fuse YAMAHA WR 250F 2016 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: WR 250F, Model: YAMAHA WR 250F 2016Pages: 428, PDF Size: 14.13 MB
Page 21 of 428
IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS2GB7020PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment.
See “SPECIAL TOOLS”.
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them.4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS2GB7021REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.
Page 64 of 428
ELECTRICAL SPECIFICATIONS
2-11
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.18–4.62
Starting circuit cut-off relay
Coil resistance 75.6–92.5
Headlight relay
Coil resistance 86.4–105.6
Fuses
Main fuse 15.0 A
Radiator fan motor fuse 5.0 A
Spare fuse 15.0 A
Page 85 of 428
CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Coupler for connecting optional part
6. Engine stop switch coupler
7. Rectifier/regulator coupler
8. AC magneto lead
9. Starter knob/idle screw
10. Starter motor lead
11. Radiator fan fuse
12. Taillight
13. Headlight relay (yellow tape)
14. Starting circuit cut-off relay (no identification
tape)
15. Diode
16. Holder plate
17. Left of the vehicle:radiator fan motor relay (blue
tape)
Right of the vehicle:main relay (red tape)
18. Neutral switch lead
19. Engine bracket
20. Front engine bracket
21. Plastic locking tie
22. Radiator hose
23. Neutral switch coupler
24. Crankshaft position sensor coupler
25. Tension arm
26. Wire harness
27. Tank rail
28. Rectifier/regulator
29. Rectifier/regulator bracket
30. Rear frame
31. Side cover 5
32. Crankcase cover
33. Crankcase
34. Lead holder
35. Frame
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to
the bracket.
D. Insert and fix the rectifier/regulator coupler to the
bracket.
E. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
F. Place the rear grommet of the starter motor lead
matching the rear end of the side cover.
G. Insert the radiator fan motor fuse into the protru-
sion of the holder plate.
H. Place the diode on top of the rear fender on the
inner side of the rear frame.
I. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
J. Route the AC magneto lead under the starter
clutch cover.
K. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
L. Insert the plastic locking tie into the bracket hole
and clamp the clutch cable. Clamp it so that the
lock of the plastic locking tie faces downward,
and then cut off the end of the plastic locking tie.
M. Pass the clutch cable with no downward sag al-
lowed.N. Place the grommet of the clutch cable so that it
contacts the radiator hose. Route the clutch cable
outside the neutral switch lead, AC magneto lead
and starter motor lead.
O. Route each lead so that the leads are not pinched
between the radiator hose and the frame.
P. 40 mm (1.57 in)
Q. Clamp the clutch cable, AC magneto lead, neu-
tral switch lead and starter motor lead by the plas-
tic locking tie. Make sure that they are clamped at
the positioning tapes in the clutch cable and the
starter motor lead. Make the lock on the plastic
locking tie face the front of the vehicle, and cut
the end.
R. Clamp the starter motor lead to the inside of the
tension arm with a plastic locking tie. Clamp it so
that the lock of the plastic locking tie faces up-
ward and outward, and do not cut off the end of
the plastic locking tie. Route the lead so that there
is no slack at the bottom from the clamp position
onwards.
S. After connecting the neutral switch coupler, at-
tach the coupler cover.
T. After connecting the crankshaft position sensor
coupler, attach the coupler cover.
U. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
V. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
W. Pass the engine stop switch lead between the
coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
X. Insert the starter motor lead completely into the
end of the side cover 5.
Y. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
Z. Insert the clip of the plastic locking tie into the
frame. Face the lock of the plastic locking tie for-
ward, and then cut off the end.
Page 332 of 428
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
Page 335 of 428
IGNITION SYSTEM
9-3
1. Joint connector
2. Joint connector
4. AC magneto
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
22.ECU (engine control unit)
23.Ignition coil
24.Spark plug
30.Joint connector
35.Lean angle sensor
36.Engine stop switch
48.Frame ground
49.Ignition coil sub-lead
Page 336 of 428
IGNITION SYSTEM
9-4
EAS2GB7359TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Fuel tank
1. Check the fuse.
Refer to “CHECKING THE FUSES”
on page 9-68.NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69.NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
3. Check the spark plug.
Refer to “CHECKING THE FUSES”
on page 9-68.NG
Re-gap or replace the spark plug.
OK
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNI-
TION SPARK GAP” on page 9-73.OK
The ignition system is normal.
NG
5. Check the ignition coil.
Refer to “CHECKING THE IGNI-
TION COIL” on page 9-74.NG
Replace the ignition coil.
OK
6. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK-
SHAFT POSITION SENSOR” on
page 9-74.NG
Replace the stator assembly.
OK
7. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 9-64.NG
Replace the engine stop switch.
OK
Page 339 of 428
ELECTRIC STARTING SYSTEM
9-7
1. Joint connector
2. Joint connector
3. Joint connector
7. Main relay
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
13.Starter motor
14.Starter relay diode
22.ECU (engine control unit)
30.Joint connector
36.Engine stop switch
37.Neutral switch
38.Diode
39.Starting circuit cut-off relay
40.Clutch switch
41.Start switch
48.Frame ground
Page 341 of 428
ELECTRIC STARTING SYSTEM
9-9
a. WHEN THE TRANSMISSION IS IN NEU-
TRAL
b. WHEN THE CLUTCH LEVER IS PULLED
TO THE HANDLEBAR
1. Battery
2. Main fuse
3. Main relay
4. Starting circuit cut-off relay
5. Start switch
6. Diode
7. Clutch switch
8. Neutral switch
9. Starter relay
10.Starter motor
Page 342 of 428
ELECTRIC STARTING SYSTEM
9-10
EAS2GB7362TROUBLESHOOTING
The starter motor fails to turn.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Fuel tank
1. Check the fuse.
Refer to “CHECKING THE FUSES”
on page 9-68.NG
Replace the fuse(s).
OK
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69.NG
• Clean the battery terminals.
• Recharge or replace the battery.
OK
3. Check the starter motor operation.
Refer to “CHECKING THE START-
ER MOTOR OPERATION” on page
9-75.OK
Starter motor is OK. Perform the electric
starting system troubleshooting, starting
with step 5.
NG
4. Check the starter motor.
Refer to “CHECKING THE START-
ER MOTOR” on page 6-37.NG
Repair or replace the starter motor.
OK
5. Check the relay unit (Starting circuit
cut-off relay).
Refer to “CHECKING THE RE-
LAYS” on page 9-72.NG
Replace the relay unit.
OK
6. Check the diode.
Refer to “CHECKING THE DIODE”
on page 9-73.NG
Replace the diode.
OK
7. Check the starter relay.
Refer to “CHECKING THE RE-
LAYS” on page 9-72.NG
Replace the starter relay.
OK
Page 345 of 428
CHARGING SYSTEM
9-13
4. AC magneto
5. Rectifier/regulator
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
50.Negative battery lead