User manual YAMAHA WR250F SERVICE MANUAL

[. . . ] Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. [. . . ] Adjust: S drive chain slack Refer to "ADJUSTING THE DRIVE CHAIN SLACK" in chapter 3. Drive chain slack 35 X 45 mm (1. 38 X 1. 77 in) 4-79 ENGINE ENG OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 6. 5 Nm (0. 65 mSkg, 4. 7 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 90 Nm (9. 0 mSkg, 65 ftSlb) 5 Q'ty Remarks Remove the parts in the order listed. Loosen. Order Job/Part Removing the drive sprocket Bottom cowling Side cowlings Drive chain 1 2 3 4 5 6 7 8 Lock nut Shift rod Shift arm Drive sprocket cover Nut Lock washer Chain guide Drive sprocket 2 1 1 1 1 1 1 1 For installation, reverse the removal procedure. 5-1 ENGINE EAS00189 ENG EXHAUST PIPE 20 Nm (2. 0 mSkg, 15 ftSlb) 20 Nm (2. 0 mSkg, 15 ftSlb) 23 Nm (2. 3 mSkg, 17 ftSlb) 20 Nm (2. 0 mSkg, 15 ftSlb) Order Job/Part Removing the exhaust pipe Bottom cowling Side cowlings Muffler Exhaust pipe assembly Exhaust pipe gasket Q'ty Remarks Remove the parts in the order listed. Refer to "COWLINGS" in chapter 3. 1 2 3 1 1 4 For installation, reverse the removal procedure. 5-2 ENGINE EAS00188 ENG LEADS AND HOSES 20 Nm (2. 0 mSkg, 15 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) Order Job/Part Disconnecting the leads and hoses Air filter case Throttle body assembly Engine oil Oil filter cartridge Oil cooler Air cut-off valve Starter motor Q'ty Remarks Disconnect the parts in the order listed. Refer to "STARTING SYSTEM" in chapter 8. 1 2 Battery negative lead Battery positive lead 1 1 CAUTION: First, disconnect the negative battery lead, and then the positive battery lead. For connecting, reverse the disconnection procedure. 5-3 ENGINE ENG 20 Nm (2. 0 mSkg, 15 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) Order 3 4 5 6 7 8 9 10 Job/Part Clutch cable Ground lead Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler Cylinder identification sensor coupler Q'ty 1 1 1 1 1 1 1 1 Remarks Disconnect. For connecting reverse the disconnection procedure. 5-4 ENGINE EAS00191 ENG ENGINE 45 Nm (4. 5 mSkg, 33 ftSlb) 45 Nm (4. 5 mSkg, 33 ftSlb) 45 Nm (4. 5 mSkg, 33 ftSlb) 45 Nm (4. 5 mSkg, 33 ftSlb) 7 Nm (0. 7 mSkg, 5. 1 ftSlb) Order Job/Part Removing the engine Q'ty Remarks Removing the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. 1 2 3 4 5 6 7 8 9 Drive chain guide Right front engine mounting bolt Left front engine mounting bolt Self-locking nut Rear engine mounting bolt Engine bracket bolt Engine bracket Engine mounting adjust bolt Engine 1 2 2 2 2 2 1 2 1 Refer to "INSTALLING THE ENGINE". NOTE: Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts. For installation, reverse the removal procedure. 5-5 ENGINE EAS00192 ENG INSTALLING THE ENGINE 1. Install: S engine bracket 1 (to the engine) 45 Nm (4. 5 mSkg, 33 ftSlb) S engine mounting adjust bolts (temporary tighten) 2. Install: S rear engine mounting bolts 1 NOTE: S Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 3. Remove the camshaft caps and then measure the width of the Plastigauge 1 . Camshaft journal diameter 22. 967 X 22. 980 mm (0. 9042 X 0. 9047 in) 5-12 CAMSHAFTS EAS00208 ENG CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. Check: S timing chain guide (exhaust side) 1 S timing chain guide (intake side) 2 S timing chain guide (top side) 3 Damage/wear !Replace the defective part(s). EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. 5-13 CAMSHAFTS ENG b. Remove the screwdriver and slowly release the timing chain tensioner rod. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. Replace the defective part(s). EAS00215 INSTALLING THE CAMSHAFTS 1. Align: S "T" mark a on the pickup rotor (with the crankcase mating surface b ) a. When piston #1 is at TDC, align the "T" mark a with the crankcase mating surface b . [. . . ] Minimum open-circuit voltage 12. 8 V or more at 20_C (68_F) S Is the battery OK?Main, ignition and fuel injection fuses S Check the main, ignition and fuel injection fuses for continuity. YES NO Replace the right handlebar switch. 8-48 FUEL PUMP SYSTEM EAS00759 EAS00817 ELEC 5. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. [. . . ]