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Summary of Contents for Yamaha wr250f

• 1, Yamaha wr250f 5PH-28199-30 WR250F ( N ) OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU ET PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO
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• 30, Yamaha wr250f 7 — 9 TUN SETTING EC71Q000 Carburetor setting parts * For EUROPE ** For CDN, ZA, AUS and NZ Part name Size Part number Main jet Rich (STD) Lean #185 #182 #180 #178 #175 #172 #170 #168 #165 #162 #160 4MX-14943-44 4MX-14943-94 4MX-14943-43 4MX-14943-93 4MX-14943-42 4MX-14943-92 4MX-14943-41 4MX-14943-91 4MX-14943-40 4MX-14943-90 4MX-14943-39 Pilot jet Rich (STD) Lean #50 #48 #45 #42 #40 #38 #35 4MX-14948-07 4MX-14948-06 4MX-14948-05 4MX-14948-04 4MX-14948-03 4MX-14948-02 4MX-1…

• 4, 3 — 19 INSP ADJ ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Attach: ● Inductive tachometer To spark plug lead. 3. Adjust: ● Engine idling speed Adjustment steps: ● Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. ● Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Ind…

• 6, 4 — 8 ENG CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm (accelerator pump) 1 0 Air cut valve cover 1 A Spring (air cut valve) 1 B Diaphragm (air cut valve) 1 C Float c…

• 7, 4 — 9 ENG CARBURETOR Extent of removal Order Part name Q’ty Remarks G Float 1 H Needle valve 1 I Valve seat 1 J Main jet 1 K Needle jet 1 L Spacer 1 M Pilot jet 1 N Starter jet 1 O Push rod 1 Pull the push rod. P Throttle shaft assembly 1 Q Push rod link lever assembly 1 R Intake joint 1 S Pilot air jet 1 T Main air jet 1 U Cold starter plunger 1 V Hot starter plunger (red) 1 1
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• 18, –+ ELEC 6 — 7 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. *marked: Refer to “IGNITION SYSTEM” section. N OTE: ● Remove the following parts before inspection. 1) Seat 2) Fuel tank ● Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112 Inductive tachometer…

• 29, 7 — 8 TUN Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. Å Idle ı Fully open Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet …

• 24, 7 — 3 TUN SETTING Effects of the setting parts on the throttle valve opening Å Closed ı Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet 4/4 3/4 1/2 1/4 1/8 0 ı Å 1/2 3/4 1/41/8 1 2 3 4 Å ı Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even…

• 19, 6 — 8 –+ ELEC THROTTLE POSITION SENSOR SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. THROTTLE POSITION SENSOR COIL INSPECTION 1. Inspect: ● Throttle position sensor coil resistance Out of specification → Replace. 2. Loosen: ● Throttle stop screw 1 N OTE: Turn out the throttle stop screw until the throt- tle shaft is in the full close position. Tester (+) …

• 2, 3 — 10 INSP ADJ THROTTLE CABLE ADJUSTMENT THROTTLE CABLE ADJUSTMENT 1. Check: ● Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: ● Throttle grip free play Throttle grip free play adjustment steps: ● Remove the throttle cable cap 1 and throttle cable cover 2. N OTE: ● Before adjusting the throttle cable free play, the engine idle speed should be adjusted. ● When the motorcycle is accelerating, throttle c…

• 10, 4 — 12 ENG CARBURETOR Float height 1. Measure: ● Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: ● Hold the carburetor in an upside down position. N OTE: ● Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. ● If the carburetor is level, the weight of the float will push in the needle valve, result- ing in an incorrect measurement. ● Measu…

• 13, 4 — 15 ENG CARBURETOR 7. Install: ● Spring 1 ● Joint collar 2 To throttle shaft 3. N OTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. 8. Install: ● Throttle shaft assembly 1 ● Washer (metal) 2 ● Washer (resin) 3 ● Valve lever 4 N OTE: ● Apply the fluorochemical grease on the bear- ings. ● Fit the projection a on the throttle shaft assembly into the slot b in the throttle posi- t…

• 9, 4 — 11 ENG CARBURETOR 2. Inspect: ● Main jet 1 ● Pilot jet 2 ● Needle jet 3 ● Starter jet 4 ● Main air jet 5 ● Pilot air jet 6 ● Leak jet 7 Damage → Replace. Contamination → Clean. N OTE: ● Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● Never use a wire. Needle valve 1. Inspect: ● Needle valve 1 ● Valve seat 2 Groove…

• 5, Yamaha wr250f 4 — 7 ENG CARBURETOR CARBURETOR Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. 1 Clamp 2 2 Throttle position sensor lead cou- pler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Throttle cable cap 1 6 Clamp (air filter joint) 1 Loosen the screw (air filter joint). 7 Clam…

• 11, 4 — 13 ENG Starter plunger 1. Inspect: ● Cold starter plunger 1 ● Hot starter plunger (red) 2 Wear/damage → Replace. Accelerator pump 1. Inspect: ● Diaphragm (accelerator pump) 1 ● Spring (accelerator pump) 2 ● Accelerator pump cover 3 ● O-ring 4 ● Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 2. Inspect: ● Throttle shaft 1 ● Spring 2 ● Lever 1 3 ● Spring 1 4 ● Lever 2 5 …

• 17, 4 — 19 ENG 5. Install: ● Throttle cable cap 1 1 6. Install: ● Throttle cable 1 7. Adjust: ● Throttle grip free play Refer to “THROTTLE CABLE ADJUST- MENT” section in the CHAPTER 3. 8. Install: ● Throttle cable cover 1 ● Screw (throttle cable cover) 2 N OTE: Install the throttle cable cover with its pawl a hung on the carburetor. 1 2 a T R . . 4 Nm (0.4 m · kg, 2.9 ft · lb) 9. Install: ● Throttle position sensor lead coupler 1 ● Clamp 2 …

Как перевести мили в километры?

1 миля равна 1,609344 километрам, а 1 километр — 0,62137119 милям.

В чем разница между топливом E10 и E5?

В топливе E10 содержится до десяти процентов этанола, в то время как в E5 содержится менее пяти процентов. Соответственно, топливо E10 менее вредит окружающей среде.

Какова рекомендуемая частота замены масляного фильтра в двигателе Yamaha?

В большинстве двигателей масляный фильтр необходимо менять через каждые 6000 километров (около 4000 миль).

Как часто следует менять масло в двигателе Yamaha?

В большинстве двигателей масло необходимо менять через каждые 6000 километров (около 4000 миль).

Как удалить ржавчину с устройства Yamaha мотоцикл?

1. Замочите поржавевшую деталь в уксусе, пока ржавчина не размокнет полностью. 2. Обрабатывайте ржавчину уксусом в течение 24 часов. 3. Удалите ржавчину с помощью металлической щетки или алюминиевой фольги.

Инструкция Yamaha WR250F (2001) доступно в русский?

К сожалению, у нас нет руководства для Yamaha WR250F (2001), доступного в русский. Это руководство доступно в английский.

Page 1 — WR250F(X)

20085UM-28199-71WR250F(X)20085UM-28199-71WR250F(X)WR250F(X)2008OWNER’S SERVICE MANUALMANUEL D’ATELIER DUPROPRIETAIRE

Page 2

1-2MACHINE IDENTIFICATIONMACHINE IDENTIFICATIONThere are two significant reasons for knowing the serial number of your machine:1. When ordering parts,

Page 3

5-6CARBURETOR19 Needle jet 120 Spacer 121 Pilot jet 122 Starter jet 123 Push rod 1 Pull the push rod.24 Throttle shaft assembly 125 Push rod link leve

Page 4 — FOREWORD

5-7CARBURETORHANDLING NOTEDo not loosen the screw (throttle position sensor) «1» except when changing the throttle position sen-sor due to f

Page 5 — HOW TO USE THIS MANUAL

5-8CARBURETORCHECKING THE ACCELERATOR PUMP1. Inspect:• Diaphragm (accelerator pump) «1»• Spring (accelerator pump) «2»• Accelerato

Page 6 — Ω), Voltage (V)

5-9CARBURETOR9. Install:• Push rod «1»While holding down the lever 1 «2», in-sert the push rod farthest into the car-buretor. 10.

Page 7 — TABLE OF CONTENTS

5-10CARBURETORa. Fully turn in the accelerator pump adjusting screw «3».b. Check that the link lever «4» has free play «b&quo

Page 8

5-11AIR INDICTOIN SYSTEMAIR INDICTOIN SYSTEMREMOVING THE AIR INDUCTION SYSTEMOrder Part name Q’ty Remarks1 Bracket 12 Air cut-off valve assembly

Page 9 — DESCRIPTION

5-12AIR INDICTOIN SYSTEMCHECKING THE AIR INDUCTION SYSTEM1. Inspect:• Air induction hoseCrack/damage→ Replace.• Air induction pipeCrack/damage → Repla

Page 10 — MACHINE IDENTIFICATION

5-13CAMSHAFTSCAMSHAFTSREMOVING THE CYLINDER HEAD COVEROrder Part name Q’ty RemarksSeat and fuel tank Refer to «SEAT, FUEL TANK AND SIDE COVE

Page 11 — CHECKING OF CONNECTION

5-14CAMSHAFTSREMOVING THE CAMSHAFTSOrder Part name Q’ty Remarks1 Timing mark accessing screw 1 Refer to removal section.2 Crankshaft end accessin

Page 12 — SPECIAL TOOLS

5-15CAMSHAFTSREMOVING THE CAMSHAFT1. Remove:• Timing mark accessing screw «1»• Crankshaft end accessing screw «2»2. Align:• T.D.C.

Page 13

1-3CHECKING OF CONNECTIONALL REPLACEMENT PARTS1. We recommend to use Yamaha genuine parts for all replace-ments. Use oil and/or grease rec-ommended by

Page 14

5-16CAMSHAFTSMeasurement steps:a. Install the camshaft onto the cylin-der head.b. Position a strip of Plastigauge® «1» onto the camshaft.c.

Page 15

5-17CAMSHAFTSThe camshafts should be installed onto the cylinder head so that the punch mark «c» on the exhaust cam-shaft and the punch mark

Page 16 — CONTROL FUNCTIONS

5-18CYLINDER HEADCYLINDER HEADREMOVING THE CYLINDER HEADOrder Part name Q’ty RemarksSeat and fuel tank Refer to «SEAT, FUEL TANK AND SIDE CO

Page 17 — MULTI-FUNCTION DISPLAY

5-19CYLINDER HEADCHECKING THE CYLINDER HEAD1. Eliminate:• Carbon deposits (from the com-bustion chambers)Use a rounded scraper.Do not use a sharp inst

Page 18

5-20VALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSREMOVING THE VALVES AND VALVE SPRINGSOrder Part name Q’ty RemarksCylinder head Refer to «

Page 19

5-21VALVES AND VALVE SPRINGSREMOVING THE VALVE LIFTER AND VALVE COTTER1. Remove:• Valve lifter «1»• Pad «2»Identify each lifter &

Page 20

5-22VALVES AND VALVE SPRINGS• Margin thickness «a»Out of specification→ Replace.5. Measure:• Runout (valve stem)Out of specification → Repla

Page 21

5-23VALVES AND VALVE SPRINGS2. Measure:• Compressed spring force «a»Out of specification→ Replace.b. Installed length3. Measure:• Spring til

Page 22 — STARTING AND BREAK-IN

5-24CYLINDER AND PISTONCYLINDER AND PISTONREMOVING THE CYLINDER AND PISTONOrder Part name Q’ty RemarksCylinder head Refer to «CYLINDER HEAD

Page 23

5-25CYLINDER AND PISTONREMOVING THE PISTON AND PISTON RING1. Remove:• Piston pin clip «1»• Piston pin «2»• Piston «3»• P

Page 24 — TORQUE-CHECK POINTS

1-4SPECIAL TOOLSSPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool wil

Page 25 — CLEANING AND STORAGE

5-26CYLINDER AND PISTON3. Measure:• Ring end gapOut of specification→ Replace.You cannot measure the end gap on the expander spacer of the oil control

Page 26 — GENERAL SPECIFICATIONS

5-27CYLINDER AND PISTON3. Install:• Cylinder gasket «1» • Cylinder «2»Install the cylinder with one hand while compressing the pis

Page 27

5-28CLUTCHCLUTCHREMOVING THE CLUTCHOrder Part name Q’ty RemarksDrain the engine oil. Refer to «CHANGING THE ENGINE OIL» section in the

Page 28 — MAINTENANCE SPECIFICATIONS

5-29CLUTCH14 Nut (clutch boss) 1 Refer to removal section.15 Lock washer 1 Refer to removal section.16 Clutch boss 1 Refer to removal section.17 Thrus

Page 29

5-30CLUTCHREMOVING THE CLUTCH BOSS1. Remove:• Nut «1»• Lock washer «2»• Clutch boss «3»Straighten the lock washer tab an

Page 30

5-31CLUTCH2. Install:• Lock washer «1» • Nut (clutch boss) «2»Use the clutch holding tool «3» to hold the clutch boss.A.

Page 31

5-32CLUTCHTighten the bolts in stage, using a crisscross pattern.

Page 32

5-33OIL FILTER ELEMENT AND WATER PUMPOIL FILTER ELEMENT AND WATER PUMPREMOVING THE OIL FILTER ELEMENT AND WATER PUMPOrder Part name Q’ty RemarksD

Page 33

5-34OIL FILTER ELEMENT AND WATER PUMP9 Washer 1 Refer to removal section.10 Impeller shaft 1 Refer to removal section.11 Oil seal 2 Refer to removal s

Page 34

5-35OIL FILTER ELEMENT AND WATER PUMPREMOVING THE IMPELLER SHAFT1. Remove:• Impeller «1»• Washer «2»• Impeller shaft «3»

Page 35

1-5SPECIAL TOOLSSteering nut wrenchYU-33975, 90890-01403 This tool is used when tighten the steering ring nut to specification.Damper rod holderYM-014

Page 36 — TIGHTENING TORQUES

5-36OIL FILTER ELEMENT AND WATER PUMPINSTALLING THE RIGHT CRANKCASE COVER1. Install:• Dowel pin «1»• O-ring «2» • Collar «3&q

Page 37

5-37BALANCERBALANCERREMOVING THE BALANCEROrder Part name Q’ty RemarksPrimary driven gear Refer to «CLUTCH» section.Right crankcase cov

Page 38

5-38BALANCERREMOVING THE BALANCER1. Straighten the lock washer tab.2. Loosen:• Nut (primary drive gear) «1»• Nut (balancer shaft driven gear

Page 39

5-39OIL PUMPOIL PUMPREMOVING THE OIL PUMPOrder Part name Q’ty RemarksPrimary driven gear Refer to «CLUTCH» section.Right crankcase cove

Page 40

5-40OIL PUMPREMOVING THE OIL TANKOrder Part name Q’ty RemarksDrain the engine oil.Refer to «CHANGING THE ENGINE OIL» section in the CHA

Page 41

5-41OIL PUMPCHECKING THE OIL PUMP1. Inspect:• Oil pump drive gear «1»• Oil pump drive shaft «2»• Rotor housing «3»• Oil

Page 42

5-42KICK SHAFT AND SHIFT SHAFTKICK SHAFT AND SHIFT SHAFTREMOVING THE KICK SHAFT AND SHIFT SHAFTOrder Part name Q’ty RemarksOil pump Refer to &qu

Page 43

5-43KICK SHAFT AND SHIFT SHAFT17 Pawl 218 Pawl pin 219 Spring 220 Bolt (stopper lever) 121 Stopper lever 122 Torsion spring 123 Segment 1 Refer to rem

Page 44 — LUBRICATION DIAGRAMS

5-44KICK SHAFT AND SHIFT SHAFTREMOVING THE KICK SHAFT ASSEMBLY1. Remove:• Kick shaft assembly «1»Unhook the torsion spring «2» fro

Page 45

5-45KICK SHAFT AND SHIFT SHAFTINSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY1. Install:• Spring «1»• Pawl pin «2»• Pawl «

Page 46 — CABLE ROUTING DIAGRAM

1-6SPECIAL TOOLSValve spring compressorYM-4019, 90890-04019 This tool is needed to remove and install the valve assemblies.Clutch holding toolYM-91042

Page 47

5-46KICK SHAFT AND SHIFT SHAFTINSTALLING THE KICK IDLE GEAR1. Install:• Kick idle gear «1»• Washer «2»• Circlip «3» • Ap

Page 48

5-47AC MAGNETO AND STARTER CLUTCHAC MAGNETO AND STARTER CLUTCHREMOVING THE AC MAGNETO AND STARTER CLUTCHOrder Part name Q’ty RemarksDrain the eng

Page 49

5-48AC MAGNETO AND STARTER CLUTCHTighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb)

Page 50

5-49AC MAGNETO AND STARTER CLUTCHREMOVING THE ROTOR1. Remove:• Nut (rotor) «1»• WasherUse the sheave holder «2».2. Remove:• Rotor

Page 51

5-50AC MAGNETO AND STARTER CLUTCH2. Install:• Holder «1»• Bolt «2»Pass the pickup coil lead and charging coil lead under the holde

Page 52

5-51AC MAGNETO AND STARTER CLUTCH• Bolt [crankcase cover (left)] «3»Tighten the bolts in stage, using a crisscross pattern.11. Install:• Was

Page 53

5-52ENGINE REMOVALENGINE REMOVALREMOVING THE ENGINEOrder Part name Q’ty RemarksHold the machine by placing the suitable stand under the frame.Ref

Page 54 — MAINTENANCE INTERVALS

5-53ENGINE REMOVALNegative battery lead Disconnect at the engine side.1 Engine guard 12 Neutral switch 13 Drive chain sprocket cover 14 Nut (drive spr

Page 55

5-54ENGINE REMOVALHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE DRIVE SPROCKET1. Remove:• Nut (drive

Page 56

5-55ENGINE REMOVALTighten the nut while applying the rear brake.3. Bend the lock washer tab to lock the nut.4. Install:• Drive chain sprocket guide &q

Page 57

1-7SPECIAL TOOLSVacuum/pressure pump gauge setYB-35956-A, 90890-06756This tool is used to check the air in-duction system.YAMAHA Bond No. 1215 (ThreeB

Page 58

5-56CRANKCASE AND CRANKSHAFTCRANKCASE AND CRANKSHAFTREMOVING THE CRANKSHAFTOrder Part name Q’ty RemarksEngie Refer to «ENGINE REMOVAL»

Page 59

5-57CRANKCASE AND CRANKSHAFT9 Right crankcase 1 Refer to removal section.10 Left crankcase 1 Refer to removal section.11 Oil strainer 112 Crankshaft 1

Page 60

5-58CRANKCASE AND CRANKSHAFTREMOVING THE CRANKCASE BEARINGOrder Part name Q’ty RemarksTransmissionRefer to «TRANSMISSION, SHIFT CAM AND SHIF

Page 61

5-59CRANKCASE AND CRANKSHAFTDISASSEMBLING THE CRANKCASE1. Separate:• Right crankcase• Left crankcaseSeparation steps:a. Remove the crankcase bolts &qu

Page 62 — → Add coolant

5-60CRANKCASE AND CRANKSHAFTCHECKING THE OIL STRAINER1. Inspect:• Oil strainerDamage→ Replace.CHECKING THE OIL DELIVERY PIPE 21. Inspect:• Oil deliver

Page 63

5-61CRANKCASE AND CRANKSHAFT5. Install:• Dowel pin «1»• O-ring «2» • Right crankcaseTo left crankcase.• Apply the lithium soap bas

Page 64 — → Adjust

5-62TRANSMISSION, SHIFT CAM AND SHIFT FORKTRANSMISSION, SHIFT CAM AND SHIFT FORKREMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORKOrder Part name Q&a

Page 65

5-63TRANSMISSION, SHIFT CAM AND SHIFT FORKREMOVING THE TRANSMISSION1. Remove:• Main axle «1»• Drive axle «2»• Shift cam• Shift for

Page 66

5-64TRANSMISSION, SHIFT CAM AND SHIFT FORK4. Install:• Collar «1»• Apply the lithium soap base grease on the oil seal lip.• When installing

Page 67 — →Turn the

6-1FRONT WHEEL AND REAR WHEELCHASSISFRONT WHEEL AND REAR WHEELREMOVING THE FRONT WHEELOrder Part name Q’ty RemarksHold the machine by placing the

Page 68

1-8CONTROL FUNCTIONSCONTROL FUNCTIONSMAIN SWITCHFunctions of the respective switch po-sitions are as follows:ON:The engine can be started only at this

Page 69

6-2FRONT WHEEL AND REAR WHEELREMOVING THE REAR WHEELOrder Part name Q’ty RemarksHold the machine by placing the suitable stand under the engine.R

Page 70

6-3FRONT WHEEL AND REAR WHEELHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE REAR WHEEL1. Remove:• Whe

Page 71 — →Replace as

6-4FRONT WHEEL AND REAR WHEEL• Bolt (brake disc) «2» Tighten the bolts in stage, using a crisscross pattern.3. Install:• Collar «1»

Page 72

6-5FRONT WHEEL AND REAR WHEEL2. Install:• Brake disc «1»• Bolt (brake disc) «2» Tighten the bolts in stage, using a crisscross pat

Page 73

6-6FRONT BRAKE AND REAR BRAKEFRONT BRAKE AND REAR BRAKEREMOVING THE FRONT BRAKEOrder Part name Q’ty RemarksHold the machine by placing the suitab

Page 74

6-7FRONT BRAKE AND REAR BRAKEREMOVING THE REAR BRAKEOrder Part name Q’ty RemarksHold the machine by placing the suitable stand under the engine.R

Page 75

6-8FRONT BRAKE AND REAR BRAKEDISASSEMBLING THE BRAKE CALIPEROrder Part name Q’ty RemarksA. FrontB. RearAB1Pad pin 112 Brake pad 2 23 Pad support

Page 76

6-9FRONT BRAKE AND REAR BRAKEDISASSEMBLING THE BRAKE MASTER CYLINDEROrder Part name Q’ty RemarksA. FrontB. Rear1 Brake master cylinder cap 12 Dia

Page 77

6-10FRONT BRAKE AND REAR BRAKEHANDLING NOTESupport the machine securely so there is no danger of it falling over.DRAINING THE BRAKE FLUID1. Remove:• B

Page 78

6-11FRONT BRAKE AND REAR BRAKEA. FrontB. RearCHECKING THE BRAKE CALIPER1. Inspect:• Brake caliper cylinder inner sur-face «a»Wear/score mark

Page 79

1-9MULTI-FUNCTION DISPLAYCOLD STARTER KNOBWhen cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is

Page 80

6-12FRONT BRAKE AND REAR BRAKE• Pad pin plug «4»INSTALLING THE REAR BRAKE CALIPER1. Install:• Pad support «1»• Brake pad «2&q

Page 81

6-13FRONT BRAKE AND REAR BRAKE2. Install:• Brake lever «1»• Bolt (brake lever) «2»• Nut (brake lever) «3»Apply the silic

Page 82

6-14FRONT BRAKE AND REAR BRAKE• Nut (brake hose holder) «2»Align the top «a» of the brake hose holder with the paint «b»

Page 83

6-15FRONT BRAKE AND REAR BRAKE3. Inspect:• Brake fluid levelFluid at lower level→ Fill up.Refer to «CHECKING THE BRAKE FLUID LEVEL» section

Page 84

6-16FRONT FORKFRONT FORKREMOVING THE FRONT FORKOrder Part name Q’ty RemarksHold the machine by placing the suitable stand under the engine.Refer

Page 85

6-17FRONT FORKDISASSEMBLING THE FRONT FORKOrder Part name Q’ty Remarks1 Front fork cap bolt 1 Refer to removal section.2 Fork spring 1 Drain the

Page 86

6-18FRONT FORKHANDLING NOTESupport the machine securely so there is no danger of it falling over.The front fork requires careful atten-tion. So it is

Page 87

6-19FRONT FORKThe bending value is shown by one half of the dial gauge reading.Do not attempt to straighten a bent inner tube as this may dangerous-ly

Page 88

6-20FRONT FORK9. Install:• Slide metal «1»• Oil seal washer «2»To outer tube slot.Press the slide metal into the outer tube with f

Page 89 — → Clean

6-21FRONT FORKBe sure to install the spring guide «2» when checking the oil level.Never fail to make the oil level ad-justment between the m

Page 90

1-10MULTI-FUNCTION DISPLAYTo reset the digits, select the tripme-ter involved and push the «RST» but-ton for 2 seconds or more.CHANGEOVER TO

Page 91

6-22FRONT FORK4. Tighten:• Pinch bolt (upper bracket) «1»• Pinch bolt (lower bracket) «2»Tighten the lower bracket to speci-fied t

Page 92

6-23HANDLEBARHANDLEBARREMOVING THE HANDLEBAROrder Part name Q’ty RemarksHeadlight 1 Hot starter cable 1 Disconnect at the lever side.2 Hot starte

Page 93

6-24HANDLEBARREMOVING THE BRAKE MASTER CYLINDER1. Remove:• Brake master cylinder bracket «1»• Brake master cylinder «2»• Do not le

Page 94

6-25HANDLEBAR5. Install:• Right grip «1»• Collar «2»Apply the adhesive on the tube guide «3».• Before applying the adhes

Page 95 — RADIATOR

6-26HANDLEBARApply the lithium soap base grease on the clutch cable end and hot start-er cable end.13. Adjust:• Clutch lever free playRefer to «A

Page 96

6-27STEERINGSTEERINGREMOVING THE STEERINGOrder Part name Q’ty RemarksTIGHTENING STEPS:• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)• Loosen it o

Page 97

6-28STEERING9 Bearing race cover 110 Upper bearing 111 Lower bearing 1 Refer to removal section.12 Bearing race 2 Refer to removal section.Order Part

Page 98

6-29STEERINGHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE STEERING RING NUT1. Remove:• Steering ring

Page 99

6-30STEERING7. Install:• Front fork «1»• Upper bracket «2»• Main switch «3»• Front brake hose guide bracket «4»

Page 100 — CARBURETOR

6-31SWINGARMSWINGARMREMOVING THE SWINGARMOrder Part name Q’ty RemarksHold the machine by placing the suitable stand under the engine.Refer to &qu

Page 101

1-11MULTI-FUNCTION DISPLAY3. Run the machine and start timer measurement.4. To stop timer measurement, pushing the «SLCT1» button and «

Page 102

6-32SWINGARMDISASSEMBLING THE SWINGARMOrder Part name Q’ty Remarks1 Cap 2 Refer to removal section.2 Relay arm 13 Connecting rod 14 Collar 25 Oil

Page 103

6-33SWINGARMHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE CAP1. Remove:• Left cap «1»Remov

Page 104

6-34SWINGARMINSTALLING THE SWINGARM1. Install:• Bushing «1»• Thrust bearing «2»• Oil seal «3»• Collar «4»To sw

Page 106

6-36REAR SHOCK ABSORBERREAR SHOCK ABSORBERREMOVING THE REAR SHOCK ABSORBEROrder Part name Q’ty RemarksHold the machine by placing the suitable st

Page 107 — CAMSHAFTS

6-37REAR SHOCK ABSORBER3 CDI unit coupler 34 Plastic band 15 Clamp (air filter joint) 1 Only loosening.6Rear frame 17 Bolt (rear shock absorber-relay

Page 108

6-38REAR SHOCK ABSORBERHANDLING NOTE• Support the machine securely so there is no danger of it falling over.• This rear shock absorber is pro-vided wi

Page 109

6-39REAR SHOCK ABSORBER3. Install:• Lower bearing «1»Install the bearing by pressing it on the side having the manufacture’s marks or n

Page 110

6-40REAR SHOCK ABSORBER8. Install:• Plastic band• Taillight coupler• Locking tie

Page 111

7-1ELECTRICAL COMPONENTS AND WIRING DIAGRAMELECTRICALELECTRICAL COMPONENTS AND WIRING DIAGRAMELECTRICAL COMPONENTS1. Headlight2. Multi-function displa

Page 113

1-12MULTI-FUNCTION DISPLAYFUNCTION DIAGRAMA short push on the button changes the operation in the arrowed direction.A short push on the button changes

Page 114 — VALVES AND VALVE SPRINGS

7-2ELECTRICAL COMPONENTS AND WIRING DIAGRAMWIRING DIAGRAM1. Headlight2. Multi-function display3. Engine stop switch4. Clutch switch5. Diode6. Starter

Page 115

7-3IGNITION SYSTEMIGNITION SYSTEMINSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine being attributable

Page 116

7-4IGNITION SYSTEMSPARK GAP TEST1. Disconnect the ignition coil from spark plug.2. Remove the ignition coil cap.3. Connect the dynamic spark tester &q

Page 117

7-5ELECTRIC STARTING SYSTEM4. Inspect:• Sealed portion of ignition coil «a»• Spark plug terminal pin «b»• Threaded portion of spar

Page 118 — CYLINDER AND PISTON

7-6ELECTRIC STARTING SYSTEMINSPECTION STEPSIf the starter motor will not operate, use the following inspection steps.*1 marked: Refer to «CHECKIN

Page 119

7-7ELECTRIC STARTING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit→ Repair

Page 120

7-8ELECTRIC STARTING SYSTEM2. Inspect:• Rubber part «a»Tears/damage→ Replace.

Page 121

7-9ELECTRIC STARTING SYSTEMREMOVING THE STARTER MOTOROrder Part name Q’ty RemarksExhaust pipeRefer to «EXHAUST PIPE AND SILENCER» secti

Page 122

7-10ELECTRIC STARTING SYSTEMDISASSEMBLING THE STARTER MOTOROrder Part name Q’ty Remarks1 Starter motor front cover 12 Washer (starter motor front

Page 123

7-11ELECTRIC STARTING SYSTEMCHECKING AND REPAIRING THE STARTER MOTOR1. Check:• CommutatorDirt→Clean with 600 grit sandpa-per.2. Measure:• Commutator d

Page 124

1-13MULTI-FUNCTION DISPLAYThe following diagram illustrates the multi-function display regarding the direction and operation condition in-volved in ea

Page 125

7-12ELECTRIC STARTING SYSTEM5. Install:• Gasket• Bolt «1»• O-ring «2» Apply the lithium soap base grease on the O-ring.

Page 126

7-13CHARGING SYSTEMCHARGING SYSTEMINSPECTION STEPSIf the battery is not charged, use the following inspection steps.*1 marked: Refer to «CHECKING

Page 127

7-14CHARGING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit→ Repair or repl

Page 128

7-15THROTTLE POSITION SENSOR SYSTEMTHROTTLE POSITION SENSOR SYSTEMINSPECTION STEPSIf the throttle position sensor will not operate, use the following

Page 129

7-16THROTTLE POSITION SENSOR SYSTEMHANDLING NOTEDo not loosen the screw (throttle position sensor) «1» except when changing the throttle pos

Page 130

7-17THROTTLE POSITION SENSOR SYSTEM10. Put the aligning marks «a» on the throttle position sensor and car-buretor.11. Stop the engine.12. Re

Page 131 — BALANCER

7-18LIGHTING SYSTEMLIGHTING SYSTEMINSPECTION STEPSRefer to the following flow chart when inspecting the lighting system for possible problems.• Remove

Page 132

7-19LIGHTING SYSTEMCHECKING THE TAILLIGHT (LEDs)1. Disconnect the taillight coupler.2. Connect two jumper leads «1» from the battery termina

Page 133 — OIL PUMP

7-20SIGNALING SYSTEMSIGNALING SYSTEMINSPECTION STEPSIf the speedometer will not operate, use the following inspection steps.*1 marked: Refer to «

Page 134

7-21SIGNALING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit→ Repair or rep

Page 135

1-14STARTING AND BREAK-INSTARTING AND BREAK-INFUELAlways use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race

Page 138

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED ON RECYCLED PAPER PRINTED IN JAPAN2007.08-0.8×1 CR(E)

Page 139

1-15STARTING AND BREAK-INThe engine fails to startPull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 1

Page 140

1-16TORQUE-CHECK POINTSTORQUE-CHECK POINTSConcerning the tightening torque, refer to «TIGHTENING TORQUES» section in the CHAPTER 2.Frame con

Page 142

2-1GENERAL SPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSModel name: WR250FX (USA, CDN, AUS, NZ)WR250F (ZA)Model code number: 5UMH (USA)5UMK (CDN)

Page 143

2-2GENERAL SPECIFICATIONSAir filter: Wet type elementFuel:Type Premium unleaded gasoline only with a research octane number of 95 or higher.Tank capac

Page 144

2-3MAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINEShock absorber:Front shock absorber Coil spring/oil damperRear shock absorber Coil spring

Page 145

2-4MAINTENANCE SPECIFICATIONSIntake «A» 29.65–29.75 mm (1.1673–1.1713 in) 29.55 mm (1.1634 in)Intake «B» 22.45–22.55 mm (0.8839–0.

Page 146 — ENGINE REMOVAL

WR250F (X)OWNER’S SERVICE MANUAL©2007 by Yamaha Motor Co., Ltd.1st Edition, July 2007All rights reserved. Any reprinting orunauthorized use witho

Page 147

2-5MAINTENANCE SPECIFICATIONS»D» margin thickness (IN) 0.8 mm (0.0315 in) —-«D» margin thickness (EX) 0.7 mm (0.0276 in) —-Ste

Page 148

2-6MAINTENANCE SPECIFICATIONSTilt limit* (IN) —- 2.5°/1.6 mm (2.5°/0.063 in)Tilt limit* (EX) —- 2.5°/1.6 mm (2.5°/0.063 in)Direction of winding (t

Page 149

2-7MAINTENANCE SPECIFICATIONSOil ring:Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) —-End gap (installed) 0.10–0.40 mm (0.004–0.016 in) —-Cra

Page 150 — CRANKCASE AND CRANKSHAFT

2-8MAINTENANCE SPECIFICATIONSCarburetor:Type/manufacturer FCR-MX37/KEIHIN —-I. D. mark 5UME E0 —-Main jet (M.J) #170 —-Main air jet (M.A.J) #115

Page 151

2-9MAINTENANCE SPECIFICATIONSCHASSISItem Standard LimitSteering system:Steering bearing type Taper roller bearing —-Front suspension:Front fork trav

Page 152

2-10MAINTENANCE SPECIFICATIONSELECTRICALFront disc brake:Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm (9.84 × 0.10 in)Pad th

Page 153

2-11TIGHTENING TORQUESTIGHTENING TORQUESENGINE△ — marked portion shall be checked for torque tightening after break-in or before each race.Rectifier/r

Page 154

2-12TIGHTENING TORQUESCylinder M6 × 1.0 1 10 1.0 7.2Balancer weight M6 × 1.0 2 10 1.0 7.2Balancer shaft driven gear M14 × 1.0 1 50 5.0 36Timing chain

Page 155

2-13TIGHTENING TORQUESCHASSIS△ — marked portion shall be checked for torque tightening after break-in or before each race.Air induction pipe M6 × 1.0

Page 156

2-14TIGHTENING TORQUES△ Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1△ Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1Throt

Page 157

FOREWORDINTRODUCTIONCongratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast ex-perience in the pro

Page 158 — → Repair

2-15TIGHTENING TORQUES1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen t

Page 159 — FRONT WHEEL AND REAR WHEEL

2-16TIGHTENING TORQUESELECTRICALTighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m •kg, 47 ft•lb)

Page 160

2-17TIGHTENING TORQUESGENERAL TORQUE SPECIFICATIONSThis chart specifies torque for stan-dard fasteners with standard I.S.O. pitch threads. Torque spec

Page 162

2-19LUBRICATION DIAGRAMSLUBRICATION DIAGRAMS1. Oil filter element2. Oil pump3. Drive axle4. Main axle5. Intake camshaft6. Exhaust camshaft7. Oil tank8

Page 163

2-20LUBRICATION DIAGRAMS1. Crankshaft2. Oil filter element3. Oil tank4. Oil hoseA. From oil pump

Page 164 — FRONT BRAKE AND REAR BRAKE

2-21CABLE ROUTING DIAGRAMCABLE ROUTING DIAGRAM1. Fuel tank breather hose2. Clamp3. Diode4. Hot starter cable5. Wire harness6. Hump (frame)7. Cylinder

Page 165

2-22CABLE ROUTING DIAGRAMB. Fasten the throttle cable, hot starter cable and rectifier/regula-tor lead onto the frame. Locate the clamp end facing the

Page 166

2-23CABLE ROUTING DIAGRAM1. Throttle cable (pull)2. Throttle cable (return)3. Catch tank hose4. Ignition coil5. Clamp6. Air induction hose (air cut-of

Page 167

2-24CABLE ROUTING DIAGRAM1. Brake master cylinder2. Brake hose holder3. Brake hoseA. Install the brake hose so that its pipe portion directs as shown

Page 168

TO THE NEW OWNERThis manual will provide you with a good basic understanding of fea-tures, operation, and basic mainte-nance and inspection items of t

Page 169

2-25CABLE ROUTING DIAGRAM1. Clamp2. Positive battery lead3. Battery4. Negative battery lead5. Taillight coupler6. CDI unit coupler (6-pin)7. CDI unit

Page 170

2-26CABLE ROUTING DIAGRAMC. Pass the starter motor lead through the hole in the relay holder.D. Fit the cover securely.E. Connect the wire harness to

Page 171

2-27CABLE ROUTING DIAGRAM1. Throttle cable2. Clamp3. Brake hose4. Clutch cable5. Hose guide6. Main switch coupler7. Wire harness8. Headlight coupler9.

Page 172

2-28CABLE ROUTING DIAGRAME. Pass the throttle cables, clutch cable and hot starter cable be-tween the upper bracket and multi-function display bracket

Page 173

3-1MAINTENANCE INTERVALSREGULAR INSPECTION AND ADJUSTMENTSMAINTENANCE INTERVALSThe following schedule is intended as a general guide to maintenance an

Page 174 — FRONT FORK

3-2MAINTENANCE INTERVALSCLUTCHInspect and adjust●● Inspect housing, friction plate, clutch plate and spring.Replace●TRANSMISSIONInspect●Replace bearin

Page 175

3-3MAINTENANCE INTERVALSFUEL TANK, COCKClean and inspect●●BRAKESAdjust lever position and pedal height●●Lubricate pivot point ●●Check brake disc surfa

Page 176

3-4MAINTENANCE INTERVALSTIRE, WHEELSInspect air pressure, wheel run-out, tire wear and spoke loose-ness●●Retighten sprocket bolt ●●Inspect bearings ●R

Page 177

3-5PRE-OPERATION INSPECTION AND MAINTENANCEPRE-OPERATION INSPECTION AND MAINTENANCEBefore riding for break-in operation or practice, make sure the mac

Page 178

3-6ENGINEENGINEREMOVING THE SEAT, FUEL TANK AND SIDE COVERSOrder Part name Q’ty RemarksTurn the fuel cock to «OFF».Disconnect the fuel

Page 179

HOW TO READ DESCRIPTIONSTo help identify parts and clarify pro-cedure steps, there are exploded dia-grams at the start of each removal and disassembly

Page 180

3-7ENGINEREMOVING THE SIDE COVER1. Remove:• Bolt (side cover)• Right side cover «1»Draw the side cover backward to re-move it because its cl

Page 181 — HANDLEBAR

3-8ENGINEREMOVING THE EXHAUST PIPE AND SILENCEROrder Part name Q’ty RemarksRight side coverRefer to «SEAT, FUEL TANK AND SIDE COVERS» s

Page 182

3-9ENGINECHECKING THE SILENCER AND EXHAUST PIPE1. Inspect:• Gasket «1»Damage→ Replace.INSTALLING THE SILENCER AND EXHAUST PIPE1. Install:• G

Page 183

3-10ENGINEHandling notes of coolant:The coolant is harmful so it should be handled with special care.• When coolant splashes to your eye.Thoroughly wa

Page 184

3-11ENGINE2. Adjust:• Throttle grip free playThrottle grip free play adjustment steps:a. Slide the adjuster cover.b. Loosen the locknut «1».

Page 185 — STEERING

3-12ENGINE5. Inspect:• Air filter elementDamage→ Replace.6. Apply:• Foam-air-filter oil or equivalent oil to the element• Squeeze out the excess oil.

Page 186

3-13ENGINE• Oil filler cap «4»• Oil tank drain bolt «5»• Crankcase oil drain bolt «6»• Oil filter element drain bolt &qu

Page 187

3-14ENGINEADJUSTING THE ENGINE IDLING SPEED1. Start the engine and thoroughly warm it up.2. Adjust:• Engine idling speedAdjustment steps:a. Turn the t

Page 188

3-15ENGINE• Place a rag in the timing chain space to prevent pads from falling into the crankcase.• Identity each valve lifter and pad position very c

Page 190

TABLE OF CONTENTSGENERAL INFORMATION1SPECIFICATIONS2REGULAR INSPECTION AND ADJUSTMENTS3TUNING4ENGINE5CHASSIS6ELECTRICAL7

Page 191

3-17CHASSISCLEANING THE SPARK ARRESTER (For USA)• Be sure the exhaust pipe and si-lencer are cool before cleaning the spark arrester.• Do not start th

Page 192

3-18CHASSIS2. Remove:• Brake lever cover3. Adjust:• Brake lever positionBrake lever position adjustment steps:a. Loosen the locknut «1».b. T

Page 193

3-19CHASSISi. Install the brake caliper «8» and tighten the pad pin «9».j. Install the pad pin plug «10».3. Inspect:• Br

Page 194 — REAR SHOCK ABSORBER

3-20CHASSIS3. Inspect:• Brake fluid levelRefer to «CHECKING THE BRAKE FLUID LEVEL» section.4. Check:• Brake pedal operationA softy or spongy

Page 195

3-21CHASSISWhen installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings.7. Install:• Link plate• Press the link

Page 196

3-22CHASSIS1. Elevate the front wheel by placing a suitable stand under the engine.2. Remove the air bleed screw «1» and release the interna

Page 197

3-23CHASSISNever attempt to turn the adjuster beyond the maximum or minimum setting.5. Tighten:• Locknut6. Install:• Rear frame (upper)• Rear frame (l

Page 198

3-24CHASSISCHECKING THE TIRE PRESSURE1. Measure:• Tire pressureOut of specification→ Adjust.• Check the tire while it is cold.• Loose bead stoppers al

Page 199 — ELECTRICAL

3-25CHASSIS• Install the collar «6» with the larger inside diameter facing downward.• The handlebar upper holder should be installed with th

Page 200 —

3-26CHASSISLUBRICATIONTo ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.1. All c

Page 201 — IGNITION SYSTEM

CONTENTSCHAPTER 1GENERAL INFOR-MATIONDESCRIPTION … 1-1MACHINE IDENTIFICATION … 1-2INCLUDED PARTS … 1-2IMPORTANT I

Page 202

3-27ELECTRICALELECTRICALCHECKING THE SPARK PLUG1. Remove:• Spark plug2. Inspect:• Electrode «1»Wear/damage→ Replace.• Insulator color «

Page 203 — ELECTRIC STARTING SYSTEM

3-28ELECTRICAL3. Remove:• Battery band• Battery4. Measure:• Battery chargeMeasurement steps:a. Connect a pocket tester «1» to the battery te

Page 204

3-29ELECTRICALCharging method using a variable voltage charger

Page 205

3-30ELECTRICALCharging method using a constant voltage charger

Page 206

3-31ELECTRICAL6. Install:• Battery• Battery band7. Connect:• Battery leads(to the battery terminals)First, connect the positive lead «1», th

Page 207

3-32ELECTRICALADJUSTING THE HEADLIGHT BEAMS1. Adjust:• Headlight beam (vertically)Adjusting steps:a. Turn the adjusting screw «1» in di-rect

Page 208

4-1ENGINETUNINGENGINECARBURETOR SETTING• The air/fuel mixture will vary de-pending on atmospheric conditions. Therefore, it is necessary to take into

Page 209

4-2ENGINEADJUSTING THE PILOT JETThe richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet «1&

Page 210

4-3ENGINECARBURETOR SETTING PARTSMain jet SizePart number (-14943-)Rich #182 4MX-94#180 4MX-43#178 4MX-93#175 4MX-42#172 4MX-92(STD) #170 4MX-41#168 4

Page 211 — CHARGING SYSTEM

4-4ENGINEEXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM* This should be taken simply for an example. It is necessary to set the carburetor while

Page 212

1-1DESCRIPTIONGENERAL INFORMATIONDESCRIPTION• The machine you have purchased may differ slightly from those shown in the following.• Designs and speci

Page 213

4-5CHASSISCHASSISSELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)<Requirement for selection of sec-ondary gear reduction ratio>• It is gene

Page 214

4-6CHASSISA. Air spring characteristics in relation to oil level changeB. LoadC. Stroke1. Max. oil level2. Standard oil level3. Min. oil levelADJUSTIN

Page 215 — → Black/Blue lead

4-7CHASSISCHOOSING SET LENGTH1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length «a» be

Page 216 — LIGHTING SYSTEM

4-8CHASSISSUSPENSION SETTING (FRONT FORK)• If any of the following symptoms is experienced with the standard position as the base, make resetting by r

Page 217

4-9CHASSISSUSPENSION SETTING (REAR SHOCK ABSORBER)• If any of the following symptoms is experienced with the standard position as the base, make reset

Page 218 — SIGNALING SYSTEM

5-1RADIATORENGINERADIATORREMOVING THE RADIATOROrder Part name Q’ty RemarksDrain the coolant.Refer to «CHECKING THE COOLANT» sec-tion in

Page 219

5-2RADIATOR13 Catch tank breather hose 114 Catch tank 1Order Part name Q’ty Remarks

Page 220

5-3RADIATORHANDLING NOTEDo not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under press

Page 221

5-4CARBURETORCARBURETORREMOVING THE CARBURETOROrder Part name Q’ty RemarksSeat and fuel tank Refer to «SEAT, FUEL TANK AND SIDE COVERS»

Page 222 — 2007.08-0.8×1 CR

5-5CARBURETORDISASSEMBLING THE CARBURETOROrder Part name Q’ty Remarks1 Carburetor breather hose 42 Valve lever housing cover 13 Screw (throttle s