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Yamaha YBR250 2007 - User Manual

Yamaha YBR250 2007
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YBR250
SERVICE MANUAL
5D1-F8197-E0
2007

Table of Contents

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Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details on identifying the vehicle's VIN and model label for service.

FEATURES

Overview of the motorcycle's main features, including the FI system.

IMPORTANT INFORMATION

Crucial guidelines for maintenance, parts, and safety before starting work.

CHECKING THE CONNECTIONS

Procedure for inspecting electrical connections for stains, rust, and moisture.

SPECIAL TOOLS

List of specialized tools required for tune-up and assembly procedures.

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS

Basic dimensional and weight data for the YBR250 model.

ENGINE SPECIFICATIONS

Detailed technical data for the engine, including dimensions, fuel, and oil.

CHASSIS SPECIFICATIONS

Specifications related to the frame, wheels, tires, brakes, and suspension systems.

ELECTRICAL SPECIFICATIONS

Technical data for the ignition, starting, charging, lighting, and signaling systems.

TIGHTENING TORQUES

Specifies tightening torques for standard fasteners and components.

LUBRICATION POINTS AND LUBRICANT TYPES

Identifies lubrication points and recommended lubricant types for engine and chassis.

CABLE ROUTING

Illustrates the correct routing for various wires, cables, and hoses on the motorcycle.

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND LUBRICATION TABLE

Schedule of routine maintenance tasks based on odometer reading and annual checks.

COWLING AND SIDE COVERS

Procedure for removing and installing side covers and related components.

FUEL TANK MAINTENANCE

Steps for removing, checking, and installing the fuel tank and pump.

ENGINE CHECKS AND ADJUSTMENTS

Covers valve clearance, idle speed, throttle play, compression, and fluid levels.

CHASSIS CHECKS AND ADJUSTMENTS

Procedures for checking brakes, tires, steering head, forks, and suspension.

ELECTRICAL SYSTEM CHECKS

Guidance on checking battery, fuses, bulbs, and basic system operations.

CHAPTER 4 CHASSIS

FRONT WHEEL AND BRAKE DISC

Procedures for removing, checking, and installing the front wheel and brake disc.

REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET

Service procedures for the rear wheel, brake disc, and sprocket assembly.

FRONT BRAKE

Detailed information on brake pads, master cylinder, and calipers.

FRONT FORK

Instructions for removing, disassembling, checking, assembling, and installing front fork legs.

HANDLEBAR

Procedures for removing, checking, and installing the handlebar.

STEERING HEAD

Steps for removing, checking, and installing the steering head components.

REAR SHOCK ABSORBER ASSEMBLY

Guidelines for handling, disposing, removing, checking, and installing the rear shock absorber.

SWINGARM AND DRIVE CHAIN

Maintenance and inspection of the swingarm and drive chain.

CHAPTER 5 ENGINE

REMOVING THE ENGINE

Steps for removing the engine, including exhaust, leads, and ignition coil.

CYLINDER HEAD

Procedures for removing, checking, and installing the cylinder head and related parts.

ROCKER ARMS AND CAMSHAFT

Service information for removing, checking, and installing rocker arms and camshaft.

VALVES AND VALVE SPRINGS

Steps for removing, checking, and installing valves, springs, and guides.

CYLINDER AND PISTON

Procedures for removing, checking, and installing the cylinder, piston, and rings.

CLUTCH

Details on clutch cover, pull lever shaft, and clutch assembly service.

OIL PUMP AND BALANCER GEAR

Information on oil pump and balancer gear removal, checking, and assembly.

OIL COOLER

Procedures for checking and assembling the oil cooler system.

SHIFT SHAFT

Steps for disassembling, checking, and installing the shift shaft and stopper lever.

STARTER CLUTCH AND AC MAGNETO

Service procedures for the starter clutch and AC magneto.

CRANKSHAFT AND CRANKCASES

Instructions for disassembling, checking, and assembling the crankshaft and crankcases.

TRANSMISSION

Procedures for removing, checking, and installing the transmission components.

MAIN AXLE; DRIVE AXLE

Service information for the main axle and drive axle assemblies.

CHAPTER 6 FUEL INJECTION SYSTEM

ELECTRICAL CIRCUIT DIAGRAM

Schematic diagram of the motorcycle's electrical system for fuel injection.

ECU SELF-DIAGNOSTIC FUNCTION

Explanation of the ECU's self-diagnostic capabilities and fault code indications.

SELF-DIAGNOSTIC FUNCTION TABLE

Reference table detailing fault codes, symptoms, fail-safe actions, and vehicle operability.

TROUBLESHOOTING METHOD

General procedures for diagnosing and resolving fuel injection system issues.

DIAGNOSTIC MODE

Steps for accessing and using the F.I. diagnostic tool in normal and diagnostic modes.

TROUBLESHOOTING DETAILS

Specific troubleshooting steps for each fault code number displayed by the FI diagnostic tool.

THROTTLE BODY MAINTENANCE

Procedures for removing, checking, and installing the throttle body and related components.

AIR INDUCTION SYSTEM

Information on the air induction system, including diagrams and checks.

CHAPTER 7 ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS OVERVIEW

Diagram showing the location of various electrical system components on the motorcycle.

SWITCH CONTINUITY CHECK

Procedure for testing switch continuity using a pocket tester.

SWITCH INSPECTION

Guidance on checking each switch for damage, wear, connections, and continuity.

BULB AND SOCKET CHECK

Instructions for checking bulbs and sockets for damage, wear, and continuity.

IGNITION SYSTEM

Details on the ignition system, including circuit diagrams and troubleshooting.

ELECTRIC STARTING SYSTEM

Information on the electric starting system, circuit diagrams, and troubleshooting.

STARTER MOTOR SERVICE

Procedures for removing, checking, and assembling the starter motor.

CHARGING SYSTEM

Details on the charging system, circuit diagrams, and troubleshooting.

LIGHTING SYSTEM

Information on the lighting system, including circuit diagrams and troubleshooting.

SIGNALING SYSTEM

Details on the signaling system, circuit diagrams, and troubleshooting.

CHAPTER 8 TROUBLESHOOTING

STARTING FAILURES

Troubleshooting guide for engine and fuel system issues that prevent starting.

INCORRECT ENGINE IDLING SPEED

Diagnosing and resolving problems related to unstable or incorrect engine idling speed.

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Troubleshooting steps for performance issues at medium and high speeds.

FAULTY GEAR SHIFTING

Diagnosing and resolving problems with gear shifting difficulty or jumps out of gear.

FAULTY CLUTCH

Troubleshooting for clutch slip, drag, and other related issues.

OVERHEATING ISSUES

Identifying causes and solutions for engine and brake overheating.

POOR BRAKING PERFORMANCE

Troubleshooting steps for issues like worn pads, fluid leaks, or brake drag.

FAULTY FRONT FORK LEGS

Diagnosing and resolving problems related to oil leaks or unstable handling from front forks.

UNSTABLE HANDLING

Troubleshooting causes of unstable handling related to tires, wheels, frame, and suspension.

FAULTY LIGHTING OR SIGNALING SYSTEM

Diagnosing and fixing issues with headlights, taillights, turn signals, and horn.

ELECTRICAL DIAGRAM AND COLOR CODE

Reference for electrical circuit diagrams and wire color codes.

Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details on identifying the vehicle's VIN and model label for service.

FEATURES

Overview of the motorcycle's main features, including the FI system.

IMPORTANT INFORMATION

Crucial guidelines for maintenance, parts, and safety before starting work.

CHECKING THE CONNECTIONS

Procedure for inspecting electrical connections for stains, rust, and moisture.

SPECIAL TOOLS

List of specialized tools required for tune-up and assembly procedures.

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS

Basic dimensional and weight data for the YBR250 model.

ENGINE SPECIFICATIONS

Detailed technical data for the engine, including dimensions, fuel, and oil.

CHASSIS SPECIFICATIONS

Specifications related to the frame, wheels, tires, brakes, and suspension systems.

ELECTRICAL SPECIFICATIONS

Technical data for the ignition, starting, charging, lighting, and signaling systems.

TIGHTENING TORQUES

Specifies tightening torques for standard fasteners and components.

LUBRICATION POINTS AND LUBRICANT TYPES

Identifies lubrication points and recommended lubricant types for engine and chassis.

CABLE ROUTING

Illustrates the correct routing for various wires, cables, and hoses on the motorcycle.

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND LUBRICATION TABLE

Schedule of routine maintenance tasks based on odometer reading and annual checks.

COWLING AND SIDE COVERS

Procedure for removing and installing side covers and related components.

FUEL TANK MAINTENANCE

Steps for removing, checking, and installing the fuel tank and pump.

ENGINE CHECKS AND ADJUSTMENTS

Covers valve clearance, idle speed, throttle play, compression, and fluid levels.

CHASSIS CHECKS AND ADJUSTMENTS

Procedures for checking brakes, tires, steering head, forks, and suspension.

ELECTRICAL SYSTEM CHECKS

Guidance on checking battery, fuses, bulbs, and basic system operations.

CHAPTER 4 CHASSIS

FRONT WHEEL AND BRAKE DISC

Procedures for removing, checking, and installing the front wheel and brake disc.

REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET

Service procedures for the rear wheel, brake disc, and sprocket assembly.

FRONT BRAKE

Detailed information on brake pads, master cylinder, and calipers.

FRONT FORK

Instructions for removing, disassembling, checking, assembling, and installing front fork legs.

HANDLEBAR

Procedures for removing, checking, and installing the handlebar.

STEERING HEAD

Steps for removing, checking, and installing the steering head components.

REAR SHOCK ABSORBER ASSEMBLY

Guidelines for handling, disposing, removing, checking, and installing the rear shock absorber.

SWINGARM AND DRIVE CHAIN

Maintenance and inspection of the swingarm and drive chain.

CHAPTER 5 ENGINE

REMOVING THE ENGINE

Steps for removing the engine, including exhaust, leads, and ignition coil.

CYLINDER HEAD

Procedures for removing, checking, and installing the cylinder head and related parts.

ROCKER ARMS AND CAMSHAFT

Service information for removing, checking, and installing rocker arms and camshaft.

VALVES AND VALVE SPRINGS

Steps for removing, checking, and installing valves, springs, and guides.

CYLINDER AND PISTON

Procedures for removing, checking, and installing the cylinder, piston, and rings.

CLUTCH

Details on clutch cover, pull lever shaft, and clutch assembly service.

OIL PUMP AND BALANCER GEAR

Information on oil pump and balancer gear removal, checking, and assembly.

OIL COOLER

Procedures for checking and assembling the oil cooler system.

SHIFT SHAFT

Steps for disassembling, checking, and installing the shift shaft and stopper lever.

STARTER CLUTCH AND AC MAGNETO

Service procedures for the starter clutch and AC magneto.

CRANKSHAFT AND CRANKCASES

Instructions for disassembling, checking, and assembling the crankshaft and crankcases.

TRANSMISSION

Procedures for removing, checking, and installing the transmission components.

MAIN AXLE; DRIVE AXLE

Service information for the main axle and drive axle assemblies.

CHAPTER 6 FUEL INJECTION SYSTEM

ELECTRICAL CIRCUIT DIAGRAM

Schematic diagram of the motorcycle's electrical system for fuel injection.

ECU SELF-DIAGNOSTIC FUNCTION

Explanation of the ECU's self-diagnostic capabilities and fault code indications.

SELF-DIAGNOSTIC FUNCTION TABLE

Reference table detailing fault codes, symptoms, fail-safe actions, and vehicle operability.

TROUBLESHOOTING METHOD

General procedures for diagnosing and resolving fuel injection system issues.

DIAGNOSTIC MODE

Steps for accessing and using the F.I. diagnostic tool in normal and diagnostic modes.

TROUBLESHOOTING DETAILS

Specific troubleshooting steps for each fault code number displayed by the FI diagnostic tool.

THROTTLE BODY MAINTENANCE

Procedures for removing, checking, and installing the throttle body and related components.

AIR INDUCTION SYSTEM

Information on the air induction system, including diagrams and checks.

CHAPTER 7 ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS OVERVIEW

Diagram showing the location of various electrical system components on the motorcycle.

SWITCH CONTINUITY CHECK

Procedure for testing switch continuity using a pocket tester.

SWITCH INSPECTION

Guidance on checking each switch for damage, wear, connections, and continuity.

BULB AND SOCKET CHECK

Instructions for checking bulbs and sockets for damage, wear, and continuity.

IGNITION SYSTEM

Details on the ignition system, including circuit diagrams and troubleshooting.

ELECTRIC STARTING SYSTEM

Information on the electric starting system, circuit diagrams, and troubleshooting.

STARTER MOTOR SERVICE

Procedures for removing, checking, and assembling the starter motor.

CHARGING SYSTEM

Details on the charging system, circuit diagrams, and troubleshooting.

LIGHTING SYSTEM

Information on the lighting system, including circuit diagrams and troubleshooting.

SIGNALING SYSTEM

Details on the signaling system, circuit diagrams, and troubleshooting.

CHAPTER 8 TROUBLESHOOTING

STARTING FAILURES

Troubleshooting guide for engine and fuel system issues that prevent starting.

INCORRECT ENGINE IDLING SPEED

Diagnosing and resolving problems related to unstable or incorrect engine idling speed.

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Troubleshooting steps for performance issues at medium and high speeds.

FAULTY GEAR SHIFTING

Diagnosing and resolving problems with gear shifting difficulty or jumps out of gear.

FAULTY CLUTCH

Troubleshooting for clutch slip, drag, and other related issues.

OVERHEATING ISSUES

Identifying causes and solutions for engine and brake overheating.

POOR BRAKING PERFORMANCE

Troubleshooting steps for issues like worn pads, fluid leaks, or brake drag.

FAULTY FRONT FORK LEGS

Diagnosing and resolving problems related to oil leaks or unstable handling from front forks.

UNSTABLE HANDLING

Troubleshooting causes of unstable handling related to tires, wheels, frame, and suspension.

FAULTY LIGHTING OR SIGNALING SYSTEM

Diagnosing and fixing issues with headlights, taillights, turn signals, and horn.

ELECTRICAL DIAGRAM AND COLOR CODE

Reference for electrical circuit diagrams and wire color codes.

Yamaha YBR250 2007 Specifications

General IconGeneral
Displacement249 cc
Bore x Stroke74.0 mm x 58.0 mm
Compression Ratio9.8:1
Fuel SystemCarburetor
IgnitionTCI
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Rear SuspensionSwingarm (monocross)
Front BrakeSingle disc
Rear BrakeDrum
Overall Width745 mm
Overall Height1, 065 mm
Seat Height780 mm
Wheelbase1, 360 mm
Ground Clearance175 mm
Fuel Capacity19.2 liters
Dry Weight138 kg
Engine TypeAir-cooled, 4-stroke, SOHC, 2-valve, single cylinder
Maximum Torque20.0Nm @ 6, 500rpm
Rear Tire130/70-17M/C 62H

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