relay YAMAHA WR 250F 2009 User Guide

6-36
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER
REMOVING THE REAR SHOCK ABSORBEROrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Seat and side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Silencer Refer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING THE COOLANT" sec-
tion 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 "CHECKING AND CHARGING THE
BATTERY" section in the CHAPTER 3.
Disconnect the starter relay coupler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 4

6-37
REAR SHOCK ABSORBER
2 Taillight coupler1
3 CDI unit coupler 3
4 Plastic band 1
5 Clamp (air filter joint) 1 Only loosening.
6 Rear frame 1
7 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
9 Rear shock absorber 1
10 Locknut 1 Only loosening.
11 Adjuster 1 Only loosening.
12 Lower spring guide 1
13 Upper spring guide 1
14 Spring (rear shock absorber) 1
15 Bearing 2 Refer to removal section.
Order
Part name Q'tyRemarks

6-39
REAR SHOCK ABSORBER
2. Install:• Stopper ring (upper bearing) "1"
After installing the stopper ring, push
back the bearing until it contacts the
stopper ring.
3. Install:• Lower bearing "1"
Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
INSTALLING THE SPRING (REAR
SHOCK ABSORBER)
1. Install:
• Spring "1"
• Upper spring guide "2"
• Lower spring guide "3"
2. Tighten: •Adjuster "1" 3. Adjust:
• Spring length (installed)Refer to "ADJUSTING THE
REAR SHOCK ABSORBER
SPRING PRELOAD" section in
the CHAPTER 3.
4. Tighten:
• Locknut "1"
INSTALLING THE REAR SHOCK
ABSORBER
1. Install: • Dust seal "1"
• O-ring "2"
•Collar "3"
• Apply the molybdenum disulfide grease on the dust seal lips and col-
lars.
• Apply the lithium soap base grease on the O-rings.
2. Install:• Bushing "1"
•Collar "2"
• Dust seal "3"
• Apply the molybdenum disulfide grease on the bearing and dust seal
lips.
• Install the dust seals with their lips
facing outward.
3. Install:• Rear shock absorber
4. Install: • Bolt (rear shock absorber-frame)
"1"
• Washer "2"
• Nut (rear shock absorber-frame) "3"
Apply the molybdenum disulfide
grease on the bolt.
5. Install:• Bolt (rear shock absorber-relay arm)"1"
• Nut (rear shock absorber-relay
arm) "2"
Apply the molybdenum disulfide
grease on the bolt.
6. Install:• Rear frame "1"
• Bolt [rear frame (upper)] "2"
• Bolt [rear frame (lower)] "3"
Installed depth of the
bearing "a":
4 mm (0.16 in)
Nut (rear shock absorb-
er-frame):56 Nm (5.6 m•kg, 40
ft•lb)
Nut (rear shock absorb-
er-relay arm): 53 Nm (5.3 m•kg, 38
ft•lb)
Bolt [rear frame (upper)]: 38 Nm (3.8 m•kg, 27
ft•lb)
Bolt [rear frame (lower)]: 32 Nm (3.2 m•kg, 23
ft•lb)

7-1
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL COMPONENTS1. Headlight
2. Multi-function display
3. Engine stop switch
4. Clutch switch
5. Diode
6. Starter relay diode
7. Throttle position sensor
8. Starter relay
9. Fuse
10. Starting circuit cut-off relay
11. CDI unit 12. Taillight
13. Neutral switch
14. Starter motor
15. AC magneto
16. Rectifier/regulator
17. Ignition coil
18. Spark plug
19. Start switch
20. Main switch
21. Speed sensor
22. Battery

7-2
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
WIRING DIAGRAM
1. Headlight
2. Multi-function display
3. Engine stop switch
4. Clutch switch
5. Diode
6. Starter relay diode
7. Throttle position sensor
8. Starter relay
9. Fuse
10. Starting circuit cut-off relay
11. CDI unit
12. Taillight
13. Neutral switch
14. Starter motor
15. AC magneto
16. Rectifier/regulator
17. Ignition coil
18. Spark plug
19. Start switch
20. Main switch
21. Speed sensor
22. Battery
*1: For USA, CDN and EUROPE
*2: For AUS, NZ and ZACOLOR CODE
BBlack
Br Brown
Ch Chocolate
Dg Dark green
GGreen
Gy Gray
LBlue
OOrange
RRed
Sb Sky blue
WWhite
Y Yellow
B/L Black/Blue
B/W Black/White
L/B Blue/Black
L/R Blue/Red
L/Y Blue/Yellow
L/W Blue/White
R/B Red/Black
R/W Red/White


7

7-5
ELECTRIC STARTING SYSTEM
3. Inspect:• Secondary coil resistanceOut of specification →Replace.
4. Inspect: • Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"Wear →Replace.
CHECKING THE AC MAGNETO
1. Inspect: • Pickup coil resistanceOut of specification →Replace. CHECKING THE NEUTRAL
SWITCH
1. Inspect:
• Neutral switch conduction
Not conductive while it is in neutral →
Replace.
Conductive while it is engaged →Re-
place.
Set the tester selection position to " Ω
× 1".
CHECKING THE CDI UNIT
Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again.
ELECTRIC STARTING
SYSTEM
STARTING CIRCUIT CUT-OFF
SYSTEM OPERATION
If the main switch is set to "ON", the
starter motor can only operate if at
least one of the following conditions is
met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the han- dlebar (the clutch switch is closed).
The starting circuit cut-off relay pre-
vents the starter motor from operating
when neither of these conditions has
been met. In this instance, the start-
ing circuit cut-off relay is open so cur-
rent cannot reach the starter motor.
When at least one of the above con-
ditions has been met the starting cir-
cuit cut-off relay is closed and the
engine can be started by pressing the
start switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR 1. Battery
2. Main fuse
3. Main switch
4. Starting circuit cut-off relay
5. Start switch
6. Diode
7. Clutch switch
8. Neutral switch
9. Starter relay
10. Starter motor
Tester (+) lead
→Orange lead "1"
Tester (-) lead →Spark plug termi-
nal "2"
Secondary coil resis- tance Tester se-
lector posi- tion
4.6–6.8
k Ωat 20 °C
(68 °F) k
Ω × 1
Tester (+) lead →Red lead "1"
Tester (-) lead →White lead "2"
Pickup coil resistance Tester se-
lector posi- tion
248–372 Ω
at 20 °C (68
°F) Ω × 100
Tester (+) lead
→Sky blue lead "1"
Tester (-) lead →Ground "2"
Result Conductive (while gear
is in neutral)

7-6
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to "CHECKING THE FUSE" section in the CHAPTER 3.
*2 marked: Refer to "CHECKING AND CHARGING THE BATTERY" section in the CHAPTER 3.
*3 marked: Refer to "CHECKING THE MAIN SWITCH" section.
*4 marked: Refer to "CHECKING THE NEUTRAL SWITCH" section.
• Remove the following parts before inspection.
1. Seat
2. Rear fender
• Use 12 V battery in this inspection.
• Use the following special tools in this inspection.
*1 Check fuse.No good→Replace fuse and check wire harness.
OK ↓
*2 Check battery. No good→Recharge or replace.
OK ↓
Check each coupler and wire connection. No good →Repair or replace.
OK ↓
*3 Check main switch. No good→Replace.
OK ↓
Check starter motor operation. No good→Repair or replace.
OK ↓
Check starting circuit cut-off relay. No good→Replace.
OK ↓
Check starter relay. No good→Replace.
OK ↓
*4 Check neutral switch. No good→Replace.
OK ↓
Check clutch switch. No good→Replace.
OK ↓
Check diode. No good→Replace.
OK ↓
Check start switch. No good→Replace.
Pocket tester:
YU-3112-C/90890-03112

7-7
ELECTRIC STARTING SYSTEM
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:• Couplers and leads connection
Rust/dust/looseness/short-circuit
→ Repair or replace.
CHECKING THE STARTER
MOTOR OPERATION
1. Connect the positive battery ter- minal "1" and starter motor lead
"2" with a jumper lead "3".
Not operate →Repair or replace
the starter motor.
• A wire that is used as a jumper lead must have at least the same
capacity or more as that of the
battery lead, otherwise the jump-
er lead may burn.
• This check is likely to produce
sparks, therefore make sure
nothing flammable is in the vicin-
ity.
CHECKING THE STARTING
CIRCUIT CUT-OFF RELAY
1. Remove:• Starting circuit cut-off relay
2. Inspect: • Starting circuit cut-off relay con-duction
Use 12 V battery.
Not conductive while the battery is
connected →Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to "Ω
× 1".
CHECKING THE STARTER RELAY
1. Remove:
• Starter relay
2. Inspect:
• Starter relay conductionUse 12 V battery.
Not conductive while the battery is
connected →Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to " Ω
× 1".
CHECKING THE CLUTCH SWITCH
1. Inspect:
• Clutch switch conduction
Not conductive while it is pulled →Re-
place.
Conductive while it is freed →Re-
place.
Set the tester selection position to " Ω
× 1".
CHECKING THE DIODE
1. Remove the diode from wire har- ness.
2. Inspect: • Diode continuity
Use pocket tester (tester selec-
tion position Ω × 1)
Incorrect continuity →Replace.
Battery (+) lead
→Blue/Black lead
"1"
Battery (-) lead →Brown lead "2"
Tester (+) lead →Blue/White lead
"3"
Tester (-) lead →Black lead "4"
Result Conductive (while the
battery is connected)
Battery (+) lead →Starter relay ter-
minal "1"
Battery (-) lead →Starter relay ter-
minal "2"
Tester (+) lead →Starter relay ter-
minal "3"
Tester (-) lead →Starter relay ter-
minal "4"
ResultConductive (while the
battery is connected)
Tester (+) lead →Black lead "1"
Tester (-) lead →Black lead "2"
Result Conductive (while the
clutch lever is pulled)
Tester (+) →Blue/Red
terminal "1"
Tester (-) →Sky blue
terminal "2" Continu-
ous
Tester (+) →Blue/Red
terminal "1"
Tester (-) →Blue/Yel-
low terminal "3" Continu-
ous
Tester (+) →Sky blue
terminal "2"
Tester (-) →Blue/Red
terminal "1" No con-
tinuous
Tester (+) →Blue/Yel-
low terminal "3"
Tester (-) →Blue/Red
terminal "1" No con-
tinuous