WR250FR
Page
WR250FR
Introduction
Page
Always Wear Protective Apparel
Always Maintain Your Machine in Proper Working Order
Park the Machine Carefully Turn OFF the Engine
Gasoline can Cause Injury
Properly Secure the Machine Before Transporting IT
M. Machine Weights
Weights of machines without fuel
Particularly Important Information
Finding the Required
HOW to Read Descriptions
Manual Format
GEN Spec Info Insp ENG ADJ
Memo
Index
Chapter Regular Inspection Adjustments
SEAT, Fuel Tank
Valves and Valve Springs
Right Crankcase Cover
AC Magneto
Electrical Components
Throttle Position Sensor
Description Info
Description
Machine Identification
Vehicle Identification Number
Engine Serial Number
Model Label
Preparation for Removal and Disassembly
Important Information
ALL Replacement Parts
Lock WASHERS/PLATES and Cotter Pins
GASKETS, OIL Seals and O-RINGS
Bearings and OIL Seals
Circlips
Checking of Connection
Special Tools
Part number Tool name/How to use Illustration
ACC-QUICK-GS-KT
Main Switch
Main switch indicator light
Engine Stop Switch
Start Switch
Clutch Lever
Shift Pedal
Kickstarter Crank
Throttle Grip
Rear Brake Pedal
Fuel Cock
Cold Starter Knob
HOT Starter Lever
Light Switch
Valve Joint
Spark Plug Wrench
Nipple Wrench
Fuel
Starting and BREAK-IN
AIR Filter Maintenance
Starting a Cold Engine
Do not warm up the engine for extended periods of time
Restarting an engine after a fall
Starting a Warm Engine
Engine fails to start
BREAK-IN Procedures
Cylinder and Crankshaft
About one hour of break-in operation is necessary
PISTON, RING, VALVES, Camshafts and Gears
TORQUE-CHECK Points
Cleaning and Storage
Cleaning
Storage
General Specifications
5UM4 CDN, AUS, NZ, ZA
FCR-MX37
CDI
Maintenance Specifications
Engine
Head diameter Face width Seat width Margin thickness
1.6 mm
Spec
USA EUROPE, CDN ZA, AUS, NZ
Spec
Part to be tightened Thread size ’ty Tightening torque
Silencer
Chassis
USA, CDN Europe AUS, NZ, ZA
USA, CDN, ZA EUROPE, AUS, NZ
Upper bracket and outer tube
Nipple spoke Rear wheel sprocket
M4 ⋅
Electrical
5UL-00/DENSO
ACM33221 M06/MATSUSHITA
General Torque Specifications
Definition of Units
Torque
Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130
Cable Routing Diagram
Spec
Spec
Spec
Spec
Spec
Spec
Spec
Spec
Maintenance Intervals
Insp ADJ
Maintenance Intervals ADJ
Cooling System
Marked For USA
PRE-OPERATION Inspection and Maintenance
General Inspection and Maintenance
Coolant Replacement
Do not remove the radiator cap when the engine is hot
Engine
Coolant Level Inspection
Coolant Replacement
Fill Radiator Engine To specified level
Radiator CAP Inspection
Radiator CAP Opening Pressure Inspection
Clutch Adjustment
Radiator cap opening pressure KPa 1.1 kg/cm2, 15.6 psi
Cooling System Inspection
Standard pressure KPa 1.8 kg/cm2, 25.6 psi
Throttle Cable Adjustment
Clutch lever free play adjustment steps
Throttle Cable Adjustment
Throttle grip free play adjustment steps
HOT Starter Lever Adjustment
Hot starter lever free play adjustment steps
Throttle Lubrication
Hot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24
AIR Filter Cleaning
AIR Filter Cleaning
Insp ADJ
Engine OIL Level Inspection
Engine OIL Level Inspection
Engine OIL Replacement
Engine OIL Replacement
API Standard
Replacement steps
Oil filter element cover 10 Nm 1.0 m kg, 7.2 ft lb
Install Copper washer 1 New Oil strainer frame
Pilot Screw Adjustment
OIL Pressure Inspection
Engine Idling Speed Adjustment
Valve Clearance Inspection and Adjustment
Valve Clearance Inspection and Adjustment
Mm increments
Pad range Pad Availability Increments 20 mm
40 mm
Last digit of pad Rounded value
Example
Intake
Exhaust
Spark Arrester Cleaning For USA
Chassis
CHASSIS/BRAKE System AIR Bleeding
Brake System AIR Bleeding
Front Brake Adjustment
Front Brake Adjustment
Brake lever position adjustment steps
Rear Brake Adjustment
Front Brake PAD Inspection and Replacement
Do not reuse the drained brake fluid
Front Brake PAD Inspection and Replacement
Bleed screw Nm 0.6 m kg, 4.3 ft lb
Rear Brake PAD Inspection and Replacement
Rear Brake PAD Inspection and Replacement
Pad pin plug Nm 0.3 m kg, 2.2 ft lb
Brake pad thickness Mm 0.25 in Limit 1.0 mm 0.04
Pad pin 18 Nm 1.8 m kg, 13 ft lb
Rear Brake PAD Insulator Inspection
Brake Fluid Level Inspection
Sprockets INSPECTION/DRIVE Chain Inspection
Sprockets Inspection
Drive Chain Inspection
Drive chain length 10 links Limit 150.1 mm 5.91
Drive Chain Inspection
Drive Chain Slack Adjustment
Drive Chain Slack Adjustment
Drive chain slack adjustment steps
Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0
Front Fork OIL Seal and Dust Seal Cleaning
Axle nut 125 Nm 12.5 m kg, 90 ft lb
Locknut 16 Nm 1.6 m kg, 11 ft lb
Front Fork Inspection
Front Fork Rebound Damping Force Adjustment
Front Fork Internal Pressure Relieving
Front Fork Compression Damping Force Adjustment
Standard position 9 clicks out Clicks out
Standard position 14 clicks out Clicks out
Rear Shock Absorber Inspection
Rear Shock Absorber Inspection
Rear Shock Absorber Spring Preload Adjustment
Standard position About 7 clicks out About 10 clicks out
Rear Shock Absorber LOW Compression Damping Force Adjustment
Standard position About 9 clicks out About 10 clicks out
Standard position About 1-1/4 turns out
Tire Pressure Check
Standard tire pressure KPa 1.0 kgf/cm2, 15 psi
Spokes Inspection and Tightening
Wheel Inspection
Steering Head Inspection and Adjustment
Steering Head Inspection Adjustment
Steering ring nut adjustment steps
Steering nut wrench YU-33975/90890-01403
38 Nm 3.8 m kg, 27 ft lb
Steering nut wrench
Avoid over-tightening
Lubrication
Lubrication
Electrical
Spark Plug Inspection
Spark plug gap ~ 0.8 mm 0.028 ~ 0.031
Ignition Timing Check
Ignition Timing Check
Battery Inspection and Charging
Battery Inspection and Charging
Keep Batteries and Electrolyte OUT of Reach of Children
First AID in Case of Bodily Contact External
Remove Battery band
Measurement steps
Example
Charge Battery
Charging method using a variable voltage charger
Charging method using a constant voltage charger
Battery REPLACEMENT/FUSE Inspection
Battery Replacement
First, connect the positive lead 1, then the negative lead
Recommended lubricant Lithium soap base grease
Pocket tester YU-3112-C/90890-03112
Fuse Inspection
Items Amperage rating ’ty
Adjusting steps
Adjusting the Headlight Beams
Replacing the Headlight Bulbs
SEAT, Fuel Tank and Side Covers
SEAT, Fuel Tank and Side Covers Removal
Removal Points
Side cover
Exhaust Pipe and Silencer
Exhaust Pipe Silencer Removal
Assembly and Installation Silencer and exhaust pipe
Silencer and exhaust pipe
Radiator
Radiator Removal
Handling Note
Assembly and Installation Radiator
Radiator
Install Right radiator Bolt right radiator
Carburetor
Carburetor Removal
Carburetor Disassembly
Carburetor Disassembly
ENG
Pilot screw
Carburetor
Needle valve
Throttle valve
Jet needle
Standard clip position No.4 Groove
Float height
Float height Mm 0.31 Measurement and adjustment steps
Float
Assembly and Installation Carburetor
Starter plunger
Accelerator pump
Air cut valve
ENG
ENG
Pilot screw Turns out example 8 turns out
ENG
Carburetor installation
Accelerator pump timing adjustment Adjustment steps
Throttle valve height Mm 0.06
Carburetor ENG
Carburetor ENG
Cylinder Head Cover
Camshafts
Cylinder Head Cover Removal
Camshafts
Camshafts Removal
Camshaft
Runout camshaft Less than 0.03 mm 0.0012
Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb
Assembly and Installation Camshaft
Installation steps
Decompression system
Timing chain tensioner
CA U TI O N
Bolt timing chain tensioner
Camshafts ENG
Tensioner cap bolt
Quick gasket ACC-QUICK-GS-KT Yamaha Bond No
Cylinder Head
Cylinder Head Removal
Cylinder head
Assembly and Installation Cylinder head
Valves and Valve Springs
Valves and Valve Springs Removal
Valve lifter and valve cotter
Valve spring compressor YM-4019/90890-04019
Valve
Margin thickness Intake Mm 0.0315 in Exhaust Mm 0.0276
Runout limit 01 mm 0.0004
Lapping steps
Valve spring
Assembly and Installation Valve and valve spring
Combination of cylinder head and valve lifter
Combination Cylinder head mark Valve lifter mark b Color
Yellow
Valve spring compressor YM-4019/90890-04019
Cylinder and Piston
Cylinder and Piston Removal
Piston and piston ring
Piston pin puller set YU-1304/90890-01304
Do not use a hammer to drive the piston pin out
Cylinder and piston
Cylinder bore C 77.00 ~ 77.01 mm 0315 ~ 3.0319
05 mm 0.002
2nd step
Piston size P
Piston ring
Side clearance
Limit
End gap
Piston pin
Inside diameter piston 16.002 ~ 16.013 mm 0.6300 ~ 0.6304
Cylinder
Install Bolt cylinder
Clutch
Clutch Removal
ENG
Clutch housing and boss
Clutch boss
Clutch holding tool YM-91042/90890-04086
Primary driven gear
Friction plate
Clutch plate
Warp limit Mm 0.004 Push lever shaft
Push rod
Assembly and Installation Push lever shaft
Clutch
ENG
Install Push rod 2 Ball Push rod 1
OIL Filter ELEMENT, Water Pump and Right Crankcase Cover
ENG
Oil seal
Impeller shaft
Oil delivery pipe
Impeller shaft gear
Assembly and Installation Oil seal
Bearing
Right crankcase cover
Kickstarter crank
Water pump housing
Oil filter element
Balancer
Balancer Removal
Balancer shaft drive gear and balancer shaft driven gear
Balancer shaft
Primary drive gear Nut primary drive gear
OIL Pump Removal and DIS Assembly
OIL Pump
ENG
Oil pump
Assembly and Installation Oil pump
Bolt oil pump assembly L = 30 mm 1.18
Kick Shaft and Shift Shaft
Kick Shaft and Shift Shaft Removal
ENG
Kick shaft assembly
Shift guide and shift lever assembly
Segment
Kick shaft and ratchet wheel
Shift shaft
Assembly and Installation
Stopper lever
Install Torsion spring Stopper lever Bolt stopper lever
Kick shaft assembly
Kick idle gear
AC Magneto and Starter Clutch
AC Magneto and Stator Removal
ENG
Rotor
Rotor puller YM-04141/90890-04141
AC magneto
Woodruff key
Assembly and Installation AC magneto and starter clutch
Install Holder Bolt
Plain washer rotor Nut rotor
Bolt engine guard rear
Engine Removal
Engine Removal
ENG
Drive sprocket
Engine removal
Assembly and Installation Engine installation
Brake pedal
Oil hose and neutral switch
Nm 0.4 m · kg, 2.9 ft · lb
Crankcase and Crankshaft
Crankcase and Crank Shaft Removal
ENG
Crankcase Bearing
Crankcase Bearing Removal
Crankcase
Separation steps
Crankcase separating tool YU-1135-A/90890-01135
Crankshaft
Timing chain and timing chain guide
Dial gauge and stand YU-3097/90890-01252 Standard Limit
Assembly and Installation Crankcase bearing
Do not use a hammer to drive in the crank- shaft
Apply Sealant On the right crankcase
Tighten Hose guide Clutch cable holder Bolt crankcase
TRANSMISSION, Shift CAM and Shift Fork
TRANSMISSION, Shift CAM Shift Fork Removal
Transmission
Gears
Assembly and Installation Transmission
Shift fork, shift cam and segment
ENG
ENG
Front Wheel and Rear Wheel Chas
Front Wheel and Rear Wheel
Front Wheel
Front Wheel Removal
Rear Wheel
Rear Wheel Removal
Wheel bearing if necessary
Rear wheel
Wheel
Wheel axle
Wheel axle bending limit 0.5 mm 0.020
Do not attempt to straighten a bent axle
Brake disc
Front wheel
105 Nm 10.5 m · kg, 75 ft · lb
Tighten Bolt axle holder
Install Trip meter cable
50 Nm 5.0 m · kg, 36 ft · lb
125 Nm 12.5 m · kg, 90 ft · lb
Front Brake and Rear Brake Chas
Front Brake and Rear Brake
Front Brake
Front Brake Removal
Rear Brake
Rear Brake Removal
Brake Caliper Disassembly
Brake Caliper Disassem BLY
Brake Master Cylinder Disassembly
Brake Master Cylinder Disassembly
Brake fluid
Brake master cylinder
Brake caliper piston seal kit
Use only new brake fluid
Brake caliper
Brake hose
Always use new piston seals and dust seals
Front brake caliper
Rear brake caliper
Brake master cylinder kit
Front brake master cylinder
Rear brake master cylinder
Front brake hose
CAU TI on
Always use new copper washers
CAU T ION
Install rear brake only Protector Bolt protector
Front Fork
Front Fork Chas
Front Fork Removal
Front Fork Disassembly
Front Fork Disassembly
Front fork cap bolt
Inner tube
Take care not to scratch the inner tube
Oil seal removal steps
Damper rod
Base valve
Fork spring
Fork spring free length 460 mm 18.1 in Limit 455 mm 17.9
Inner tube bending limit 0.2 mm 0.008
Assembly and Installation Front fork assembly
Front Fork Chas
Fork seal driver YM-01442/90890-01442
Front Fork Chas
Front Fork Chas
Front Fork Chas
Installation
Front fork top end standard a 5 mm 0.20 10 mm 0.39
Tighten Pinch bolt upper bracket
Handlebar
Handlebar Chas
Handlebar Removal
Grip
Handlebar
Assembly and Installation Handlebar
Install Grip cap cover Cover throttle cable cap
Hot starter lever holder Bolt hot starter lever holder
Handlebar Chas
Steering
Steering Chas
Steering Removal
Steering Chas
Steering ring nut
Take care not to damage the steering shaft thread
Ball race
Steering stem
Bearing and ball race
Lower bracket
Install Washer Steering ring nut
Install Washer Steering stem nut
Install Trip meter Bolt trip meter
Swingarm
Swingarm Chas
Swingarm Removal
Swingarm Disassembly
Swingarm Disassembly
Swingarm
Relay arm
Connecting rod
Bearing and oil seal
Installed depth of bearings a 5 mm 0.20
Installed depth of bearings a 5 mm 0.20 Swingarm
80 Nm 8.0 m · kg, 58 ft · lb
Tighten Nut relay arm
Bolt drive chain support cover = 10 mm 0.39
Rear Shock Absorber
Rear Shock Absorber Chas
Rear Shock Absorber Removal
Starting circuit cut-off relay coupler
Handling Note
Rear shock absorber
Install Spring Upper spring guide Lower spring guide
Tighten Adjuster Spring length installed a
Bolt rear frame lower
Rear Shock Absorber Chas
Wiring Diagram
Electrical Components and Wiring Diagram
Color Code
MAP-CONTROLLED CDI Unit
Function of Component
Ignition System
Inspection Steps
Engine Stop Switch Inspection
Ignition System Elec +
Spark GAP Test
COUPLERS, Leads and Ignition Coil Connection Inspection
Battery + lead → Red/Black lead 1 Battery lead → Black lead
Main Switch Inspection
Tester + lead → Red lead Tester lead → Brown lead
Resistance Position 08 ~ 0.10 Ω at 20 C 68 F
Ignition Coil Inspection
Resistance Position ~ 6.8 kΩ at
Neutral Switch Inspection
AC Magneto Inspection
Resistance Position 248 ~ 372 Ω at 20 C 68 F
Tester + lead → Sky blue lead 1 Tester lead → Ground
Electric Starting System
Starting Circuit CUT-OFF System Operation
Inspection Steps
Battery
To battery
Couplers and Leads Connection Inspection
Starter Motor Operation
Starter Relay Inspection
Clutch Switch Inspection
Pull Free
Electric Starting System Elec +
Start Switch Inspection
Diode Inspection
Starter Motor Removal
Starter Motor
Starter Motor Disassem BLY
Min. commutator diameter 16.6 mm 0.65
Inspection and Repair
Mica undercut 1.5 mm 0.06
Be careful not to damage the brush during installation
Assembly
Min. brush length Mm 0.14
New
Charging System
Charging Voltage Inspection
Tester + lead → Red lead Tester lead → Black lead
Voltage Position 14.1 ~ 14.9 V at DCV-20 000 r/min
Resistance Position 288 ~ 0.432 Ω at 20 C 68 F
Throttle Position Sensor System
Throttle Position Sensor Coil Inspection
Throttle Position Sensor System Elec +
~ 6 kΩ at
Coil variable resistance
Throttle Position Sensor Replacement and Adjustment
At 20 C 68 F
Tester + lead → Yellow lead Tester lead → Black lead
Throttle position Tester selector
58 ~ 0.78
DCV
Throttle Position Sensor Input Voltage Inspection
~ 6 DCV-20
Lighting System
OFF
Light Switch Inspection
RECTIFIER/REGULATOR Inspection
Setting
Carburetor setting
Settings
Main system
Effects of the setting parts on the throttle valve opening
Pilot system
Standard main jet #185 #172
Main jet adjustment
Effects of changing the main jet reference
Setting T U N
Effects of adjusting the pilot jet reference
Jet needle groove position adjustment
Jet needle adjustment
Standard jet needle
Obdvs Obelp
Effects of changing the jet needle reference
Leak jet adjustment accelerator pump adjustment
Standard leak jet #90 Relationship with throttle opening
STD
Examples of carburetor setting depending on symptom
Selection of the secondary reduction ratio Sprocket
Standard secondary reduction ratio 52/13
9383B-13218
5GS-25448-50
Sprocket
5NY-25448-00
Front fork setting
Change in level and characteristics of fork oil
Spring preload adjustment
Setting of spring after replacement
Part Number
Spring
Mark
Rate
Choosing set length
Rear suspension setting
Standard figure 90 ~ 100 mm 3.5 ~ 3.9
Setting of spring after replacement
Setting
Adjustment b
Rear shock absorber setting parts
Spring Free Extent
Suspension setting
One passenger is astride seat
Printed on Recycled Paper Shingai Iwata Shizuoka Japan