2007 YAMAHA YBR250 check engine

TABLE OF CONTENTESSAFETY INFORMATION .................... 1-1
DESCRIPTION ................................... 2-1Left view ........................................ 2 - 1
Right view ...................................... 2 - 2
Controls and instruments ............. 2 - 3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 3-1 Main switch/steering lock ............. 3 - 1
Indicator and warning lights ........ 3 - 2
Speedometer ................................. 3 - 2
Tachometer .................................... 3 - 3
Multi-function display ................... 3 - 3
Handlebar switches ...................... 3 - 4
Clutch lever ................................... 3 - 5
Shift pedal ..................................... 3 - 6
Brake lever .................................... 3 - 6
Brake pedal ................................... 3 - 6
Fuel tank cap ................................. 3 - 7
Fuel ................................................ 3 - 7
Catalytic converter ........................ 3 - 8
Seat ................................................ 3 - 9
Helmet holder ................................ 3 - 9
Storage compartment .................3-10
Adjusting the shock aborber
assemblies ............................... 3-10
Luggage strap holders ...............3-11
Sidestand ..................................... 3-11
Ignition circuit cut-off system .....3-12 PRE-OPERATION CHECKS .............. 4-1
Pre-operation check list ............... 4 - 2
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1 Starting the engine ....................... 5 - 1
Shifting ........................................... 5 - 2
Tips for reducing fuel
consumption .............................. 5 - 3
Engine break-in ............................ 5 - 3
Parking .......................................... 5 - 4
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................. 6-1 Owner’s tool kit .............................. 6 - 1
Periodic maintenance and lubrication chart ......................... 6 - 2
Removing and installing the cowling and panels ................... 6 - 6
Checking the spark plug .............. 6 - 7
Engine oil and oil filter element ... 6-8
Cleaning the air filter element ... 6-11
Checking the engine idling
speed ........................................ 6-12
Checking the throttle cable free play .................................... 6-12
Valve clearance .. ........................6-12
Tires ............................................. 6-13
Cast wheels ................................. 6-15
Adjusting the clutch lever free play .................................... 6-15Adjusting the brake pedal
position and free play .............6-16
Adjusting the rear brake light switch ........................................ 6-17
Checking the front brake pads
and rear brake shoes ..............6-17
Checking the front brake fluid level .......................................... 6-18
Changing the brake fluid ...........6-18
Drive chain slack ........................6-19
Cleaning and lubricating the
drive chain ............................... 6-20
Checking and lubricating the cables ....................................... 6-21
Checking and lubricating the throttle grip and cable .............6-21
Checking and lubricating the
brake and clutch levers ...........6-21
Checking and lubricating the brake and shift pedals ............6-22
Checking and lubricating the sidestand .................................. 6-22
Lubricating the rear
suspension .............................. 6-23
Checking the front fork ...............6-23
Checking the steering ................6-24
Checking the wheel bearings ....6-24
Battery .......................................... 6-24
Replacing the fuses ....................6-26
Replacing the headlight bulb ....6-27
Replacing a turn signal light bulb or the tail/brake light bulb .......6-28
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1-3
1
SAFETY INFORMATION
as possible on both sides of the
motorcycle to minimize imbalance
or instability.
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Shifting weights can create a
sudden imbalance. Make sure that
accessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
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Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items,
including such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be
responsible for the proper selection,
installation and use of non-Yamaha
accessories. Use extreme caution when
selecting and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under“Loading” when mounting accessories.
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Never install accessories or carry
cargo that would impair the
performance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or
obscure lights or reflectors.lAccessories fitted to the
handlebar or the front fork area
can create instability due to
improper weight distribution or
aerodynamic changes. If
accessories are added to the
handlebar or front fork area, they
must be as lightweight as
possible and should be kept to a
minimum.lBulky or large accessories may
seriously affect the stability of the
motorcycle due to aerodynamic
effects. Wind may attempt to lift
the motorcycle, or the motorcycle
may become unstable in cross
winds. These accessories may
also cause instability whenpassing or being passed by large
vehicles.
lCertain accessories can displace
the operator from his or her
normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such
accessories are not
recommended.
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Use caution when adding electrical
accessories. If electrical
accessories exceed the capacity of
the motorcycle’s electrical system,
an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
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GASOLINE IS HIGHLY
FLAMMABLE:lAlways turn the engine off when
refueling.lTake care not to spill any gasoline
on the engine or exhaust system
when refueling.lNever refuel while smoking or in
the vicinity of an open flame.
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INSTRUMENT AND CONTROL FUNCTIONS
EAU11003
Indicator and warning lights1. Turn signal indicator light “
/
”
2. Neutral indicator light “N”
3. High beam indicator light “”
4. Fuel level warning light “
”
5. Engine trouble warning light “
”
EAU11030
Turn signal indicator lights
“
” and “
”
The corresponding indicator light flashes
when the turn signal switch is pushed
to the left or right.
EAU11060
Neutral indicator light “N”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “
”
This indicator light comes on when the
high beam of the headlight is switched
on.EAU11350
Fuel level warning light “
”
This warning light comes on when the
fuel level drops below approximately
4.5 L (1.19 US gal) (1.00 Imp. gal). When
this occurs, refuel as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
EAU11470
Engine trouble warning light “
”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system.
EAU11601
Speedometer1. Speedometer
2. TachometerThe speedometer shows the riding
speed.
When the key is turned to “ON”, the
speedometer needle will sweep once
across the speed range and then return
to zero in order to test the electrical
circuit.
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3-12
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INSTRUMENT AND CONTROL FUNCTIONSbelow and have a Yamaha dealer
repair it if it does not function
properly.
EAU15311
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch, clutch
switch and neutral switch) has the
following functions. It prevents starting when the transmission is in gear and the
sidestand is up, but the clutch lever
is not pulled.
 It prevents starting when the transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
 It cuts the running engine when the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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3-13
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INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO NOTE:
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5-1
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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
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Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or function
that you do not thoroughly
understand.
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Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are
poisonous, and inhaling them
can cause loss of
consciousness and death within
a short time. Always make sure
that there is adequate
ventilation.
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Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised
completely, it could contact the
ground and distract the operator,
resulting in a possible loss of
control.
EAUW0090
Starting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
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The transmission is in gear with the
clutch lever pulled and the
sidestand up.
EWA10290
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Before starting the engine, check
the function of the ignition
circuit cut-off system according
to the procedure described on
page 3-12.
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Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure
that the engine stop switch is set
to “
”.
ECAW0041
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The engine trouble warning light
should come on for a few
seconds, then go off. If the warning light does not go off,
ask a Yamaha dealer to check the
motorcycle.
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The speedometer needle will
sweep across the speed range
and then return to zero. The
tachometer needle will sweep
across the r/min range and then
return to zero. If either needle
does not sweep across their
ranges, ask a Yamaha dealer to
check the motorcycle.
2. Shift the transmission into the
neutral position.When the transmission is in the neutral
position, the neutral indicator light should
be on, otherwise have a Yamaha dealer
check the electrical circuit.3. Start the engine by pushing thestart switch.If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to
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OPERATION AND IMPORTANT RIDING POINTS
EAU16810
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Shift up swiftly, and avoid high
engine speeds during acceleration.
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Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
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Turn the engine off instead of letting
it idle for an extended length of time
(e.g., in traffic jams, at traffic lights
or at railroad crossings).
EAU16841
Engine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle
operation or any condition that might
result in engine overheating must be
avoided.
EAU17100
0-1000 km (0-600 mi)
Avoid prolonged operation above 5000
r/min.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above 6000
r/min.
ECA11150
After 1000 km (600 mi) of operation,
the engine oil must be changed, and
the oil filter element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
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Keep the engine speed out of the
tachometer red zone.
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If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehicle.
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Remove the seat. (See page 3-9.)
2. Remove the screws, and then pullthe panel to the outside as shown.To install the panel1. Place the panel in the original position, and install the screws.
2. Install the seat.
EAU19630
Checking the spark plugl
The spark plug is an important
engine component, which is easy
to check. Since heat and deposits
will cause any spark plug to slowly
erode, the spark plug should be
removed and checked in
accordance with the periodic
maintenance and lubrication chart.
In addition, the condition of the
spark plug can reveal the condition
of the engine.
To remove the spark plug 1. Remove cowling. (See page 6-6.)
1. Spark plug cap2. Remove the spark plug cap.
3. Remove the spark plug as shown, with the spark plug wrench included
in the owner’s tool kit.
1. Spark plug wrenchTo check the spark plug1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the
motorcycle is ridden normally).If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the motorcycle.2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
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