radiator cap YAMAHA WR 250F 2015 User Guide

ENGINE
3-11
5. Install:
• Copper washer
• Coolant drain bolt
6. Pour coolant.
EWA
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a
doctor.
• If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
necessary, correct the antifreeze concen-
tration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:
• Radiator cap
8. Start the engine, warm this up for 3 minutes,
stop it, and then wait for it to cool down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-10.
EAS2GB2087CHECKING THE RADIATOR CAP
1. Check:
• Seal (radiator cap) “1”
• Valve and valve seat “2”Crack/damage  Replace.
Exist fur deposits  Clean or replace.
EAS2GB2088CHECKING THE RADIATOR CAP OPENING
PRESSURE
1. Check:
• Radiator cap opening pressure
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a. Install the radiator cap tester adapter “2” and
the radiator cap tester “3” to the radiator cap
“1,” and activate the tester to check whether
it can stay for 5 to 10 seconds within stan-
dard pressure values.
TIP
Before attaching the cap to the tester, apply
water to its sealing surface.
No stay  Replace.
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Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended coolant
High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator capacity (including all
routes)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Coolant mixing ratio
1:1 (Coolant:Water)
New
T R..
Radiator cap opening pressure
107.9–137.3 kPa (1.08–1.37 kg/
cm
2,15.6–19.9 psi)
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984

ENGINE
3-12
EAS2GB2089CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:
• Coolant level
2. Install:
• Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections
Coolant leaks  Correct or replace.
• Radiator hoses
Bulges  Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GB2090ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”
Out of specification  Regulate.
2. Adjust:
• Clutch lever free play
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Handlebar side
a. Turn the adjuster “1” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
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Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”. Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
Test pressure value
196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
a b
1

RADIATOR
7-3
EAS2GB2332HANDLING NOTEEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
EAS2GB2333CHECKING THE RADIATOR
1. Check:
• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
Crack/damage  Replace.

ELECTRICAL COMPONENTS....................................................................... 9-60
CHECKING THE SWITCHES .................................................................. 9-64
CHECKING THE BULBS AND BULB SOCKETS .................................... 9-67
CHECKING THE FUSES ......................................................................... 9-68
CHECKING AND CHARGING THE BATTERY ........................................ 9-69
CHECKING THE RELAYS ....................................................................... 9-72
CHECKING THE DIODE .......................................................................... 9-73
CHECKING THE IGNITION SPARK GAP................................................ 9-73
CHECKING THE SPARK PLUG CAP ...................................................... 9-73
CHECKING THE IGNITION COIL ............................................................ 9-74
CHECKING THE CRANKSHAFT POSITION SENSOR........................... 9-74
CHECKING THE LEAN ANGLE SENSOR............................................... 9-75
CHECKING THE STARTER MOTOR OPERATION ................................ 9-75
CHECKING THE STATOR COIL ............................................................. 9-76
CHECKING THE RECTIFIER/REGULATOR ........................................... 9-76
CHECKING THE SPEED SENSOR ......................................................... 9-77
CHECKING THE FUEL SENDER ............................................................ 9-77
CHECKING THE RESISTER ................................................................... 9-77
CHECKING THE RADIATOR FAN MOTOR ............................................ 9-78
CHECKING THE COOLANT TEMPERATURE SENSOR........................ 9-78
CHECKING THE THROTTLE POSITION SENSOR ................................ 9-79
CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE .. 9-79
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................ 9-80
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................... 9-80
CHECKING THE FUEL INJECTOR ......................................................... 9-81

TROUBLESHOOTING
10-2
EAS2GB2411POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to “STARTING FAILURES” on page 10-
1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
2. Throttle body
• Defective throttle body
3. ECU
• Faulty ECU
EAS2GB2412SHIFTING IS DIFFICULT
Refer to “CLUTCH” on page 6-40.
EAS2GB2413SHIFT PEDAL DOES NOT MOVE
Engine
1. Shift shaft
• Bent shift shaft
2. Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
3. Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS2GB2414JUMPS OUT OF GEAR
Engine
1. Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
2. Shift forks
• Worn shift fork
3. Shift drum
• Incorrect axial play
• Worn shift drum groove
4. Transmission
• Worn gear dog
EAS2GB2415CLUTCH SLIPS
Engine
1. Clutch
• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS2GB2416CLUTCH DRAGS
Engine
1. Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS2GB2417OVERHEATING
Engine
1. Cylinder head and piston
• Heavy carbon buildup
• Clogged coolant passages
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe