Eng | Yamaha WR250FM guide

ENGINE REMOVAL

ENG

Extent of removal:					1 Engine removal

Extent of removal				Order	Part name	Q’ty		Remarks

					Ignition coil
					Disconnect the AC magneto lead.
					Starter motor lead			Disconnect at the starter motor side.
					Negative battery lead			Disconnect at the engine side.
					Right engine guard

				1	Neutral switch	1
				1	Neutral switch	1
				2	Drive chain sprocket cover	1
				3	Nut (drive sprocket)	1
				3	Nut (drive sprocket)	1
				4	Lock washer	1		Refer to “REMOVAL POINTS”.
				5	Drive sprocket	1
				5	Drive sprocket	1
				6	Clip	1
	1			7	Bolt (brake pedal)	1
				8	Brake pedal	1
				9	Upper engine bracket	2
				10	Lower engine bracket	2
				11	Engine mounting bolt	3
				12	Pivot shaft	1		Refer to “REMOVAL POINTS”.
				12	Pivot shaft	1
				13	Engine	1
				13	Engine	1

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Image 209

Yamaha WR250FM service manual Eng

Contents

WR250FR Page WR250FR Introduction Page Always Maintain Your Machine in Proper Working Order Always Wear Protective Apparel Properly Secure the Machine Before Transporting IT Gasoline can Cause InjuryPark the Machine Carefully Turn OFF the Engine Weights of machines without fuel M. Machine Weights Finding the Required Particularly Important Information Manual Format HOW to Read Descriptions GEN Spec Info Insp ENG ADJ Memo Index Chapter Regular Inspection Adjustments Valves and Valve Springs SEAT, Fuel TankRight Crankcase Cover AC Magneto Throttle Position Sensor Electrical Components Description Description Info Vehicle Identification Number Machine IdentificationEngine Serial Number Model Label Important Information Preparation for Removal and Disassembly Lock WASHERS/PLATES and Cotter Pins ALL Replacement PartsGASKETS, OIL Seals and O-RINGS Bearings and OIL Seals Circlips Checking of Connection Special Tools Part number Tool name/How to use Illustration ACC-QUICK-GS-KT Main switch indicator light Main SwitchEngine Stop Switch Start Switch Shift Pedal Clutch LeverKickstarter Crank Throttle Grip Fuel Cock Rear Brake PedalCold Starter Knob HOT Starter Lever Valve Joint Light SwitchSpark Plug Wrench Nipple Wrench Fuel Starting a Cold Engine AIR Filter MaintenanceStarting and BREAK-IN Do not warm up the engine for extended periods of time Engine fails to start Starting a Warm EngineRestarting an engine after a fall Cylinder and Crankshaft BREAK-IN ProceduresAbout one hour of break-in operation is necessary PISTON, RING, VALVES, Camshafts and Gears TORQUE-CHECK Points Cleaning Cleaning and Storage Storage 5UM4 CDN, AUS, NZ, ZA General Specifications FCR-MX37 CDI Engine Maintenance Specifications Head diameter Face width Seat width Margin thickness 1.6 mm Spec USA EUROPE, CDN ZA, AUS, NZ Spec Part to be tightened Thread size ’ty Tightening torque Silencer USA, CDN Europe AUS, NZ, ZA Chassis USA, CDN, ZA EUROPE, AUS, NZ Upper bracket and outer tube Nipple spoke Rear wheel sprocket M4 ⋅ 5UL-00/DENSO Electrical ACM33221 M06/MATSUSHITA Definition of Units General Torque SpecificationsTorque Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130 Cable Routing Diagram Spec Spec Spec Spec Spec Spec Spec Spec Insp ADJ Maintenance Intervals Cooling System Maintenance Intervals ADJ Marked For USA General Inspection and Maintenance PRE-OPERATION Inspection and Maintenance Do not remove the radiator cap when the engine is hot Coolant ReplacementEngine Coolant Level Inspection Coolant Replacement Fill Radiator Engine To specified level Radiator CAP Opening Pressure Inspection Radiator CAP Inspection Radiator cap opening pressure KPa 1.1 kg/cm2, 15.6 psi Clutch AdjustmentCooling System Inspection Standard pressure KPa 1.8 kg/cm2, 25.6 psi Clutch lever free play adjustment steps Throttle Cable AdjustmentThrottle Cable Adjustment Throttle grip free play adjustment steps Hot starter lever free play adjustment steps HOT Starter Lever AdjustmentThrottle Lubrication Hot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24 AIR Filter Cleaning AIR Filter Cleaning Insp ADJ Engine OIL Level Inspection Engine OIL Level Inspection API Standard Engine OIL ReplacementEngine OIL Replacement Oil filter element cover 10 Nm 1.0 m kg, 7.2 ft lb Replacement steps Install Copper washer 1 New Oil strainer frame OIL Pressure Inspection Pilot Screw Adjustment Valve Clearance Inspection and Adjustment Engine Idling Speed Adjustment Valve Clearance Inspection and Adjustment 40 mm Pad range Pad Availability Increments 20 mmMm increments Example Last digit of pad Rounded value Exhaust Intake Spark Arrester Cleaning For USA Brake System AIR Bleeding CHASSIS/BRAKE System AIR BleedingChassis Brake lever position adjustment steps Front Brake AdjustmentFront Brake Adjustment Front Brake PAD Inspection and Replacement Rear Brake Adjustment Bleed screw Nm 0.6 m kg, 4.3 ft lb Front Brake PAD Inspection and ReplacementDo not reuse the drained brake fluid Rear Brake PAD Inspection and Replacement Rear Brake PAD Inspection and ReplacementPad pin plug Nm 0.3 m kg, 2.2 ft lb Brake pad thickness Mm 0.25 in Limit 1.0 mm 0.04 Pad pin 18 Nm 1.8 m kg, 13 ft lb Brake Fluid Level Inspection Rear Brake PAD Insulator Inspection Sprockets Inspection Sprockets INSPECTION/DRIVE Chain InspectionDrive Chain Inspection Drive chain length 10 links Limit 150.1 mm 5.91 Drive Chain Inspection Drive Chain Slack Adjustment Drive Chain Slack AdjustmentDrive chain slack adjustment steps Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0 Axle nut 125 Nm 12.5 m kg, 90 ft lb Front Fork OIL Seal and Dust Seal CleaningLocknut 16 Nm 1.6 m kg, 11 ft lb Front Fork Inspection Front Fork Internal Pressure Relieving Front Fork Rebound Damping Force Adjustment Standard position 9 clicks out Clicks out Front Fork Compression Damping Force Adjustment Rear Shock Absorber Inspection Rear Shock Absorber InspectionStandard position 14 clicks out Clicks out Rear Shock Absorber Spring Preload Adjustment Standard position About 7 clicks out About 10 clicks out Standard position About 9 clicks out About 10 clicks out Rear Shock Absorber LOW Compression Damping Force Adjustment Standard position About 1-1/4 turns out Standard tire pressure KPa 1.0 kgf/cm2, 15 psi Tire Pressure CheckSpokes Inspection and Tightening Wheel Inspection Steering Head Inspection Adjustment Steering Head Inspection and AdjustmentSteering ring nut adjustment steps Steering nut wrench YU-33975/90890-01403 Avoid over-tightening Steering nut wrench38 Nm 3.8 m kg, 27 ft lb Lubrication Lubrication Spark Plug Inspection ElectricalSpark plug gap ~ 0.8 mm 0.028 ~ 0.031 Ignition Timing Check Ignition Timing Check Battery Inspection and Charging Battery Inspection and ChargingKeep Batteries and Electrolyte OUT of Reach of Children First AID in Case of Bodily Contact External Remove Battery band Example Measurement steps Charge Battery Charging method using a variable voltage charger Charging method using a constant voltage charger Battery Replacement Battery REPLACEMENT/FUSE InspectionFirst, connect the positive lead 1, then the negative lead Recommended lubricant Lithium soap base grease Items Amperage rating ’ty Fuse InspectionPocket tester YU-3112-C/90890-03112 Replacing the Headlight Bulbs Adjusting the Headlight BeamsAdjusting steps SEAT, Fuel Tank and Side Covers Removal SEAT, Fuel Tank and Side Covers Side cover Removal Points Exhaust Pipe Silencer Removal Exhaust Pipe and Silencer Silencer and exhaust pipe Assembly and Installation Silencer and exhaust pipe Radiator Removal Radiator Radiator Assembly and Installation RadiatorHandling Note Install Right radiator Bolt right radiator Carburetor Removal Carburetor Carburetor Disassembly Carburetor Disassembly ENG Carburetor Pilot screw Throttle valve Needle valveJet needle Standard clip position No.4 Groove Float Float height Mm 0.31 Measurement and adjustment stepsFloat height Starter plunger Assembly and Installation CarburetorAccelerator pump Air cut valve ENG ENG Pilot screw Turns out example 8 turns out ENG Throttle valve height Mm 0.06 Accelerator pump timing adjustment Adjustment stepsCarburetor installation Carburetor ENG Carburetor ENG Cylinder Head Cover Removal CamshaftsCylinder Head Cover Camshafts Removal Camshafts Camshaft Runout camshaft Less than 0.03 mm 0.0012 Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb Installation steps Assembly and Installation CamshaftDecompression system Timing chain tensioner CA U TI O N Tensioner cap bolt Camshafts ENGBolt timing chain tensioner Quick gasket ACC-QUICK-GS-KT Yamaha Bond No Cylinder Head Removal Cylinder Head Cylinder head Assembly and Installation Cylinder head Valves and Valve Springs Removal Valves and Valve Springs Valve spring compressor YM-4019/90890-04019 Valve lifter and valve cotter Valve Margin thickness Intake Mm 0.0315 in Exhaust Mm 0.0276 Runout limit 01 mm 0.0004 Lapping steps Valve spring Combination of cylinder head and valve lifter Assembly and Installation Valve and valve springCombination Cylinder head mark Valve lifter mark b Color Yellow Valve spring compressor YM-4019/90890-04019 Cylinder and Piston Removal Cylinder and Piston Piston pin puller set YU-1304/90890-01304 Piston and piston ringDo not use a hammer to drive the piston pin out Cylinder and piston 05 mm 0.002 Cylinder bore C 77.00 ~ 77.01 mm 0315 ~ 3.03192nd step Piston size P Side clearance Piston ringLimit End gap Inside diameter piston 16.002 ~ 16.013 mm 0.6300 ~ 0.6304 Piston pin Cylinder Install Bolt cylinder Clutch Removal Clutch ENG Clutch boss Clutch housing and bossClutch holding tool YM-91042/90890-04086 Primary driven gear Clutch plate Friction plateWarp limit Mm 0.004 Push lever shaft Push rod Clutch Assembly and Installation Push lever shaft ENG Install Push rod 2 Ball Push rod 1 OIL Filter ELEMENT, Water Pump and Right Crankcase Cover ENG Oil delivery pipe Impeller shaftOil seal Bearing Assembly and Installation Oil sealImpeller shaft gear Right crankcase cover Kickstarter crank Oil filter element Water pump housing Balancer Removal Balancer Balancer shaft Balancer shaft drive gear and balancer shaft driven gear Primary drive gear Nut primary drive gear OIL Pump OIL Pump Removal and DIS Assembly ENG Oil pump Assembly and Installation Oil pump Bolt oil pump assembly L = 30 mm 1.18 Kick Shaft and Shift Shaft Removal Kick Shaft and Shift Shaft ENG Shift guide and shift lever assembly Kick shaft assemblySegment Kick shaft and ratchet wheel Stopper lever Assembly and InstallationShift shaft Install Torsion spring Stopper lever Bolt stopper lever Kick shaft assembly Kick idle gear AC Magneto and Stator Removal AC Magneto and Starter Clutch ENG Rotor puller YM-04141/90890-04141 RotorAC magneto Woodruff key Assembly and Installation AC magneto and starter clutch Install Holder Bolt Plain washer rotor Nut rotor Bolt engine guard rear Engine Removal Engine Removal ENG Engine removal Drive sprocket Brake pedal Assembly and Installation Engine installation Oil hose and neutral switch Nm 0.4 m · kg, 2.9 ft · lb Crankcase and Crank Shaft Removal Crankcase and Crankshaft ENG Crankcase Bearing Removal Crankcase Bearing Separation steps Crankcase Timing chain and timing chain guide CrankshaftCrankcase separating tool YU-1135-A/90890-01135 Dial gauge and stand YU-3097/90890-01252 Standard Limit Do not use a hammer to drive in the crank- shaft Assembly and Installation Crankcase bearing Apply Sealant On the right crankcase Tighten Hose guide Clutch cable holder Bolt crankcase TRANSMISSION, Shift CAM Shift Fork Removal TRANSMISSION, Shift CAM and Shift Fork Gears Transmission Shift fork, shift cam and segment Assembly and Installation Transmission ENG ENG Front Wheel and Rear Wheel Front Wheel and Rear Wheel ChasFront Wheel Front Wheel Removal Rear Wheel Removal Rear Wheel Wheel Rear wheelWheel bearing if necessary Wheel axle bending limit 0.5 mm 0.020 Wheel axleDo not attempt to straighten a bent axle Brake disc Front wheel 105 Nm 10.5 m · kg, 75 ft · lb Tighten Bolt axle holder Install Trip meter cable 50 Nm 5.0 m · kg, 36 ft · lb 125 Nm 12.5 m · kg, 90 ft · lb Front Brake and Rear Brake Front Brake and Rear Brake ChasFront Brake Front Brake Removal Rear Brake Removal Rear Brake Brake Caliper Disassem BLY Brake Caliper Disassembly Brake Master Cylinder Disassembly Brake Master Cylinder Disassembly Brake fluid Use only new brake fluid Brake caliper piston seal kitBrake master cylinder Brake hose Brake caliper Front brake caliper Always use new piston seals and dust seals Rear brake caliper Brake master cylinder kit Front brake master cylinder Rear brake master cylinder Front brake hose Always use new copper washers CAU TI on CAU T ION Install rear brake only Protector Bolt protector Front Fork Removal Front Fork ChasFront Fork Front Fork Disassembly Front Fork Disassembly Front fork cap bolt Take care not to scratch the inner tube Inner tubeOil seal removal steps Damper rod Fork spring Base valveFork spring free length 460 mm 18.1 in Limit 455 mm 17.9 Inner tube bending limit 0.2 mm 0.008 Assembly and Installation Front fork assembly Front Fork Chas Fork seal driver YM-01442/90890-01442 Front Fork Chas Front Fork Chas Front Fork Chas Front fork top end standard a 5 mm 0.20 10 mm 0.39 Installation Tighten Pinch bolt upper bracket Handlebar Removal Handlebar ChasHandlebar Handlebar Grip Assembly and Installation Handlebar Install Grip cap cover Cover throttle cable cap Hot starter lever holder Bolt hot starter lever holder Handlebar Chas Steering Removal Steering ChasSteering Steering Chas Take care not to damage the steering shaft thread Steering ring nutBall race Steering stem Lower bracket Bearing and ball race Install Washer Steering ring nut Install Washer Steering stem nut Install Trip meter Bolt trip meter Swingarm Removal Swingarm ChasSwingarm Swingarm Disassembly Swingarm Disassembly Relay arm Swingarm Bearing and oil seal Connecting rod Installed depth of bearings a 5 mm 0.20 Swingarm Installed depth of bearings a 5 mm 0.20 80 Nm 8.0 m · kg, 58 ft · lb Tighten Nut relay arm Bolt drive chain support cover = 10 mm 0.39 Rear Shock Absorber Removal Rear Shock Absorber ChasRear Shock Absorber Starting circuit cut-off relay coupler Handling Note Rear shock absorber Install Spring Upper spring guide Lower spring guide Tighten Adjuster Spring length installed a Bolt rear frame lower Rear Shock Absorber Chas Color Code Electrical Components and Wiring DiagramWiring Diagram Function of Component MAP-CONTROLLED CDI Unit Inspection Steps Ignition System Ignition System Elec + Engine Stop Switch InspectionSpark GAP Test COUPLERS, Leads and Ignition Coil Connection Inspection Tester + lead → Red lead Tester lead → Brown lead Main Switch InspectionBattery + lead → Red/Black lead 1 Battery lead → Black lead Resistance Position ~ 6.8 kΩ at Ignition Coil InspectionResistance Position 08 ~ 0.10 Ω at 20 C 68 F AC Magneto Inspection Neutral Switch InspectionResistance Position 248 ~ 372 Ω at 20 C 68 F Tester + lead → Sky blue lead 1 Tester lead → Ground Starting Circuit CUT-OFF System Operation Electric Starting System Inspection Steps To battery BatteryCouplers and Leads Connection Inspection Starter Motor Operation Pull Free Clutch Switch InspectionStarter Relay Inspection Diode Inspection Start Switch InspectionElectric Starting System Elec + Starter Motor Disassem BLY Starter MotorStarter Motor Removal Mica undercut 1.5 mm 0.06 Inspection and RepairMin. commutator diameter 16.6 mm 0.65 Min. brush length Mm 0.14 AssemblyBe careful not to damage the brush during installation New Charging System Tester + lead → Red lead Tester lead → Black lead Charging Voltage InspectionVoltage Position 14.1 ~ 14.9 V at DCV-20 000 r/min Resistance Position 288 ~ 0.432 Ω at 20 C 68 F Throttle Position Sensor System ~ 6 kΩ at Throttle Position Sensor System Elec +Throttle Position Sensor Coil Inspection At 20 C 68 F Throttle Position Sensor Replacement and AdjustmentCoil variable resistance Throttle position Tester selector Tester + lead → Yellow lead Tester lead → Black lead58 ~ 0.78 DCV ~ 6 DCV-20 Throttle Position Sensor Input Voltage Inspection Lighting System RECTIFIER/REGULATOR Inspection Light Switch InspectionOFF Carburetor setting Setting Settings Pilot system Effects of the setting parts on the throttle valve openingMain system Effects of changing the main jet reference Main jet adjustmentStandard main jet #185 #172 Setting T U N Jet needle groove position adjustment Effects of adjusting the pilot jet reference Standard jet needle Jet needle adjustmentObdvs Obelp Effects of changing the jet needle reference Standard leak jet #90 Relationship with throttle opening Leak jet adjustment accelerator pump adjustment STD Examples of carburetor setting depending on symptom Standard secondary reduction ratio 52/13 Selection of the secondary reduction ratio Sprocket 5GS-25448-50 9383B-13218Sprocket 5NY-25448-00 Change in level and characteristics of fork oil Front fork setting Spring preload adjustment Setting of spring after replacement Spring Part NumberMark Rate Standard figure 90 ~ 100 mm 3.5 ~ 3.9 Rear suspension settingChoosing set length Setting of spring after replacement Setting Spring Free Extent Rear shock absorber setting partsAdjustment b Suspension setting One passenger is astride seat Printed on Recycled Paper Shingai Iwata Shizuoka Japan