relay YAMAHA WR 250F 2017 Service Manual

FUEL INJECTION SYSTEM
9-52
TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.
TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay. Fault code No. 50
ItemFaulty ECU memory. (When this malfunction is detected in the
ECU, the fault code number might not appear on the meter.)
Fail-safe systemUnable to start engine
Unable to drive vehicle
Diagnostic code No.—
Diagnostic tool display—
Procedure—
ItemProbable cause of malfunc-
tion and checkMaintenance jobConfirmation of service
completion
1 Malfunction in ECU. Replace the ECU. Push the start switch.
Check that the fault code
number is not displayed.
Fault code No. Waiting for connection
Item No communication signal is received from the ECU.
Fail-safe systemAble to start engine (Unable when ECU is malfunctioning)
Able to drive vehicle (Unable when ECU is malfunctioning)
Diagnostic code No.—
Diagnostic tool display—
Procedure—
ItemProbable cause of malfunc-
tion and checkMaintenance jobConfirmation of service
completion
1 Connection of Yamaha diag-
nostic tool coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins).Improperly connected 
Connect the coupler securely
or repair/replace the wire har-
ness.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 2.
2 Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins).Improperly connected 
Connect the coupler securely
or repair/replace the wire har-
ness.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 3.

FUEL INJECTION SYSTEM
9-55
TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.
Fault code No. Er-4
ItemRegistered data cannot be received from the Yamaha diagnos-
tic tool.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.—
Diagnostic tool display—
Procedure—
ItemProbable cause of malfunc-
tion and checkMaintenance jobConfirmation of service
completion
1 Connection of Yamaha diag-
nostic tool coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins).Improperly connected 
Connect the coupler securely
or repair/replace the wire har-
ness.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 2.
2 Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins).Improperly connected 
Connect the coupler securely
or repair/replace the wire har-
ness.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 3.
3 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
light green–light greenPush the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 4.
4 Yamaha diagnostic tool mal-
function.Replace the Yamaha diag-
nostic tool.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 5.
5 Malfunction in ECU. Replace the ECU.

FUEL PUMP SYSTEM
9-57
1. Joint connector
2. Joint connector
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
22.ECU (engine control unit)
26.Fuel pump
30.Joint connector
36.Engine stop switch
48.Frame ground

ELECTRICAL COMPONENTS
9-63
1. Intake air temperature sensor
2. Intake air pressure sensor
3. Throttle position sensor
4. Starter relay
5. Main fuse
6. Headlight relay
7. Starting circuit cut-off relay
8. Lean angle sensor
9. Radiator fan motor fuse
10.Radiator fan motor relay
11.Main relay
12.Coolant temperature sensor

ELECTRICAL COMPONENTS
9-72
10.Install:
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GBB386CHECKING THE RELAYS
Check each switch for continuity with the pock-
et tester. If the continuity reading is incorrect,
replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester ( 1) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification  Replace.
Starter relay
Main relayStarting circuit cut-off relay
Headlight relay Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
21 3
4
R/WBr/WR/YL/G
1 23
4
L/R
BrR
R,R/W
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1 23
4
G/B
L/B
L/G,L/W
1 23
4
R,R/Y
GR

ELECTRICAL COMPONENTS
9-73
Radiator fan motor relay
EAS2GBB387CHECKING THE DIODE
1. Check:
•Diode
Out of specification  Replace.
TIP
The pocket tester and the analog pocket tester
readings are shown in the following table.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.b. Connect the pocket tester ( 1) to the di-
ode coupler as shown.
c. Check the diode for continuity.
d. Check the diode for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GBB388CHECKING THE IGNITION SPARK GAP
1. Check:
• Ignition spark gap
Out of specification  Perform the ignition
system troubleshooting, starting with step 4.
Refer to “TROUBLESHOOTING” on page 9-
4.
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as shown.
c. Push the engine stop switch.
d. Measure the ignition spark gap “a”.
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
No continuity
Tester positive lead  Sky blue
“1”
Tester negative lead  Green/
Black “2”
Continuity
Tester positive lead  Green/
Black “2”
Tester negative lead  Sky blue
“1”
No continuity
Tester positive lead  Red “3”
Tester negative lead  Red/Blue
“4”
Continuity
Tester positive lead  Red/Blue
“4”
Tester negative lead  Red “3”
1 23
4
P/L
R/L
R/W
Br,R/W
Minimum ignition spark gap
6.0 mm (0.24 in)
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
2. Spark plug cap
2
1
4
3
R Sb
G/B R/L

TROUBLESHOOTING
10-1
EAS2GBB405
TROUBLESHOOTING
EAS2GBB406GENERAL INFORMATION
TIP
The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure
in this manual for checks, adjustments, and re-
placement of parts.
EAS2GBB407STARTING FAILURES
Engine
1. Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose
2. Fuel pump
• Faulty fuel pump
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in airElectrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
4. Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
5. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
6. Switches and wiring
• Faulty ECU
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Improperly grounded circuit
• Loose connections
7. Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS2GBB408INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improper throttle cable free play
• Flooded throttle body

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
10-7
*1: Symbols used in the explanations of the malfunction history
: Normal
: There is currently a malfunction or abnormal condition.
: A malfunction or abnormal condition occurred previously, but the affected system or component
is currently operating normally.
ACTUATOR OPERATION TABLE62 Malfunction history ( )
code erasure *1
• There is no history.
• There is some history.•00
• Other: Displays the total
number of ( ) and ( ).Replace all ( ) with ( )
by the operation start pro-
cessing.
64 Setting history display
• There is no history.
• There is some history.
• History is unknown (Histo-
ry data is damaged).Displays the presence or ab-
sence of the setting history by
Power Tuner.
•00
•01
•02—
65 Setting map erasure
• There is no setting.
• There is some setting.Displays the presence or ab-
sence of the setting history by
Power Tuner.
•00
•01Erase all setting maps by
the operation start process-
ing.
70 Program version number Displays a program version
No.—
Diag-
nostic
code
No.Item Actuation Procedure
30 Ignition coil Actuates the ignition coil five
times at one-second inter-
vals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the ignition coil is
actuated.Check that a spark is gener-
ated five times.
• Connect an ignition
checker.
36 Injector Actuates the injector five
times at one-second inter-
vals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the radiator fan
motor relay is actuated.TIP: Before performing
this operation, be sure to
disconnect the fuel pump
coupler.
Check that injector is actu-
ated five times by listening
for the operating sound. Diag-
nostic
code
No.Item Display Procedure

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
10-8
51 Radiator fan motor relay Actuates the radiator fan mo-
tor relay five times at five-sec-
ond intervals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the radiator fan
motor relay is actuated.Check that the radiator fan
motor relay is actuated five
times by listening for the op-
erating sound.
52 Headlight relay Actuates the headlight relay
five times at five-second in-
tervals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the headlight re-
lay is actuated.Check that the headlight re-
lay is actuated five times by
listening for the operating
sound. Diag-
nostic
code
No.Item Actuation Procedure

EAS2GBB426
WIRING DIAGRAM
WR250F/WR250FH 2017
1. Joint connector
2. Joint connector
3. Joint connector
4. AC magneto
5. Rectifier/regulator
6. Headlight relay
7. Main relay
8. Engine ground
9. Battery
10. Frame ground
11. Starter relay
12. Main fuse
13. Starter motor
14. Starter relay diode
15. Indicator light
16. Engine trouble warning light
17. Fuel level warning light
18. Resistor
19. Fuel sender
20. Diode
21. Coupler for connecting option-
al part
22. ECU (engine control unit)
23. Ignition coil
24. Spark plug
25. Injector
26. Fuel pump
27. Radiator fan motor relay
28. Radiator fan motor fuse
29. Radiator fan motor
30. Joint connector
31. Intake air temperature sensor
32. Coolant temperature sensor
33. Throttle position sensor
34. Intake air pressure sensor
35. Lean angle sensor
36. Engine stop switch
37. Neutral switch
38. Diode
39. Starting circuit cut-off relay
40. Clutch switch
41. Start switch
42. Joint connector
43. Taillight
44. Headlight
45. Coupler for connecting option-
al switch
46. Speed sensor
47. Multi-function display
48. Frame ground
49. Ignition coil sub-lead
50. Negative battery lead
EAS2GBB427
COLOR CODE
BBlack
Br Brown
Ch Chocolate
Dg Dark green
G Green
Gy Gray
LBlue
Lg Light green
O Orange
PPink
RRed
Sb Sky blue
WWhite
Y Yellow
B/L Black/Blue
B/O Black/Orange
B/W Black/White
B/Y Black/Yellow
Br/W Brown/White
G/B Green/Black
G/W Green/White
G/Y Green/Yellow
L/B Blue/Black
L/G Blue/Green
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
P/L Pink/Blue
R/B Red/Black
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
W/B White/Black
Y/B Yellow/Black
Y/G Yellow/Green
Y/R Yellow/Red