YAMAHA YBR250 2007 Repair Manual

6-28
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24281
Replacing a turn signal light
bulb or the tail/brake light
bulb1. Remove the lens by removing thescrews.
1
1.Screw
1
1. Screw2. Remove the defective bulb bypushing it in and turning it
counterclockwise. 3. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
4. Install the lens by installing the screws.
ECA10680
Do not overtighten the screws,
otherwise the lens may break.
EAU37270
Replacing the auxiliary light
bulb
1
1. Auxiliary light bulbIf the auxiliary light bulb burns out,
replace it as follows.1. Remove the headlight unit by removing the screws.
2. Remove the socket (together with the bulb) by pulling it out.
3. Remove the defective bulb by pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the bulb) by pushing it in.
6. Install the headlight unit by installing the screws.
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6-29
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24350
Supporting the motorcycleSince this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear wheel
or performing other maintenance
requiring the motorcycle to stand upright.
Check that the motorcycle is in a stable
and level position before starting any
maintenance. A strong wooden box can
be placed under the engine for added
stability.
To service the front wheel1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack
under the frame in front of the rear
wheel.
2. Raise the front wheel off the ground by using a motorcycle stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side of
the frame in front of the rear wheel or
under each side of the swingarm.
EAU24360
Front wheel
EAUW0180
To remove the front wheel
EWA10820
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It is advisable to have a Yamaha
dealer service the wheel.
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Securely support the motorcycle
so that there is no danger of it
falling over.
1. Loosen the front wheel axle pinch
bolt and the wheel axle.1 2
1. Wheel axle
2. Wheel axle pinch bolt
2. Lift the front wheel off the ground
according to the procedure on page
6-29.
3. Pull the wheel axle out, and then remove the wheel.
ECA11070
Do not apply the brake after the wheel
has been removed together with the
brake disc, otherwise the brake pads
will be forced shut.
EAUW0160
To install the front wheel1. Lift the wheel up between the fork legs.Make sure that there is enough space
between the brake pads before inserting
the brake disc into the caliper.2. Insert the wheel axle.
3. Lower the front wheel so that it ison the ground.
4. Tighten the wheel axle to the specified torque.
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6-30
6
PERIODIC MAINTENANCE AND MINOR REPAIRTightening torque:Wheel axle:
60 Nm (6.0 m.kgf, 44 ft.lbt)5. Tighten the front fork pinch bolt to
the specified torque.Tightening torque:Front fork pinch bolt: 55 Nm (5.5 m.kgf, 40ft.lbt)6. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25430
To remove the rear wheel
EWA10820
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It is advisable to have a Yamaha
dealer service the wheel.
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Securely support the motorcycle
so that there is no danger of it
falling over.
1. Loosen the axle nut and the brake
torque rod nut at the brake shoe
plate.
2. Lift the rear wheel off the ground according to the procedure on page
6-29.
3. Disconnect the brake torque rod from the brake shoe plate by
removing the nut and the bolt.
3
2
4 5
1. Drive chain slack adjusting nut
2. Brake torque rod
3. Locknut
4. Brake pedal free play adjusting nut
5. Axle nut4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake camshaft
lever.
5. Loosen the locknut and the drive chain adjusting nut on both ends
of the swingarm.
6. Remove the axle nut, and then pull the wheel axle out.
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6-31
6
PERIODIC MAINTENANCE AND MINOR REPAIR
7. Push the wheel forward, and thenremove the drive chain from the
rear sprocket.The drive chain does not need to be
disassembled in order to remove and
install the wheel.8. Remove the wheel.
EAUW0170
To install the rear wheel1. Insert the wheel axle from the left- hand side, and then install the drive
chain onto the rear sprocket.
2. Install the axle nut.
3. Install the brake rod onto the brake camshaft lever, and then install the
brake pedal free play adjusting nut. 4. Connect the brake torque rod to the
brake shoe plate by installing the
bolt and the nut, and then tighten
the nut to the specified torque.
Tightening torque:Brake torque rod nut: 49 Nm (4.9 m.kgf, 36 ft.lbt)5. Adjust the drive chain slack. (See
page 6-19.)
6. Lower the rear wheel so that it is on the ground.
7. Tighten the axle nut to the specified torque.Tightening torque:Axle nut: 104 Nm (10.4 m.kgf, 77 ft.lbt)8. Adjust the brake pedal position and
free play. (See page 6-16)
EWA10660
After adjusting the brake pedal free
play, check the operation of the brake
light.
EAU25850
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it to
a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service the
motorcycle properly.
Use only genuine Yamaha replacement
parts. Imitation parts may look like
Yamaha parts, but they are often inferior,
have a shorter service life and can lead
to expensive repair bills.
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6-32
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25901
Troubleshooting chart
EWA10840
Keep away open flames and do not smoke while checking or working on the \
fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition. Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
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7-1MOTORCYCLE CARE AND STORAGE
7
EAU26001
CareWhile the open design of a motorcycle
reveals the attractiveness of the
technology, it also makes it more
vulnerable. Rust and corrosion can
develop even if high-quality components
are used. A rusty exhaust pipe may go
unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning1. Cover the muffler outlet with a plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers as well as all electrical couplers
and connectors, including the spark
plug cap, are tightly installed.
3. Remove extremely stubborn dirt, like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets, sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA10770
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Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the
affected area any longer than
instructed. Also, thoroughly
rinse the area off with water,
immediately dry it, and then
apply a corrosion protection
spray.
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Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge with
mild detergent and water to
clean plastic.
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Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
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Do not use high-pressure
washers or steam-jet cleaners
since they cause water seepage
and deterioration in the
following areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric
components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
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For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the
windshield. Test the product on
a small hidden part of the
windshield to make sure that it
does not leave any marks. If the
windshield is scratched, use a
quality plastic polishing
compound after washing.
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7-2
MOTORCYCLE CARE AND STORAGE
7
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge, and
then rinse thoroughly with clean water.
Use a toothbrush or bottlebrush for hard-
to-reach areas. Stubborn dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few
minutes before cleaning.After riding in the rain, near the sea oron salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the rain,
near the sea or on salt-sprayed roads.Salt sprayed on roads in the winter may
remain well into spring.1. Clean the motorcycle with coldwater and a mild detergent, after
the engine has cooled down.
ECA10790
Do not use warm water since it
increases the corrosive action of the
salt.2. Apply a corrosion protection sprayon all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Immediately dry the drive chain and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion
protection spray on all metal,
including chrome- and nickel-
plated, surfaces. 5. Use spray oil as a universal cleaner
to remove any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before storing or covering it.
EWA11130
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Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires with
warm water and a mild
detergent. Before riding at
higher speeds, test the
motorcycle’s braking
performance and cornering
behavior.
ECA10800
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Apply spray oil and wax
sparingly and make sure to wipe
off any excess.
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7-3MOTORCYCLE CARE AND STORAGE
7
rubber and plastic parts, but treat
them with a suitable care
product.
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Avoid using abrasive polishing
compounds as they will wear
away the paint.
Consult a Yamaha dealer for advice on
what products to use.
EAUM1900
StorageShort-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
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Storing the motorcycle in a
poorly ventilated room or
covering it with a tarp, while it
is still wet, will allow water and
humidity to seep in and cause
rust.
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To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia) and
areas where strong chemicals
are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the “Care” section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating. 3. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the
spark plug on the cylinder head so
that the electrodes are grounded.
(This will limit sparking during the
next step.)
d. Turn the engine over several times with the starter. (This will coat the
cylinder wall with oil.)
e. Remove the spark plug cap from the spark plug, and then install the
spark plug and the spark plug cap.
EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.4. Lubricate all control cables and thepivoting points of all levers and
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7-4
MOTORCYCLE CARE AND STORAGE
7pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a little
every month in order to prevent the
tires from becoming degraded in
one spot.
6. Cover the muffler outlets with plastic bags to prevent moisture
from entering them.
7. Remove the battery and fully charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an
excessively cold or warm place
[less than 0 °C (30 °F) or more than
30 °C (90 °F)]. For more information
on storing the battery, see page
6-25~6-26.
Make any necessary repairs before
storing the motorcycle.
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8-1
SPECIFICATIONS
8
Dimensions:Overall length:2025 mm (79.7 in)
Overall width: 745 mm (29.3 in)
Overall height:
1065 mm (41.9 in)
Seat height:
805 mm (31.7 in)
Wheelbase: 1360 mm (53.5 in)
Ground clearance:
190 mm (7.5 in)
Minimum turning radius:
2395 mm (94.3 in)Weight:With oil and fuel:154.0 kg (339 lb)Engine:Engine type:Air cooled 4-stroke, SOHC
Cylinder arrangement: Forward-inclined single cylinder
Displacement:
249.0 cm
3 (15.2 cu.in)
Bore x stroke:
74.0 x 58.0 mm (2.91 x 2.28 in)
Compression ratio: 9.80:1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:SAE20W40 or SAE20W50Recommended engine oil grade: API service SF, SG type or higher
Engine oil quantity:
Without oil filter element replacement 1.35 L (1.43 US qt) (1.19 imp. qt)
With oil filter element replacement
1.45 L (1.53 US qt) (1.28 imp. qt)Air filter:Air filter element:Wet elementFuel:Recommended fuel:Regular unleaded gasoline only
Fuel tank capacity:
19.2 L (5.07 US gal) (4.22 imp. gal)
Fuel reserve amount:
4.5 L (1.19 US gal) (1.00 imp. gal)
Fuel injection:Manufacturer:AISAN
Model/quantity: 1100-87F70/1Spark plug:Manufacturer/model:NGK/DR8EA
Spark plug gap:
0.6-0.7 mm (0.024 - 0.028 in)Clutch:Clutch type:Wet, multiple-discTransmission:Primary reduction system:Spur gear
Primary reduction ratio:
74/24 (3.083)
Secondary reduction system: Chain drive
Secondary reduction ratio:
44/15 (2.933)
Transmission type:
Constant mesh 5-speed
Operation: Left foot operation
Gear ratio:
1st:
36/14 (2.571)
2nd:
32/19 (1.684)
3rd:
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