Yamaha YBR250 2007 Manuel utilisateur

YBR250

SERVICE MANUAL

5D1-F8197-E0

2007

YBR250

SERVICE MANUAL

First edition, February 2007

Any reproduction or unauthorized use without

the written permission of Yamaha Motor da

Amazônia Ltda is expressly prohibited.

NOTICE

This manual was produced by the YAMAHA MOTOR DA AMAZÔNIA LTDA., primarily for use by

Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a

mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs

on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair

these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge

is likely to render the vehicle unsafe and unfit for use.

YAMAHA MOTOR DA AMAZÔNIA LTDA. is continually striving to improve all of its models. Modifi-

cations and significant changes in specifications or procedures will be forwarded to all authorized

Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

CAUTION:

VWARNING

NOTE:

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)

appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8 Jobsrequiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequentially.

SYMBOLS

The following symbols are not common to all

vehicles

Symbols 1- 8indicate the subject of each

chapter.

1Generalinformation

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Fuel Injection system

7Electrical system

8Troubleshooting

Symbols 9- Findicate the following:

9Serviceable with engine mounted

0Fillingfluid

ALubricant

BSpecial tool

CTighteningtorque

DClearance, wear limit

EEngine speed

FElectrical data

SymbolsG-Nin theexploded diagrams indi-

cate the types of lubricants and lubrication

points.

GEngineoil

HGear oil

IMolybdenum-disulphideoil

JBrake fluid

KWheel-bearinggrease

LLithium-soap-based grease

MMolybdenum-disulphidegrease

NSilicone grease

SymbolsO- Pinthe explodeddiagrams indi-

cate the following.

OApply locking agent (LOCTITE®)

PReplace the part.

New

GEN

INFO SPEC

CHK

ADJ

ENG

CHAS

ELEC ?

TRBL

SHTG

TABLE OF CONTENTS

GEN

INFO 1

PERIODIC CHECKS

AND ADJUSTMENTS

GENERALINFORMATION

SPECIFICATIONS

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

ENGINE

FUEL INJECTION SYSTEM

SPEC

CHK

ADJ

CHAS

ENG

ELEC

TRBL

SHTG

CHAPTER 1

GENERALINFORMATION

VEHICLE IDENTIFICATION......................................................................... 1-1

VEHICLE IDENTIFICATION NUMBER................................................... 1-1

MODEL LABEL ........................................................................................ 1-1

FEATURES .................................................................................................... 1-2

FEATURES .............................................................................................. 1-2

FI SYSTEM .............................................................................................. 1-3

IMPORTANT INFORMATION ....................................................................... 1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY........................ 1-4

REPLACEMENT PARTS......................................................................... 1-4

GASKETS, OIL SEALS AND O-RINGS.................................................. 1-4

LOCK WASHERS, PLATES AND COTTER PINS ................................ 1-5

BEARINGS AND OIL SEALS .................................................................. 1-5

CIRCLIPS................................................................................................. 1-5

CHECKING THE CONNECTIONS ............................................................... 1-6

SPECIAL TOOLS .......................................................................................... 1-7

GEN

INFO

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

Chassis serial number 1is stamped into the right

side of the steering head pipe.

VEHICLE IDENTIFICATION

MODEL LABEL

The model label (1) is affixed to the frame.

Thisinformation will beneeded to orderspare parts.

1-1

GEN

INFO

FEATURES

Themain functionof afuel supplysystem isto providefuel tothe combustionchamber atthe optimum

air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In

the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion

chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used

in the respective chamber.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that

meter the fuel through the use of jets have been provided with various auxiliary devices, so that an

optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating

conditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,

it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To

accommodatethis need, this model has adopted anelectronically controlledfuel injection (FI) system,

in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio

required by the engine at all times by using a microprocessor that regulates the fuel injection volume

according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,

better fuel economy, and reduced exhaust emissions.

FEATURES

1ECU (engine control

unit)

2Engine trouble

warning light

3Lean angle sensor

4Fuel delivery hose

5Ignition coil

6Fuel injector

7FID (fast idle

solenoid)

8Throttle body sensor

assembly

9Battery

0Air filter case

ACatalytic converter

BCrankshaft position

sensor

CEngine temperature

sensor

DSpark plug

EFuel tank

FFuel pump

GAir induction system

(A.I.System)

HO2 sensor

1-2

57F

4931

BC8 0

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