charging YAMAHA WR 250F 2007 Betriebsanleitungen (in German)

CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM............ 7-1
IGNITION SYSTEM.................... 7-5
ELECTRIC STARTING
SYSTEM................................... 7-19
CHARGING SYSTEM.............. 7-43
THROTTLE POSITION
SENSOR SYSTEM................... 7-51
LIGHTING SYSTEM................. 7-67
SIGNALING SYSTEM.............. 7-77
CHAPITRE 7
PARTIE
ELECTRIQUE
COMPOSANTS
ELECTRIQUES ET SCHEMA
DE CABLAGE................................. 7-2
SYSTEME D’ALLUMAGE............ 7-6
DEMARRAGE ELECTRIQUE... 7-19
SYSTEME DE CHARGE............. 7-44
SYSTEME DU CAPTEUR
DE POSITION DE PAPILLON
DES GAZ........................................ 7-52
ECLAIRAGE................................. 7-68
SYSTEME DE
SIGNALISATION......................... 7-78

MAINTENANCE SPECIFICATIONS
2 - 17
SPEC
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5UM-E0/YAMAHA (For USA) ----
5UM-F0/YAMAHA (Except for USA) ----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5UM 20/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH770AA/SHINDENGEN ----
Regulated voltage (AC) 12.5 ~ 13.5 V ----
Regulated voltage (DC) 14.0 ~ 15.0 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM01/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.0189 ~ 0.0231 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----

3 - 125
INSP
ADJ
BATTERY INSPECTION AND
CHARGING
WARNING
Batteries generate explosive
hydrogen gas and contain electro-
lyte which is made of poisonous
and highly caustic sulfuric acid.
Therefore, always follow these
preventive measures:
Wear protective eye gear when
handling or working near batter-
ies.
Charge batteries in a well-venti-
lated area.
Keep batteries away from fire,
sparks or open flames (e.g.,
welding equipment, lighted ciga-
rettes).
DO NOT SMOKE when charging
or handling batteries.
KEEP BATTERIES AND ELEC-
TROLYTE OUT OF REACH OF
CHILDREN.
Avoid bodily contact with elec-
trolyte as it can cause severe
burns or permanent eye injury.
FIRST AID IN CASE OF BODILY
CONTACT:
EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15
minutes and get immediate med-
ical attention.
INTERNAL
Drink large quantities of water
or milk followed with milk of
magnesia, beaten egg or vegeta-
ble oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amper-
age and charging voltage for an
MF battery are different from
those of conventional batteries.
The MF battery should be charged
as explained in the charging
method illustrations. If the battery
is overcharged, the electrolyte
level will drop considerably.
Therefore, take special care when
charging the battery.
NOTE:Since MF batteries are sealed, it is
not possible to check the charge
state of the battery by measuring the
specific gravity of the electrolyte.
Therefore, the charge of the battery
has to be checked by measuring the
voltage at the battery terminals. CONTROLE ET CHARGE DE LA
BATTERIE
AVERTISSEMENT
Les batteries produisent de l’hydro-
gène, un gaz explosif et contiennent de
l’électrolyte, composé d’acide sulfuri-
que, toxique et corrosif.
Il faut dès lors veiller à toujours pren-
dre les précautions suivantes:
Toujours porter des lunettes de pro-
tection lorsque l’on travaille à
proximité de batteries.
Charger les batteries dans un
endroit bien aéré.
Tenir les batteries à l’écart de tout
feu, étincelles ou flamme nue (équi-
pement de soudure, cigarette, etc.).
NE PAS FUMER en chargeant ou
manipulant des batteries.
TENIR BATTERIES ET ELEC-
TROLYTE HORS DE LA POR-
TEE DES ENFANTS.
Eviter tout contact avec l’électro-
lyte, car il peut gravement brûler la
peau et les yeux.
PREMIERS SOINS EN CAS DE
CONTACT DIRECT:
EXTERNE
Peau — Laver à l’eau.
Yeux — Rincer à l’eau pendant 15
minutes et consulter immédiatement
un médecin.
INTERNE
Boire une grande quantité d’eau ou
de lait, continuer avec du lait de
magnésie, un oeuf battu ou de
l’huile végétale. Consulter immédia-
tement un médecin.
ATTENTION:
La durée, l’intensité et la tension de
charge d’une batterie sans entretien
MF et d’une batterie classique sont
différentes. La batterie MF doit être
rechargée conformément à la méthode
de charge illustrée dans ce manuel. Si
l’on surcharge la batterie, son niveau
d’électrolyte diminuera considérable-
ment. Il convient donc de charger la
batterie avec beaucoup de prudence.
N.B.:
Les batteries sans entretien (MF) sont
scellées; il est donc impossible de véri-
fier leur état de charge en mesurant la
densité de l’électrolyte. Par conséquent,
vérifier la charge de la batterie en mesu-
rant la tension aux bornes de la batterie.
ELECTRICAL
PARTIE ELECTRIQUE

3 - 127
INSP
ADJ
1. Remove:
Seat
2. Disconnect:
Battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative bat-
tery lead 1, and then the positive
battery lead 2.
3. Remove:
Battery band
Battery
4. Measure:
Battery charge
ÈRelationship between the open-circuit
voltage and the charging time at 20 °C
(68 °F) (These values vary with the
temperature, the condition of the
battery plates, and the electrolyte
level.)
ÉOpen-circuit voltage
ÊCharging time (hours)
ËTime (minutes)
ÌCharging condition of the battery
ÍAmbient temperature 20 °C (68 °F)
aCharging
bCheck the open-circuit voltage
Measurement steps:
Connect a pocket tester
1 to
the battery terminals.
Tester positive probe →
battery positive terminal
Tester negative probe →
battery negative terminal
NOTE:The charge state of an MF bat-
tery can be checked by measur-
ing its open-circuit voltage (i.e.,
the voltage when the positive
terminal is disconnected).
No charging is necessary when
the open-circuit voltage equals
or exceeds 12.8 V.
Check the charge of the battery,
as shown in the charts and the
following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30%
È
1. Déposer:
Selle
2. Déconnecter:
Câbles de la batterie
(des bornes de la batterie)
ATTENTION:
Déconnecter d’abord le câble négatif
de batterie 1, puis le câble positif 2.
3. Déposer:
Sangle de la batterie
Batterie
4. Mesurer:
Charge de la batterie
È
Relation entre la tension en circuit ouvert
et le temps de charge à 20 °C (68 °F)
(Ces valeurs varient en fonction de la
température, de l’état des plaques de la
batterie et du niveau d’électrolyte.)
É
Tension en circuit ouvert
Ê
Durée de charge (heures)
Ë
Durée (minutes)
Ì
Etat de charge de la batterie
Í
Température ambiante 20 °C (68 °F)
a
Charge
b
Vérifier la tension en circuit ouvert
Etapes de la mesure:
Raccorder un multimètre 1 aux
bornes de la batterie.
Sonde positive du multimètre →
borne positive de la batterie
Sonde négative de la batterie →
borne négative de la batterie
N.B.:
On peut contrôler l’état de charge
d’une batterie sans entretien (MF)
en mesurant la tension entre ses
bornes en circuit ouvert (après
avoir déconnecté la borne posi-
tive).
Inutile de recharger tant que la ten-
sion en circuit ouvert est supé-
rieure ou égale à 12,8 V.
Contrôler la charge de la batterie,
conformément aux diagrammes et
à l’exemple suivant.
Exemple
Tension en circuit ouvert = 12,0 V
Temps de charge = 6,5 heures
Charge de la batterie = 20 à 30 %
ELECTRICAL
PARTIE ELECTRIQUE

3 - 129
INSP
ADJ
5. Charge:
Battery
(refer to the appropriate charg-
ing method illustration)
WARNING
Do not quick charge a battery.
CAUTION:
Never remove the MF battery
sealing caps.
Do not use a high-rate battery
charger since it forces a high-
amperage current into the bat-
tery quickly and can cause bat-
tery overheating and battery
plate damage.
If it is impossible to regulate the
charging current on the battery
charger, be careful not to over-
charge the battery.
When charging a battery, be
sure to remove it from the
machine. (If charging has to be
done with the battery mounted
on the machine, disconnect the
negative battery lead from the
battery terminal.)
To reduce the chance of sparks,
do not plug in the battery
charger until the battery charger
leads are connected to the bat-
tery.
Before removing the battery
charger lead clips from the bat-
tery terminals, be sure to turn
off the battery charger.
Make sure the battery charger
lead clips are in full contact with
the battery terminal and that
they are not shorted. A corroded
battery charger lead clip may
generate heat in the contact
area and a weak clip spring may
cause sparks.
If the battery becomes hot to the
touch at any time during the
charging process, disconnect
the battery charger and let the
battery cool before reconnect-
ing it. Hot batteries can explode!
As shown in the following illus-
tration, the open-circuit voltage
of an MF battery stabilizes about
30 minutes after charging has
been completed. Therefore, wait
30 minutes after charging is
completed before measuring the
open-circuit voltage. 5. Charger:
batterie
(se reporter à l’illustration de la
méthode de charge appropriée)
AVERTISSEMENT
Ne pas utiliser la méthode de charge
rapide pour recharger cette batterie.
ATTENTION:
Ne jamais ôter les bouchons d’une
batterie sans entretien (MF).
Ne pas utiliser un chargeur de bat-
terie à intensité élevée. En effet, un
ampérage trop élevé risque de pro-
voquer la surchauffe de la batterie
et l’endommagement des plaques de
la batterie.
S’il n’est pas possible de régler le
courant de charge de la batterie,
bien veiller à ne pas surcharger la
batterie.
Toujours déposer la batterie avant
de procéder à sa charge. (Si la batte-
rie doit être chargée sur la moto,
déconnecter le câble négatif de la
borne de la batterie.)
Afin de réduire le risque de produc-
tion d’étincelles, ne pas brancher le
chargeur de batterie avant d’avoir
connecté les câbles du chargeur à la
batterie.
Ne pas oublier de couper l’alimenta-
tion du chargeur avant de retirer les
pinces du chargeur des bornes de la
batterie.
Veiller à assurer un contact électri-
que parfait entre les pinces du char-
geur et les bornes de la batterie. Ne
jamais laisser les pinces entrer en
contact l’une avec l’autre. Une pince
de chargeur corrodée risque de pro-
voquer un échauffement de la batte-
rie sur la zone de contact et des
pinces lâches peuvent provoquer
des étincelles.
Si la batterie devient chaude au tou-
cher pendant la charge, débrancher
le chargeur de batterie et laisser
refroidir la batterie avant de la
rebrancher. Une batterie chaude
risque d’exploser !
Comme montré dans le schéma sui-
vant, la tension en circuit ouvert
d’une batterie MF se stabilise envi-
ron 30 minutes après la fin du char-
gement. Par conséquent, attendre
30 minutes avant de mesurer la ten-
sion en circuit ouvert.
ELECTRICAL
PARTIE ELECTRIQUE

3 - 131
INSP
ADJ
ELECTRICAL
Charging method using a variable voltage charger
Connect a charger and
ammeter to the battery
and start charging.
Is the amperage higher
than the standard charg-
ing amperage written on
the battery?NO YES Charger
Ammeter
Adjust the voltage to obtain
the standard charging amper-
age.
Set the timer to the charging
time determined by the open-
circuit voltage.
Refer to “BATTERY
INSPECTION AND CHARG-
ING” section.Adjust the charging voltage to
20 ~ 25 V.
Monitor the amperage for
3 ~ 5 minutes. Is the standard
charging amperage exceeded?
NO YES
If the amperage does not
exceed the standard charg-
ing amperage after 5 minutes,
replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging amper-
age.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V
→ Charging is complete.
12.0 ~ 12.7 V
→ Recharging is required.
Under 12.0 V
→ Replace the battery.
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Set the charging voltage to 16-
17 V. (If the charging voltage is
lower, charging will be insuffi-
cient, if it is higher, the battery will
be over-charged.) NOTE:
NOTE:
Measure the open-circuit
voltage prior to charging.

3 - 132
INSP
ADJ
ELECTRICAL
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
NO
YESIs the amperage higher
than the standard charg-
ing amperage written on
the battery?
Charge the battery until the charging
voltage reaches 15 V.
Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.
12.8 V
→ Charging is complete.
12.0 ~ 12.7 V
→ Recharging is required.
Under 12.0 V
→ Replace the battery.This type of battery charger cannot
charge an MF battery. A variable
voltage charger is recommended.Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage. NOTE:
Set the charging time to a maxi-
mum of 20 hours. NOTE:
Constant amperage chargers
are not suitable for charging
MF batteries.
CAUTION:
Charger
Ammeter
Voltmeter

5 - 199
ENGAC MAGNETO AND STARTER CLUTCH
2. Install:
Holder
1
Bolt
2
CAUTION:
Pass the pickup coil lead and
charging coil lead under the
holder while taking care not to
allow these leads to get caught
with each other. Also take care to
pass the leads so that they do not
become loose at the bend of the
holder a
in order to avoid their
contacting the starter clutch drive
gear.
NOTE:Apply the sealant to the grommet of
the AC magneto lead.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
YAMAHA Bond No. 1215
(ThreeBond® No. 1215):
90890-85505
12 a
3. Install:
Idle gear 2
1
Dowel pin
2
NOTE:Apply the engine oil on the idle gear
2.21
2
E
4. Install:
Idle gear plate
1
Bolt (idle gear plate)
2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
21
5. Install:
Washer
1
Bearing
2
Starter clutch drive gear
3
Washer 4
NOTE:Apply the engine oil on the washer,
bearing and starter clutch drive gear
inner circumference.
E12
3
4
2. Monter:
Support 1
Boulon 2
ATTENTION:
Passer le fil de la bobine d’excitation
et de la bobine de charge sous le sup-
port tout en veillant à ce que ces deux
fils ne puissent s’emmêler. Veiller éga-
lement à acheminer les fils de manière
qu’ils ne puissent se détendre au
niveau du coude du support a afin
qu’ils ne puissent pas entrer en con-
tact avec le pignon menant de
l’embrayage du démarreur.
N.B.:
Appliquer le produit d’étanchéité sur
l’oeillet caoutchouc du fil de l’alterna-
teur.
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
YAMAHA Bond N°1215
(ThreeBond® N°1215):
90890-85505
3. Monter:
Pignon fou 2 1
Goujon 2
N.B.:
Appliquer de l’huile moteur sur le
pignon fou 2.
4. Monter:
Plaque de pignon fou 1
Boulon (plaque de pignon fou) 2
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
5. Monter:
Rondelle 1
Roulement 2
Pignon menant de l’embrayage
de démarreur 3
Rondelle 4
N.B.:
Appliquer de l’huile moteur sur la ron-
delle, le roulement et la circonférence
intérieure du pignon menant de
l’embrayage du démarreur.
ALTERNATEUR AVEC ROTOR A ALIMENTATION PERMANENTE ET EMBRAYAGE DU DEMARREUR

6 - 141
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:
1 Rear shock absorber removal
2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
REAR SHOCK ABSORBER REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable
stand under the engine.
Seat and side covers Refer to “SEAT, FUEL TANK AND SIDE COVERS”
section in the CHAPTER 3.
Silencer Refer to “EXHAUST PIPE AND SILENCER” section
in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the
CHAPTER 3.
Catch tank breather hose Disconnect at the catch tank side.
Catch tank hose Disconnect at the catch tank side.
Air induction hose (air cut-off valve-air filter
case)Disconnect at the air filter case side.
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.
Disconnect the starter relay coupler.
Starter motor lead Disconnect at the starter relay side.

7 - 5
–+ELECIGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Only when the ignition checker is used.
NOTE:•Remove the following parts before inspection.
1) Seat
2) Fuel tank
•Use the following special tools in this inspection.
*1 Check fuse.Replace fuse and check
wire harness.
*2 Check battery. Recharge or replace.
Spark gap test*3 Clean or replace spark
plug.
Check entire ignition system for
connection.
(couplers, leads and ignition coil)Repair or replace.
Check engine stop switch. Replace.
Check main switch.Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check AC magneto. Pickup coil Replace.
Check neutral switch. Repair or replace.
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/
90890-03112
No good
OK
No good
OK
Spark
No spark
No good
OK
No good
OK
No good
OK
No good
OKNo good
No good
OK
No good
OK