 thicknesses in 0.05 mm (0.002 in) incre- ments Camshaft cap bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 4 3 M M TR..
ENGINE 3-6 NOTE: Refer to “CAMSHAFT” on page 5-6. Lubricate the camshaft bearings, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft sprocket marks with the edge of the cylinder head. Turn the crankshaft counterclockwise several full turns to seat the parts. f. Measure the valve clearance again. g. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained. 9. Install: All removed parts NOTE: For installation, reverse the removal procedure. Note the following points. 10.Fill the coolant as specification, and then check the coolant level. EAS20590 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the idling speed, the air filter el- ement should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up until it reaches the specified temperature. 2. Use a temperature probe tester “1” and con- tact it to the drain bolt thread. 3. Install: Digital tachometer (Red/black ignition coil leads)4. Measure: Engine idling speed Out of specification → Adjust. 5. Adjust: Engine idling speed a. Adjust the engine idling speed by turning the adjust screw “1” in direction “a” or “b”. 6. Adjust: Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 3-8. Throttle cable free play (Cable free play at surface of throttle grip flange) 3 – 5 mm EAS20640 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: Throttle cable free play “a” Out of specification → Adjust. Oil temperature 60.0 ° C (140.00 ° F) 1 Digital tachometer 90890-06760 YU-39951-B Engine idling speed 1450 – 1650 r/min Direction “a”Engine idling speed → Decrease Direction “b”Engine idling speed → Increase Throttle cable free play 3.0 – 5.0 mm 1 a b
ENGINE 3-7 2. Remove: Seat Side cover (left/right) Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. 3. Adjust: Throttle cable free play NOTE: When the throttle is opened, the accelerator ca- ble is pulled. Throttle body side a. Loosen the locknut “1” on the decelerator ca- ble. b. Turn the adjusting nut “2” in direction “a” or “b” to take up any slack on the decelerator ca- ble. c. Loosen the locknut “3” on the accelerator ca- ble. d. Turn the adjusting nut “4” in direction “a” or “b” until the specified throttle cable free play is obtained. e. Tighten the locknuts “1”, “3”. NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. Handlebar side a. Loosen the locknut “1”. b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. c. Tighten the locknut. WARNING EWA12920 After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. 4. Install: Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left/right) Side cover (left/right) Throttle cable free play 3.0 – 5.0 mm (0.12 – 0.20 in) Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. a Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. aa 2 3 14 b b 1 2a b
ENGINE 3-8 Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20690 CHECKING THE SPARK PLUG 1. Remove: Seat Side cover (left/right) Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: Ignition coil assembly “1” Spark plug Refer to “CAMSHAFT” on page 5-6. CAUTION: ECA13330 Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check: Spark plug type Incorrect → Change. 4. Check: Electrode Damage/wear → Replace the spark plug. Insulator Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: Spark plug (with a spark plug cleaner or wire brush) 6. Measure: Spark plug gap “a” Out of specification → Regap.7. Install: Spark plug NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: Ignition coil assembly Ignition coil assembly lead NOTE: Apply silicone hydrate to the sealing point of the ignition coil, and install the ignition coil assembly by positioning its connector to the right. 9. Install: Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left/right) Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAS20700 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: Timing mark accessing screw Seat Side cover (left/right) Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 2. Connect: Timing light “1” Digital tachometer Manufacturer/model NGK/CR9EK 1 Spark plug gap 0.6 – 0.7 mm (0.024 – 0.028 in) Spark plug 13 Nm (1.3 m•kg, 9.4 ft•lb) aa TR..