relay YAMAHA WR 250F 2007 Notices Demploi (in French)

MAINTENANCE SPECIFICATIONS
2 - 15
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—72 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 6 50 5.0 36
Rear brake disc cover M6 × 1.0 2 10 1.0 7.2
Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
Engine and frame (lower) M10 × 1.25 1 53 5.3 38
Upper engine bracket and frame M8 × 1.25 4 34 3.4 24
Lower engine bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 70 7.0 50
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame (upper) M8 × 1.25 1 38 3.8 27
Rear frame (lower) M8 × 1.25 2 32 3.2 23
Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank M6 × 1.0 2 9 0.9 6.5
Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator guard (lower) M6 × 1.0 2 6 0.6 4.3
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 11 1.1 8.0
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
Multi-function display bracket and upper
bracketM6 × 1.0 2 7 0.7 5.1
Multi-function display M5 × 0.8 2 4 0.4 2.9
Plate 1 and front fork protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and front fork protector—2 0.5 0.05 0.36

MAINTENANCE SPECIFICATIONS
2 - 18
SPEC
NOTE:
Tighten 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). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C (68 °F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1 Refer to NOTE.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Negative lead and cylinder head M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2 Item Standard Limit

SPEC
2 - 111
CABLE ROUTING DIAGRAM
1Clamp
2Positive battery lead
3Battery
4Negative battery lead
5Taillight coupler
6CDI unit coupler (6-pin)
7CDI unit coupler (3-pin)
8CDI unit coupler (6-pin)ÈFasten the wire harness, negative battery lead and starter
motor lead to the upper engine bracket (left side). Locate the
clamp end facing toward the upper side of the frame with the
tie end cut off on the inside of the frame.
ÉFasten the wire harness, negative battery lead and starter
motor lead to the upper engine bracket (left side). Locate the
clamp end facing toward the upper side of the frame with the
tie end cut off on the inside of the frame. Clamp the wire har-
ness and negative lead at the marking.
ÊPass the starter motor lead through the hole in the relay
holder.
ËFit the cover securely.
ÌConnect the wire harness to the starter relay.

SPEC
2 - 113
CABLE ROUTING DIAGRAM
ÍFasten the catch tank breather hose
and catch tank hose to the rear frame.
Clamp them close to where they are
joined to the frame. Fasten the pipe
tightly enough not to crush it. Locate the
clamp end facing toward the rear of the
frame with the tie end facing downward.
ÎFasten the (three) CDI unit leads and
taillight lead to the rear frame. Locate
the clamp end facing toward the upper
side of the frame and cut off the tie end.
ÏConnect the negative battery lead to
the battery negative terminal.
ÐConnect the negative battery lead to
the wire harness.ÑFasten the wire harness to the rear
frame. Locate the clamp end facing
toward the upper side of the frame and
the tie end toward the inside of the
frame. Clamp the wire harness at the
marking.
ÒPass the wire harness, starter relay
lead, starting circuit cut-off relay lead
and negative battery lead through the
hole in the relay holder.
ÓFasten the (three) CDI unit leads and
taillight lead to the rear frame. Locate
the clamp end facing toward the lower
side of the frame and cut off the tie end.ÔFasten the taillight lead to the rear
frame. Locate the clamp end facing
toward the upper side of the frame and
cut off the time end.
ÕDo not allow the taillight lead to
slacken.
ÖLocate the CDI unit lead between the
CDI unit and rear fender.
×Locate the CDI unit coupler in the clear-
ance between the upper side of the CDI
unit and lower side of the catch tank
stay.
ØLocate the CDI unit lead between the
CDI unit and rear frame.

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
FRONT FORKS
Inspect and adjust
Replace oilSuspension oil “S1”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
Inspect and adjust
Lube(After
rain
ride)Molybdenum disulfide
grease
Retighten
DRIVE CHAIN GUIDE AND ROLLERS
Inspect
SWINGARMMolybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD Molybdenum disulfide
grease
Inspect, lube and retighten
SIDESTAND
LubricateLithium base grease
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out, tire
wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE Yamaha cable lube or SAE
10W-30 motor oil
Check routing and connection
Lubricate
HOT STARTER, CLUTCH LEVER
Inspect free play
BATTERY
Check terminal for looseness and
corrosionItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks

6 - 121
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM 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.
Brake hose holder
Refer to “FRONT BRAKE AND REAR BRAKE”
section.
Rear brake caliper
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

6 - 125
CHASSWINGARM
EC578000SWINGARM DISASSEMBLY
Extent of removal:
1 Swingarm disassembly
2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Cap 2 Refer to “REMOVAL POINTS”.
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bushing 2
8 Oil seal 8
9 Bearing 10 Refer to “REMOVAL POINTS”.
1
2
3
23

6 - 129
CHASSWINGARM
EC573000REMOVAL POINTS
Cap
1. Remove:
•Left cap
1
NOTE:Remove with a slotted-head screw-
driver inserted under the mark
a on
the left cap.
EC573200Bearing
1. Remove:
•Bearing
1
NOTE:Remove the bearing by pressing its
outer race.
INSPECTION
Wash the bearings, bushings and
collars in a solvent.
Swingarm
1. Inspect:
•Bearing
1
•Bushing
2
Free play exists/unsmooth
revolution/rust
→ Replace
bearing and bushing as a set.
2. Inspect:
•Oil seal
3
Damage
→ Replace.
Relay arm
1. Inspect:
•Bearing
1
•Collar
2
Free play exists/unsmooth
revolution/rust
→ Replace
bearing and collar as a set.
2. Inspect:
•Oil seal
3
Damage
→ Replace.
POINTS DE DEPOSE
Capuchon
1. Déposer:
Capuchon gauche 1
N.B.:
Déposer en insérant un tournevis à lame
droite sous le repère a du capuchon
gauche.
Roulement
1. Déposer:
Roulement 1
N.B.:
Enlever le roulement en appuyant sur la
cage externe.
CONTROLE
Nettoyer les roulements, les bagues, les
entretoises épaulées dans du solvant.
Bras oscillant
1. Contrôler:
Roulement 1
Bague 2
Jeu/rotation irrégulière/rouille →
Remplacer ensemble le roulement
et la bague.
2. Contrôler:
Bague d’étanchéité 3
Endommagement → Remplacer.
Bras relais
1. Contrôler:
Roulement 1
Entretoise épaulée 2
Jeu/rotation irrégulière/rouille →
Remplacer ensemble le roulement
et l’entretoise épaulée.
2. Contrôler:
Bague d’étanchéité 3
Endommagement → Remplacer.
BRAS OSCILLANT

6 - 133
CHASSWINGARM
2. Install:
•Bearing
1
•Washer
2
•Oil seal
3
To relay arm.
NOTE:•Apply the molybdenum disulfide
grease on the bearing when install-
ing.
•Install the bearing by pressing it on
the side having the manufacture’s
marks or numbers.
•Apply the molybdenum disulfide
grease on the washer.
Installed depth of
bearings a
:
Zero mm (Zero in)
3. Install:
•Bearing
1
•Oil seal
2
To connecting rod.
NOTE:•Apply the molybdenum disulfide
grease on the bearing when install-
ing.
•Install the bearing by pressing it on
the side having the manufacture’s
marks or numbers.
Installed depth of
bearings a
:
Zero mm (Zero in)
Swingarm
1. Install:
•Bushing
1
•Thrust bearing
2
•Oil seal
3
•Collar
4
To swingarm
5.
NOTE:Apply the molybdenum disulfide
grease on the bushings, thrust bear-
ings, oil seal lips and contact sur-
faces of the collar and thrust bearing.
2. Monter:
Roulement 1
Rondelle 2
Bague d’étanchéité 3
Sur le bras relais.
N.B.:
Lors de l’installation, enduire le roule-
ment de graisse au bisulfure de molyb-
dène.
Monter le roulement en pressant sur le
côté où sont imprimés la marque ou le
numéro du fabricant
Appliquer la graisse au bisulfure de
molybdène sur la rondelle.
Profondeur d’installation
des roulements a:
Zéro mm (zéro in)
3. Monter:
Roulement 1
Bague d’étanchéité 2
Sur la bielle.
N.B.:
Lors de l’installation, enduire le roule-
ment de graisse au bisulfure de molyb-
dène.
Monter le roulement en pressant sur le
côté où sont imprimés la marque ou le
numéro du fabricant.
Profondeur d’installation
des roulements a:
Zéro mm (zéro in)
Bras oscillant
1. Monter:
Bague 1
Roulement de butée 2
Bague d’étanchéité 3
Entretoise épaulée 4
Sur le bras oscillant 5.
N.B.:
Appliquer la graisse au bisulfure de
molybdène sur les bagues, les roule-
ments de butée, les lèvres des bagues
d’étanchéité et les surfaces de contact de
lentretoise épaulée et du roulement de
butée.
BRAS OSCILLANT

6 - 135
CHASSWINGARM
2. Install:
•Collar
1
•Washer
2
To relay arm
3.
NOTE:Apply the molybdenum disulfide
grease on the collars and oil seal
lips.
3. Install:
•Collar
1
To connecting rod
2.
NOTE:Apply the molybdenum disulfide
grease on the collar and oil seal lips.
4. Install:
•Connecting rod
1
•Bolt (connecting rod)
2
•Washer
3
•Nut (connecting rod)
4
To relay arm
5.
NOTE:Apply the molybdenum disulfide
grease on the bolt.
T R..80 Nm (8.0 m · kg, 58 ft · lb)
5. Install:
•Relay arm
1
•Bolt (relay arm)
2
•Washer
3
•Nut (relay arm)
4
To swingarm.
NOTE:•Apply the molybdenum disulfide
grease on the bolt circumference
and threaded portion.
•Do not tighten the nut yet.
6. Install:
•Swingarm
1
•Pivot shaft
2
NOTE:•Apply the molybdenum disulfide
grease on the pivot shaft.
•Insert the pivot shaft from right
side.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
2. Monter:
Entretoise épaulée 1
Rondelle 2
Sur le bras relais 3.
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur les entretoises épaulées et
les lèvres des bagues d’étanchéité.
3. Monter:
Entretoise épaulée 1
Sur la bielle 2.
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur l’entretoise épaulée et les
lèvres des bagues d’étanchéité.
4. Monter:
Bielle 1
Boulon (bielle) 2
Rondelle 3
Ecrou (bielle) 4
Sur le bras relais 5.
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur le boulon.
T R..80 Nm (8,0 m · kg, 58 ft · lb)
5. Monter:
Bras relais 1
Boulon (bras relais) 2
Rondelle 3
Ecrou (bras relais) 4
Sur le bras oscillant.
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur la circonférence du
boulon et la partie filetée.
Ne pas encore serrer l’écrou.
6. Monter:
Bras oscillant 1
Boulon-pivot 2
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur le boulon-pivot.
Insérer le boulon-pivot du côté droit.
T R..85 Nm (8,5 m · kg, 61 ft · lb)
BRAS OSCILLANT