Yamaha Wr250r 2008 Manual
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ENGINE 3-9 (Red/black ignition coil leads) 3. Check: Ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. b. Check the firing range as shown. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable. 4. Remove: Timing light Digital tachometer 5. Install: Air scoop (left/right) Side cover (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. Timing mark accessing screw EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. 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. 4. Disconnect: Ignition coil assembly coupler 5. Remove: Ignition coil assembly Spark plug CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinders. 6. Install: Compression gauge “1” Timing light 90890-03141 Inductive clamp timing light YU-03141 Digital tachometer 90890-06760 YU-39951-B Oil temperature 55 – 65 ° C Engine idling speed 1450 – 1650 r/min 1 Compression gauge 90890-03081 Engine compression tester YU-33223
ENGINE 3-10 7. Measure: Compression pressure Out of specification → Refer to steps (c) and (d). a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. NOTE: Make use the battery is fully charged when tak- ing measurements. Make sure there is no compression leakage from the connecting section of the compres- sion gauge. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate. d. If the compression pressure is below the min- imum specification, pour a teaspoonful of en- gine oil into the spark plug bore and measure again. Refer to the following table. 8. Install: Spark plug 9. Install: Ignition coil assembly 10.Connect: Ignition coil assembly lead coupler 11.Install: Fuel tank Refer to “FUEL TANK” on page 7-1. Air scoop (left/right) Side cover (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Check: Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. Compression pressure (Stan- dard) 850 kPa (121 psi) (8.5 kg/cm 2 ) Compression pressure (Mini- mum) 740 kPa (105 psi) (7.4 kg/cm 2 ) Compression pressure (Maxi- mum) 950 kPa (135 psi) (9.5 kg/cm 2 ) Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oilPiston ring (s) wear or damage → Repair. 1 Same as without oilPiston, valves, cylinder head gasket or pis- ton possibly defec- tive → Repair. Spark plug 13 Nm (1.3 m•kg, 9.4 ft•lb) TR.. b a
ENGINE 3-11 CAUTION: ECA13360 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled “ENERGY CONSERVING II”. Do not allow foreign materials to enter the crankcase. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20810 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt.3. Remove: Engine oil filler cap “1” Engine oil drain bolt “2” (along with the gasket) 4. Drain: Engine oil (completely from the crankcase) 5. If the oil filter element is also to be replaced, perform the following procedure. a. Remove the oil filter element cover “1” and oil filter element “2”. b. Replace the O-rings “3”. c. Install the new oil filter element and the oil fil- Type YAMALUBE 4, SAE 10W-30 or SAE 20W-40 Recommended engine oil grade API service SG type or higher, JASO standard MA 10 30 50 70 90 1100 130 ˚F YAMALUBE 4 (10W-30) or SAE 10W-30 YAMALUBE 4 (20W-40) or SAE 20W-40 –10 0 10 20 30 40 –20 50 ˚C 1 2 1 3 2 1
ENGINE 3-12 ter element cover. 6. Check: Engine oil drain bolt gasket Oil filter element drain bolt gasket Damage → Replace. 7. Install: Engine oil drain bolt (along with the gasket) 8. Fill: Crankcase (with the specified amount of the recom- mended engine oil) 9. Install: Engine oil filler cap 10.Start the engine, warm it up for several min- utes, and then turn it off. 11.Check: Engine (for engine oil leaks) 12.Check: Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-12. 13.Check: Engine oil pressure a. Slightly loosen the oil check bolt “1”.b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “OIL PUMP AND BALANC- ER GEAR” on page 5-45. d. Start the engine after solving the problem (s) and check the engine oil pressure again. e. Tighten the oil check bolt to specification. EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: Clutch cable free play “a” Out of specification → Adjust. 2. Adjust: Clutch cable free play Handlebar side a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch cable free play is Oil filter element cover bolt (M10) 10 Nm (1.0 m•kg, 7.2 ft•lb) Engine oil drain bolt 20 Nm (2.0 m•kg, 14 ft•lb) Engine oil quantity Total amount 1.50 L (1.59 US qt) (1.32 Imp.qt) Without oil filter element replace- ment 1.30 L (1.37 US qt) (1.14 Imp.qt) With oil filter element replace- ment 1.40 L (1.48 US qt) (1.23 Imp.qt) TR.. TR.. Oil check bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Clutch lever free play 10.0 – 15.0 mm (0.39 – 0.59 in) 1 TR.. a
ENGINE 3-13 obtained. c. Tighten the locknut “1”. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the clutch cable side. Clutch cable side a. Slide the clutch cable cover. b. Loosen the locknuts “1”. c. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch cable free play is obtained. d. Tighten the locknut “1”. e. Return the clutch cable cover to its original position. EAS20941 CLEANING THE AIR FILTER ELEMENT 1. Remove: Air filter check hose NOTE: On the bottom of the air filter case is a check hose. If dust or water or both collects in this hose, replace the air filter element, clean the air filter case and air filter check hose. 2. Remove: Right side cover Refer to “GENERAL CHASSIS” on page 4-1. 3. Open the air filter case cover by removing its screws. 4. Remove the air filter element assembly “1” by removing the clip “2”. 5. Remove: Air filter element Remove the air filter element from the air filter element frame. 6. Clean: Air filter element (with solvent) WARNING EWA13020 Never use low flash point solvents, such as gasoline, to clean the air filter element. Such solvents may cause a fire or an explosion. NOTE: After cleaning, gently squeeze the air filter ele- ment to remove the excess solvent. CAUTION: ECA13430 Do not twist the air filter element when squeezing it. 7. Check: Air filter element Damage → Replace. 8. Apply the recommended oil to the entire sur- face of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. 2 1 a b 1 a b 2 21
ENGINE 3-14 9. Install: Air filter element frame CAUTION: ECA14401 Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect carburetor synchronization, leading to poor engine per- formance and possible overheating. 10.Install: Air filter element assembly 11.Install: Air filter cover 12.Install: Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1. EAS21020 CHECKING THE THROTTLE BODY JOINT 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. Check: Throttle body joint “1” Cracks/damage → Replace. Insulator manifold “2” Cracks/damage → Replace.3. Install: Fuel tank Refer to “FUEL TANK” on page 7-1. Air scoop (left/right) Side cover (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, vacuum and breather hoses. 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. Check: Fuel hose “1” Cracks/damage → Replace. Loose connection → Connect properly. 3. Fuel tank Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. Air scoop (left/right) Side cover (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. Recommended oil Foam air filter oil or engine oil 1 2 1
ENGINE 3-15 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSE 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. Check: Cylinder head breather hose “1” Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: ECA14920 Make sure the cylinder head breather hose is routed correctly. 3. Install: Fuel tank Refer to “FUEL TANK” on page 7-1. Air scoop (left/right) Side cover (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Remove: Muffler protector 2. Check: Exhaust pipe Muffler Cracks/damage → Replace. Gasket Exhaust gas leaks → Replace. 3. Check: Tightening torque4. Install: Muffler protector EAS21100 ADJUSTING THE EXUP CABLES 1. Remove: Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: EXUP valve pulley cover “1” 1 Exhaust pipe nut “1” 20 Nm (2.0 m•kg, 14 ft•lb) Exhaust pipe and muffler bolt “2” 20 Nm (2.0 m•kg, 14 ft•lb) Muffler and muffler bracket bolt “3” 42 Nm (4.2 m•kg, 30 ft•lb) Muffler protector bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) TR.. 1 2 3 TR..
ENGINE 3-16 3. Check: EXUP system operation NOTE: Check operation by self-diagnostics diagnosis mode No.“53”. Refer to “FUEL INJECTION SYSTEM” on page 8-29. 4. Check: EXUP cable free play (at the EXUP valve pul- ley) Connect the battery power cables to the ser- vo motor, and measure its play. 5. Adjust: EXUP cable free play NOTE: Install pulley cable 1 (black chrome plated) to stamp 1 side, and install pulley cable 2 (white chrome plated) to stamp 2 side. a. Move EXUP pully by self-diagnostics diagno- sis mode No. “53”. b. Loosen both locknuts “1”. c. Turn the adjusting bolt “2” of pulley cable 1 to the position just when the EXUP pulley starts operating. d. Turn the adjusting bolt “2” of pulley cable 2 to the position when the cable has the sametension as for pulley cable 1. e. Tighten both locknuts “1” with specification. f. Install the EXUP valve pully cover. 6. Install: Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAS28970 CLEANING THE SPARK ARRESTER 1. Clean: Spark arrester WARNING EWA14680 Select a well-ventilated area free of com- bustible materials. Always let the exhaust system cool before performing this operation. Do not start the engine when removing the tailpipe from the muffler. a. Remove the bolt “1”. b. Remove the tailpipe “2” by pulling it out of the muffler. c. Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion “a” of the tailpipe and the in- ner contact surfaces of the muffler. EXUP cable free play 0 mm 1 Locknut 6 Nm (0.6 m•kg, 4.3 ft•lb) TR.. 21 2
ENGINE 3-17 d. Insert the tailpipe into the muffler and align the bolt holes. e. Insert the bolt and tighten it. EAS21090 CHECKING THE CANISTER (FOR CALIFORNIA ONLY) 1. Remove: Canister cover Refer to “CANISTER (FOR CALIFORNIA)” on page 7-13. 2. Check: Canister Hose Cracks/damage → Replace. 3. Install: Canister cover EAS21110 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Remove: Seat Air scoop Refer to “GENERAL CHASSIS” on page 4-1. 3. Check: Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level. CAUTION: ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. However, if dis- tilled water is not available, soft water may be used. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: Coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles. 6. Install: Air scoop (left) Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21120 CHECKING THE COOLING SYSTEM 1. Remove: Seat Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. 2. Check: Radiator “1” Spark arrester bolt 12 Nm (1.2 m•kg, 8.7 ft•lb) (Apply the molybde- num-disulfide grease) Canister cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 2 a TR.. TR.. a b
ENGINE 3-18 Radiator inlet hose “2” Radiator outlet hose “3” Cracks/damage → Replace. Refer to “RADIATOR” on page 6-1, “THER- MOSTAT” on page 6-4 and “WATER PUMP” on page 6-6. 3. Install: Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank (left/right) Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21130 CHANGING THE COOLANT 1. Remove: Seat Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: Coolant reservoir hose “1” Recovery tank “2” 3. Drain: Coolant (from the recovery) 4. Remove: Radiator cap “1” Remove the radiator cap by removing lock screw “2”. WARNING EWA13030 A hot radiator is under pressure. Therefore, do not remove the radiator 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 towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move. 5. Remove: Coolant drain bolt (water pump) “1” (along with the copper washer) 6. Drain: Coolant (from the engine and radiator) 7. Install: Copper washer Coolant drain bolt (water pump) 8. Install: Reservoir tank 9. Connect: Coolant reservoir hose 2 3 1 1 2 Coolant drain bolt (engine) 10 Nm (1.0 m•kg, 7.2 ft•lb) 2 1 1 New TR..