YAMAHA YBR250 2007 Service Manual

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PERIODIC MAINTENANCE AND MINOR REPAIRSpecified spark plug:NGK / DR8EATo install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to
specification.1. Spark plug gapSpark plug gap:0.6~0.7mm (0.024-0.028 in)2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the spark plug wrench, and then
tighten it to the specified torque. Tightening torque:
Spark plug:17.5 Nm (1.75 m.kgf, 13 ft.lbt)
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4-1/2 turn past
finger tight. However, the spark plug
should be tightened to the specified
torque as soon as possible.4. Install the spark plug cap.
5. Install the cowling.
EAU37801
Engine oil and oil filter
elementThe engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element
replaced at the intervals specified in the
General periodic maintenance and
lubrication chart.
To check the engine oil level 1. Place the vehicle on a level surface and hold it in an upright
position.Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.2. Start the engine, warm it up forseveral minutes, and then turn it
off.
3. Wait a few minutes until the oil settles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
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PERIODIC MAINTENANCE AND MINOR REPAIR
The engine oil should be between the
minimum and maximum level marks.
12
3
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark4. If the engine oil is below the minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
To change the engine oil (with or
without oil filter element
replacement) 1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil.
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1. Dipstick3. Remove the engine oil filler bolt anddrain bolt to drain the oil from the
crankcase.
-2-3-4-5
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1. Engine oil drain boltCheck the washer for damage and
replace it if necessary.
4. Remove the oil filter element drainbolt to drain the oil from the oil filter
element.Skip steps 5-7 if the oil filter element is
not being replaced.5. Remove the oil filter element coverby removing the bolts.1. Oil filter element cover bolts
2. Oil filter element drain bolt6. Remove and replace the oil filterelement and O-rings.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Oil filter element
2. O-ringMake sure that the O-rings are properly
seated.7. Install the oil filter element coverby installing the bolts, then
tightening them to the specified
torque.Tightening torque:Oil filter element cover bolt: 10 Nm (1,0 m.kgf, 7.4 ft.lbf)8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
9. Install the oil filter element drain bolt, and then tighten it to the
specified torque.
Tightening torque:Engine oil drain bolt: 20 Nm (2.0 m.kgf, 15 ft.lbf)
Oil filter element drain bolt: 7 Nm (0.7 m.kgf, 5.25 ft.lbf)10. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler bolt.Recommended engine oil:See page 8-1
Oil quantity: Without oil filter element
replacement:1.35 L (1.43 US qt) (1.19
Imp.qt)
With oil filter element replacement:1.45 L (1.53 US qt) (1.28
Imp.qt)
ECA11620
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In order to prevent clutch
slippage (since the engine oil
also lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
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Make sure that no foreign
material enters the crankcase.
11. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off and
check for the cause.
12. Turn the engine off, and then check the oil level and correct it if
necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU20880
Cleaning the air filter elementThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently when riding in unusually
wet or dusty areas.1. Remove panel B. (See page 6-6.)
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2
1. Air filter case cover
2. Screw2. Remove the air filter case by
removing the screws.
3. Remove the air filter from the case.
1
1. Air filter element
4. Remove the air filter element from its guide and clean it with solvent.
After cleaning, remove the
remaining solvent by squeezing
the element.5. Apply recommended oil to theentire surface of the element and
squeeze out the excess oil. It
should be wet but not dripping.Recommended oil:Engine oil6. Insert the air filter element guide
into the air filter and install it in the
case.
7. Install the air filter case cover and panel by installing the screws.
ECA10480
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Make sure that the air filter
element is properly seated in the
air filter case.
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The engine should never be
operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21311
Checking the engine idling
speedThe engine idling speed must be
checked as follow and, if necessary,
adjusted by a Yamaha dealer at the
intervals specified in the periodic
maintenance and lubrication chart.
Start the engine and warm it up for
several minutes at 1000-2000 r/min while
occasionally revving it to 4000-5000 r/
min.The engine is warm when it quickly
responds to the throttle.Engine idling speed:1.300 - 1.500 r/min.
EAU21382
Checking the throttle cable
free play
1
1. Throttle cable free playThe throttle cable free play should
measure 3.0 - 5.0 mm (0.12 - 0.20 in)
at the throttle grip. Periodically check the
throttle cable free play and, if necessary,
have a Yamaha dealer adjust it.
EAU21401
Valve clearancel
The valve clearance changes with
use, resulting in improper air-fuel
mixture and/or engine noise. To
prevent this from occurring, the
valve clearance must be adjusted
by a Yamaha dealer at the intervals
specified in the periodic
maintenance and lubrication chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21560
TiresTo maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EWA10500
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The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
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The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo,
and accessories approved for
this model.
Tire air pressure (measured
on cold tires):0 - 90 kg (0 - 198 lb):
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250kPa (36 psi) (2.50 kgf/cm²)
Loading condition:
90 - 167 kg (198 - 368 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
167 kg (368 lb)
* Total weight of rider, passenger, cargo and accessories
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety
characteristics of your motorcycle,
you should keep the following
precautions in mind.l
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NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may
result in tire damage, loss of control, or severe injury. Make
sure that the total weight of rider,
passenger, cargo, and
accessories does not exceed the
specified maximum load for the
vehicle.
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Do not carry along loosely
packed items, which can shift
during a ride.
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Securely pack the heaviest items
close to the center of the
motorcycle and distribute the
weight evenly on both sides.
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Adjust the suspension and tire
air pressure with regard to the
load.
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Check the tire condition and air
pressure before each ride.
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PERIODIC MAINTENANCE AND MINOR REPAIRTire inspection1. Tire sidewall
2. Tire tread depthThe tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer
replace the tire immediately.Minimum tire tread depth (frontand rear):
1.6 mm (0.06 in)The tire tread depth limits may differ from
country to country. Always comply with
the local regulations.
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires.
EWA10460
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The front and rear tires should
be of the same make and design,
otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha.
Front tire:
Size: 100/80-17M/C (52S)
Manufacturer/model: PIRELLI / SPORT DEMON
Rear tire:
Size: 130/70-17M/C (62S)
Manufacturer/model:
PIRELLI / SPORT DEMON
EWA10470
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Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
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The replacement of all wheel and
brake related parts, including the
tires, should be left to a Yamaha
dealer, who has the necessary
professional knowledge and
experience.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21960
Cast wheelsTo maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified wheels.l
The wheel rims should be checked
for cracks, bends or warpage before
each ride. If any damage is found,
have a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must be
replaced.
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The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in poor
performance, adverse handling
characteristics, and a shortened
tire life.
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Ride at moderate speeds after
changing a tire since the tire surface
must first be “broken in” for it to
develop its optimal characteristics.
EAU22020
Adjusting the clutch lever
free play1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free playThe clutch lever free play should
measure 10.0 - 15.0 mm (0.39 - 0.59 in)
as shown. Periodically check the clutch
lever free play and, if necessary, adjust
it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play, turn the adjusting bolt in
direction (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
3. Tighten the locknut.
If the specified free play cannot be
obtained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22192
Adjusting the brake pedal
position and free play
EWA10670
It is advisable to have a Yamaha dealer
make these adjustments.Brake pedal position
The top of the brake pedal should be
positioned approximately 29 mm
(1.14 in) below the top of the footrest.
Periodically check the brake pedal
position and, if necessary, adjust it as
follows.1. Loosen the locknut at the brake pedal.
2. To raise the brake pedal, turn the adjusting bolt in direction (a). To
lower the brake pedal, turn the
adjusting bolt in direction (b).
3. Tighten the locknut.
EWA11230
After adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
A. Pedal height
B. Brake pedal free play
1 2
1. Adjusting bolt
2. LocknutBrake pedal free play
The brake pedal free play should
measure 15.0 - 20.0 mm (0.59 - 0.79 in)
as shown. Periodically check the brake
pedal free play and, if necessary, adjust
it as follows.
To increase the brake pedal free play, turn the adjusting nut at the brake rod in
direction (a). To decrease the b
rake pedal
free play, turn the adjusting nut in
direction (b).
1. Adjusting nut
EWA10680
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After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.
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If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.
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After adjusting the brake pedal
free play, check the operation of
the brake light.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22270
Adjusting the rear brake light
switch1. Rear brake light switch
2. Rear brake light switch adjusting nutThe rear brake light switch, which is
activated by the brake pedal, is properly
adjusted when the brake light comes on
just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To make
the brake light come on earlier, turn the
adjusting nut in direction (a). To make
the brake light come on later, turn the
adjusting nut in direction (b).
EAU22380
Checking the front brake
pads and rear brake shoesThe front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic
maintenance and lubrication chart.
EAU22430
Front brake pads
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1. Brake pad wear indicatorEach front brake pad is provided with
wear indicator grooves, which allow you
to check the brake pad wear without
having to disassemble the brake. To
check the brake pad wear, check the
wear indicator grooves. If a brake pad
has worn to the point that the wear
indicator grooves have almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22540
Rear brake shoes
1 2
1. Wear limit line
2. Brake shoe wear indicatorThe rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to
disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches the
wear limit line, have a Yamaha dealer
replace the brake shoes as a set.
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