check oil YAMAHA WR 250F 2017 Repair Manual

TRANSMISSION
6-83
EAS2GBB326CHECKING THE TRANSMISSION
1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”)
Out of specification  Replace the main ax-
le.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification  Replace the drive ax-
le.3. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace
the defective gear (s).
• Transmission gear dogs
Cracks/damage/rounded edges  Replace
the defective gear (s).
4. Check:
• Transmission gear movement
Rough movement  Replace the defective
gear (s).EAS2GBB327INSTALLING THE TRANSMISSION
1. Install:
• 6th pinion gear (27T) “1”
• 3rd/4th pinion gear (18T/21T) “2”
• Collar “3”
• 5th pinion gear (23T) “4”
• 2nd pinion gear (16T) “5”
(to the main axle “6”)
TIP
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.
2. Install:
• 2nd wheel gear (29T) “1”
• 5th wheel gear (22T) “2”
• 3rd wheel gear (26T) “3”
• 4th wheel gear (24T) “4”
• 6th wheel gear (22T) “5”
• Collar “6”
• 1st wheel gear (31T) “7”
• O-ring “8”
(to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-
fide oil to the inner and end surface of the idler
gear and the collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the
O-ring. Main axle runout limit
0.08 mm (0.0032 in)
Drive axle runout limit
0.08 mm (0.0032 in)
34
2
1
6
5
M
New

TRANSMISSION
6-85
7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar
lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.8. Check:
• Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.
3
12
6
2
4
5
3
7
1
E
E
E
2 13
E

7
COOLING SYSTEM
RADIATOR....................................................................................................... 7-1
HANDLING NOTE ...................................................................................... 7-3
CHECKING THE RADIATOR ..................................................................... 7-3
WATER PUMP.................................................................................................. 7-4
REMOVING THE OIL SEAL ....................................................................... 7-6
CHECKING THE WATER PUMP ............................................................... 7-6
CHECKING THE BEARING....................................................................... 7-6
INSTALLING THE OIL SEAL..................................................................... 7-6
ASSEMBLING THE WATER PUMP........................................................... 7-6

WATER PUMP
7-6
EAS2GBB333REMOVING THE OIL SEAL
TIP
• Remove the oil seal when the coolant level
changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal.
1. Remove:
• Oil seals “1”
EAS2GBB334CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• Impeller shaft
Cracks/damage/wear  Replace.
EAS2GBB335CHECKING THE BEARING
1. Check:
• Bearing
Rotate the inner race with your finger.
Rough spot/seizure  Replace.
EAS2GBB336INSTALLING THE OIL SEAL
1. Install:
• Oil seals “1”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Install the oil seal with its manufacture’s
marks or numbers facing the right crankcase
cover “2”.2. Install:
• Bearing “1”
TIP
Install the bearing by pressing its outer race
parallel.
EAS2GBB337ASSEMBLING THE WATER PUMP
1. Install:
• Impeller shaft assembly “1”
• Washer “2”
•Pin “3”
• Gear “4”
• Collar “5”
• Circlip “6”
TIP
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
• Apply the lithium-soap-based grease on the
impeller shaft.
1 1
New
1 1New
New
LS
LS2
New
1
2
52346
New
LS

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 ...................................................... 9-74
CHECKING THE IGNITION COIL ............................................................ 9-74
CHECKING THE CRANKSHAFT POSITION SENSOR........................... 9-75
CHECKING THE LEAN ANGLE SENSOR............................................... 9-75
CHECKING THE STARTER MOTOR OPERATION ................................ 9-76
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 ................................................................... 9-78
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 .. 9-80
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................ 9-80
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................... 9-80
CHECKING THE FUEL INJECTOR ......................................................... 9-81

IGNITION SYSTEM
9-4
EAS2GBB359TROUBLESHOOTING
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. Air filter case cover
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 SPARK
PLUG” on page 3-40.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 9-75.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 

CHARGING SYSTEM
9-14
EAS2GBB364TROUBLESHOOTING
The battery is not being charged.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
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 stator coil.
Refer to “CHECKING THE STA-
TOR COIL” on page 9-76.NG
Replace the stator assembly.
OK
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI-
FIER/REGULATOR” on page 9-76.NG
Replace the rectifier/regulator.
OK 
5. Check the entire charging system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-12.NG
Properly connect or repair the charging
system’s wiring.
OK
This circuit is OK.

FUEL INJECTION SYSTEM
9-30
EAS2GBB374ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system
is operating normally. If this function detects a malfunction in the system, it immediately operates the
engine under substitute characteristics and illuminates the engine trouble warning light to alert the
rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault
code number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an ap-
propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illu-
minating the engine trouble warning light.
Engine trouble warning light indication and fuel injection system operation
* The warning light flashes when any one of the following conditions is present and the start switch
is pushed:
Checking the engine trouble warning light
The engine trouble warning light comes on for around 2 seconds when pushing the start switch to
turn on the meter light and the engine trouble warning light comes on while the start switch is being
pushed.Warning light indica-
tionECU operationFuel injection opera-
tionVehicle operation
Flashing* Warning provided
when unable to start
engineOperation stopped Cannot be operated
Remains on Malfunction detected Operated with substi-
tute characteristics in
accordance with the
description of the mal-
functionCan or cannot be oper-
ated depending on the
fault code
12: Crankshaft position sensor 41: Lean angle sensor
(open or short circuit)
30: Lean angle sensor
(latch up detected)50: ECU internal malfunction
(faulty ECU memory)
33: Ignition coil
(Malfunction detected in the primary wire
of the ignition coil)
a. The meter light does not come on.
b. The meter light comes on.
c. Light OFF
d. Light ON for 2 seconds
ab
cdc

FUEL INJECTION SYSTEM
9-31
ECU detects an abnormal signal from a sensor
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu-
minates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS2GBB375TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32.
b. Check the fault code number displayed on the Yamaha diagnostic tool.
c. Identify the faulty system with the fault code number.
d. Identify the probable cause of the malfunction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.
3. Perform the reinstatement action for the fuel injection system. Refer to “Confirmation of service
completion” in the appropriate table in “TROUBLESHOOTING DETAILS” on page 9-35.
4. After pushing the engine stop switch, push the start switch to check whether the fault code number
is displayed.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is dis-
played.
5. Erase the malfunction history in the diagnostic mode. Refer to “SENSOR OPERATION TABLE”
(Diagnostic code No.62).
TIP
Turning off the meter light will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to
“TROUBLESHOOTING DETAILS” on page 9-35.
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOT-
ING DETAILS” on page 9-35.
Monitor the operation of the sensors and actua-
tors in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 9-35 and
“LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE
ACTIONS” on page 10-5.Check and repair.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector

FUEL INJECTION SYSTEM
9-45
2 Installed condition of lean an-
gle sensor.Check the installed direction
and condition of the sensor.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 Defective lean angle sensor. Execute the diagnostic mode.
(Code No. 08)
Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 9-75.Push the start switch.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 4.
4 Malfunction in ECU. Replace the ECU.
Fault code No. 33
ItemIgnition coil: open or short circuit detected in the primary lead
of the ignition coil.
Fail-safe systemUnable to start engine
Unable to drive vehicle
Diagnostic code No.30
ActuationActuates the ignition coil five times at one-second intervals.
The engine trouble warning light and the “WARNING” on the
Yamaha diagnostic tool screen come on each time the ignition coil
is actuated.
ProcedureCheck that a spark is generated five times.
• Connect an ignition checker.
ItemProbable cause of malfunc-
tion and checkMaintenance jobConfirmation of service
completion
1 Connection of ignition coil
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.Start the engine and let it idle
for approximately 5 seconds.
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.Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played  Service is finished.
Fault code number is dis-
played  Go to item 3. Fault code No. 30
Item Latch up detected.