Yamaha RAPTOR 250 Service Manual Page 11
- Page / 311
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
Rated. / 5. Based on customer reviews
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . 4-46
CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-46
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
OIL PUMP AND BLANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . . . . . 4-50
REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP. . . . 4-53
CHECKING THE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
CHECKING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . 4-54
ASSENBLING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . 4-56
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CHECKING THE SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
INSTALLING THE SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
PICKUP COIL ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . 4-60
REMOVING THE PICKUPCOIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-62
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-63
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . 4-64
CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4-69
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
REMOVING THE CRANKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . 4-73
REMOVING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
CHECKING THE CRANKSHAFT AND CONNECTING ROD. . . . . . . 4-73
CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET
AND TIMING CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
INSTALLING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
INSTALLING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . 4-75
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . 4-81
CHECKING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
INSTALLING THE SHIFT FORKS AND SHIFT DRUM
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
- YFM250RX 1
- EBS00001 2
- HOW TO USE THIS MANUAL 4
- EBS00006 5
- TABLE OF CONTENTS 7
- CHAPTER 1 8
- CHAPTER 2 8
- CHAPTER 3 9
- CHAPTER 4 10
- CHAPTER 5 12
- CARBURETOR 12
- CHAPTER 6 12
- CHAPTER 7 13
- ELECTRICAL 13
- CHAPTER 8 14
- TROUBLESHOOTING 14
- GENERAL INFORMATION 16
- IMPORTANT INFORMATION 17
- SPECIAL TOOLS 20
- YU-01304 21
- SPECIFICATIONS 24
- GENERAL SPECIFICATIONS 25
- ENGINE SPECIFICATIONS 27
- CHASSIS SPECIFICATIONS 34
- ELECTRICAL SPECIFICATIONS 36
- TIGHTENING TORQUES 38
- HOW TO USE THE CONVERSION 42
- GENERAL TIGHTENING TORQUE 42
- EBS00024 43
- OIL FLOW DIAGRAMS 45
- CABLE ROUTING 48
- INTRODUCTION 62
- Whenever worn to the limit 63
- Every 4 years 63
- 7 Nm (0.7 m•kg, 5.2 ft•Ib) 65
- SEAT, FENDERS AND FUEL TANK 66
- ADJUSTING THE VALVE CLEARANCE 70
- 14 Nm (1.4 m•kg, 10 ft•lb) 71
- EBS00051 72
- EBS00052 73
- ADJUSTING THE SPEED LIMITER 74
- CHECKING THE SPARK PLUG 76
- CHECKING THE IGNITION TIMING 77
- CHECKING THE ENGINE OIL LEVEL 80
- CHANGING THE ENGINE OIL 82
- ADJUSTING THE CLUTCH CABLE/ 84
- CLEANING THE SPARK ARRESTER 86
- ADJUSTING THE REAR BRAKE/ 88
- ADJUSTING THE PARKING BRAKE 88
- 16 Nm (1.6 m•kg, 11 ft•lb) 89
- CHECKING THE FRONT BRAKE PADS 90
- CHECKING THE REAR BRAKE PADS 91
- CHECKING THE BRAKE HOSES 92
- CHECKING THE BRAKE HOSES/ 93
- 21 Nm (2.1 m•kg, 15 ft•lb) 97
- ADJUSTING THE TOE-IN 98
- EBS00111 100
- 42 Nm (4.2 m•kg, 31 ft•lb) 101
- CHECKING THE TIRES 102
- LUBRICATING THE CABLES 104
- EBS00118 105
- ELECTRICAL SYSTEM 106
- Charging time (hours) 107
- CAUTION: 108
- CHECKING THE FUSES 113
- CHECKING THE FUSES/ 114
- ADJUSTING THE HEADLIGHT BEAM 114
- REPLACING A HEADLIGHT BULB 115
- 34 Nm (3.4 m•kg, 25 ft•lb) 117
- 20 Nm (2.0 m•kg, 15 ft•lb) 117
- 8 Nm (0.8 m•kg, 5.9 ft•lb) 117
- 18 Nm (1.8 m•kg, 13 ft•lb) 117
- ENGINE REMOVAL 118
- 10 Nm (1.0 m•kg, 7.4 ft•lb) 119
- 40 Nm (4.0 m 122
- CYLINDER HEAD 123
- ROCKER ARM, CAMSHAFT 131
- VALVES AND VALVE SPRINGS 137
- 17 Nm (1.7 m•kg, 13 ft•lb) 147
- CYLINDER AND PISTON 148
- 73 Nm (7.3 m•kg, 54 ft•lb) 155
- 80 Nm (8.0 m•kg, 59 ft•lb) 156
- 75 Nm (7.5 m•kg, 55 ft•lb) 156
- Lock washer 162
- 6 Nm (0.6 m•kg, 4.4 ft•lb) 166
- 55 Nm (5.5 m•kg, 41 ft•lb) 166
- 7 Nm (0.7 m•kg, 5.0 ft•lb) 168
- Inner rotor 169
- Outer rotor 169
- Oil pump housing 169
- SHIFT SHAFT 174
- 20 Nm (2.0 m•kg, 14.8 ft•lb) 183
- CRANKCASE 184
- CRANKSHAFT ASSEMBLY 188
- TRANSMISSION 193
- 2 Nm (0.2 m•kg, 1.5 ft•lb) 199
- 3.5 Nm (0.4 m•kg, 2.6 ft•lb) 199
- 28 Nm (2.8 m•kg, 21 ft•lb) 206
- 70 Nm (7.0 m•kg, 52 ft•lb) 206
- 45 Nm (4.5 m•kg, 33 ft•lb) 206
- 120 Nm (12.0 m•kg, 89 ft•lb) 208
- FRONT AND REAR WHEELS 209
- 7 Nm (0.7 m•kg, 5.2 ft•lb) 213
- 140 Nm (14.0 m•kg, 103 ft•lb) 213
- REAR AXLE AND REAR AXLE HUB 215
- FRONT AND REAR BRAKES 220
- 5 Nm (0.5 m•kg, 3.7 ft•lb) 221
- 27 Nm (2.7 m•kg, 20 ft•lb) 224
- 31 Nm (3.1 m•kg, 23 ft•lb) 226
- 2.5 Nm (0.25 m•kg, 1.8 ft•lb) 235
- 15 Nm (1.5 m•kg, 11 ft•lb) 238
- 4 Nm (0.4 m•kg, 3.0 ft•lb) 247
- STEERING SYSTEM 249
- 23 Nm (2.3 m•kg, 17 ft•lb) 252
- 25 Nm (2.5 m•kg, 18 ft•lb) 252
- 35 Nm (3.5 m•kg, 26 ft•lb) 252
- ASSEMBLIES 256
- 100 Nm (10.0 m•kg, 74 ft•lb) 260
- 110 Nm (11.0 m•kg, 81 ft•lb) 260
- DRIVE CHAIN 262
- CHECKING SWITCH CONTINUITY 269
- CHECKING THE SWITCHES 270
- CHECKING THE BULBS AND 272
- BULB SOCKETS 272
- IGNITION SYSTEM 275
- ELECTRIC STARTING SYSTEM 280
- STARTER MOTOR 287
- CHARGING SYSTEM 291
- LIGHTING SYSTEM 294
- SIGNAL SYSTEM 298
- Br Sb BrSb 301
- POOR IDLE SPEED PERFORMANCE 304
- FAULTY GEAR SHIFTING 305
- CLUTCH SLIPPING/DRAGGING 305
- OVERHEATING 306
- FAULTY BRAKE 306
- SHOCK ABSORBER MALFUNCTION 306
- FAULTY BRAKE/ 306
- UNSTABLE HANDLING 307
- YAMAHA MOTOR CO., LTD 310
- YFM250RX WIRING DIAGRAM 311
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