WR250FR
Page
WR250FR
Introduction
Page
Always Wear Protective Apparel
Always Maintain Your Machine in Proper Working Order
Properly Secure the Machine Before Transporting IT
Gasoline can Cause Injury
Park the Machine Carefully Turn OFF the Engine
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
Right Crankcase Cover
SEAT, Fuel Tank
Valves and Valve Springs
AC Magneto
Electrical Components
Throttle Position Sensor
Description Info
Description
Engine Serial Number
Machine Identification
Vehicle Identification Number
Model Label
Preparation for Removal and Disassembly
Important Information
GASKETS, OIL Seals and O-RINGS
ALL Replacement Parts
Lock WASHERS/PLATES and Cotter Pins
Bearings and OIL Seals
Circlips
Checking of Connection
Special Tools
Part number Tool name/How to use Illustration
ACC-QUICK-GS-KT
Engine Stop Switch
Main Switch
Main switch indicator light
Start Switch
Kickstarter Crank
Clutch Lever
Shift Pedal
Throttle Grip
Cold Starter Knob
Rear Brake Pedal
Fuel Cock
HOT Starter Lever
Spark Plug Wrench
Light Switch
Valve Joint
Nipple Wrench
Fuel
Starting a Cold Engine
AIR Filter Maintenance
Starting and BREAK-IN
Do not warm up the engine for extended periods of time
Engine fails to start
Starting a Warm Engine
Restarting an engine after a fall
About one hour of break-in operation is necessary
BREAK-IN Procedures
Cylinder and Crankshaft
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
Torque
General Torque Specifications
Definition of Units
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
Engine
Coolant Replacement
Do not remove the radiator cap when the engine is hot
Coolant Level Inspection
Coolant Replacement
Fill Radiator Engine To specified level
Radiator CAP Inspection
Radiator CAP Opening Pressure Inspection
Cooling System Inspection
Clutch Adjustment
Radiator cap opening pressure KPa 1.1 kg/cm2, 15.6 psi
Standard pressure KPa 1.8 kg/cm2, 25.6 psi
Throttle Cable Adjustment
Throttle Cable Adjustment
Clutch lever free play adjustment steps
Throttle grip free play adjustment steps
Throttle Lubrication
HOT Starter Lever Adjustment
Hot starter lever free play adjustment steps
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
API Standard
Engine OIL Replacement
Engine OIL Replacement
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
40 mm
Pad range Pad Availability Increments 20 mm
Mm increments
Last digit of pad Rounded value
Example
Intake
Exhaust
Spark Arrester Cleaning For USA
Brake System AIR Bleeding
CHASSIS/BRAKE System AIR Bleeding
Chassis
Brake lever position adjustment steps
Front Brake Adjustment
Front Brake Adjustment
Rear Brake Adjustment
Front Brake PAD Inspection and Replacement
Bleed screw Nm 0.6 m kg, 4.3 ft lb
Front Brake PAD Inspection and Replacement
Do not reuse the drained brake fluid
Pad pin plug Nm 0.3 m kg, 2.2 ft lb
Rear Brake PAD Inspection and Replacement
Rear Brake PAD Inspection and Replacement
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
Drive Chain Inspection
Sprockets INSPECTION/DRIVE Chain Inspection
Sprockets Inspection
Drive chain length 10 links Limit 150.1 mm 5.91
Drive Chain Inspection
Drive chain slack adjustment steps
Drive Chain Slack Adjustment
Drive Chain Slack Adjustment
Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0
Locknut 16 Nm 1.6 m kg, 11 ft lb
Front Fork OIL Seal and Dust Seal Cleaning
Axle nut 125 Nm 12.5 m kg, 90 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
Rear Shock Absorber Inspection
Rear Shock Absorber Inspection
Standard position 14 clicks out Clicks out
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
Spokes Inspection and Tightening
Tire Pressure Check
Standard tire pressure KPa 1.0 kgf/cm2, 15 psi
Wheel Inspection
Steering ring nut adjustment steps
Steering Head Inspection and Adjustment
Steering Head Inspection Adjustment
Steering nut wrench YU-33975/90890-01403
Avoid over-tightening
Steering nut wrench
38 Nm 3.8 m kg, 27 ft lb
Lubrication
Lubrication
Spark plug gap ~ 0.8 mm 0.028 ~ 0.031
Electrical
Spark Plug Inspection
Ignition Timing Check
Ignition Timing Check
Keep Batteries and Electrolyte OUT of Reach of Children
Battery Inspection and Charging
Battery Inspection and Charging
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
First, connect the positive lead 1, then the negative lead
Battery REPLACEMENT/FUSE Inspection
Battery Replacement
Recommended lubricant Lithium soap base grease
Items Amperage rating ’ty
Fuse Inspection
Pocket tester YU-3112-C/90890-03112
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Adjusting steps
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
Radiator
Assembly and Installation Radiator
Handling Note
Install Right radiator Bolt right radiator
Carburetor
Carburetor Removal
Carburetor Disassembly
Carburetor Disassembly
ENG
Pilot screw
Carburetor
Jet needle
Needle valve
Throttle valve
Standard clip position No.4 Groove
Float
Float height Mm 0.31 Measurement and adjustment steps
Float height
Accelerator pump
Assembly and Installation Carburetor
Starter plunger
Air cut valve
ENG
ENG
Pilot screw Turns out example 8 turns out
ENG
Throttle valve height Mm 0.06
Accelerator pump timing adjustment Adjustment steps
Carburetor installation
Carburetor ENG
Carburetor ENG
Cylinder Head Cover Removal
Camshafts
Cylinder Head Cover
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
Decompression system
Assembly and Installation Camshaft
Installation steps
Timing chain tensioner
CA U TI O N
Tensioner cap bolt
Camshafts ENG
Bolt timing chain tensioner
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
Combination Cylinder head mark Valve lifter mark b Color
Assembly and Installation Valve and valve spring
Combination of cylinder head and valve lifter
Yellow
Valve spring compressor YM-4019/90890-04019
Cylinder and Piston
Cylinder and Piston Removal
Do not use a hammer to drive the piston pin out
Piston and piston ring
Piston pin puller set YU-1304/90890-01304
Cylinder and piston
2nd step
Cylinder bore C 77.00 ~ 77.01 mm 0315 ~ 3.0319
05 mm 0.002
Piston size P
Limit
Piston ring
Side clearance
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 holding tool YM-91042/90890-04086
Clutch housing and boss
Clutch boss
Primary driven gear
Warp limit Mm 0.004 Push lever shaft
Friction plate
Clutch plate
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 delivery pipe
Impeller shaft
Oil seal
Bearing
Assembly and Installation Oil seal
Impeller shaft gear
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
Segment
Kick shaft assembly
Shift guide and shift lever assembly
Kick shaft and ratchet wheel
Stopper lever
Assembly and Installation
Shift shaft
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
AC magneto
Rotor
Rotor puller YM-04141/90890-04141
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
Timing chain and timing chain guide
Crankshaft
Crankcase separating tool YU-1135-A/90890-01135
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
Front Wheel and Rear Wheel Chas
Front Wheel and Rear Wheel
Front Wheel Removal
Rear Wheel
Rear Wheel Removal
Wheel
Rear wheel
Wheel bearing if necessary
Do not attempt to straighten a bent axle
Wheel axle
Wheel axle bending limit 0.5 mm 0.020
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
Front Brake and Rear Brake Chas
Front Brake and Rear 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
Use only new brake fluid
Brake caliper piston seal kit
Brake master cylinder
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 Removal
Front Fork Chas
Front Fork
Front Fork Disassembly
Front Fork Disassembly
Front fork cap bolt
Oil seal removal steps
Inner tube
Take care not to scratch the inner tube
Damper rod
Fork spring free length 460 mm 18.1 in Limit 455 mm 17.9
Base valve
Fork spring
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 Removal
Handlebar Chas
Handlebar
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 Removal
Steering Chas
Steering
Steering Chas
Ball race
Steering ring nut
Take care not to damage the steering shaft thread
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 Removal
Swingarm Chas
Swingarm
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 Removal
Rear Shock Absorber Chas
Rear Shock Absorber
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
Color Code
Electrical Components and Wiring Diagram
Wiring Diagram
MAP-CONTROLLED CDI Unit
Function of Component
Ignition System
Inspection Steps
Spark GAP Test
Engine Stop Switch Inspection
Ignition System Elec +
COUPLERS, Leads and Ignition Coil Connection Inspection
Tester + lead → Red lead Tester lead → Brown lead
Main Switch Inspection
Battery + lead → Red/Black lead 1 Battery lead → Black lead
Resistance Position ~ 6.8 kΩ at
Ignition Coil Inspection
Resistance Position 08 ~ 0.10 Ω at 20 C 68 F
Resistance Position 248 ~ 372 Ω at 20 C 68 F
Neutral Switch Inspection
AC Magneto Inspection
Tester + lead → Sky blue lead 1 Tester lead → Ground
Electric Starting System
Starting Circuit CUT-OFF System Operation
Inspection Steps
Couplers and Leads Connection Inspection
Battery
To battery
Starter Motor Operation
Pull Free
Clutch Switch Inspection
Starter Relay Inspection
Diode Inspection
Start Switch Inspection
Electric Starting System Elec +
Starter Motor Disassem BLY
Starter Motor
Starter Motor Removal
Mica undercut 1.5 mm 0.06
Inspection and Repair
Min. commutator diameter 16.6 mm 0.65
Min. brush length Mm 0.14
Assembly
Be careful not to damage the brush during installation
New
Charging System
Voltage Position 14.1 ~ 14.9 V at DCV-20 000 r/min
Charging Voltage Inspection
Tester + lead → Red lead Tester lead → Black lead
Resistance Position 288 ~ 0.432 Ω at 20 C 68 F
Throttle Position Sensor System
~ 6 kΩ at
Throttle Position Sensor System Elec +
Throttle Position Sensor Coil Inspection
At 20 C 68 F
Throttle Position Sensor Replacement and Adjustment
Coil variable resistance
58 ~ 0.78
Tester + lead → Yellow lead Tester lead → Black lead
Throttle position Tester selector
DCV
Throttle Position Sensor Input Voltage Inspection
~ 6 DCV-20
Lighting System
RECTIFIER/REGULATOR Inspection
Light Switch Inspection
OFF
Setting
Carburetor setting
Settings
Pilot system
Effects of the setting parts on the throttle valve opening
Main system
Effects of changing the main jet reference
Main jet adjustment
Standard main jet #185 #172
Setting T U N
Effects of adjusting the pilot jet reference
Jet needle groove position adjustment
Obdvs Obelp
Jet needle adjustment
Standard jet needle
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
Sprocket
9383B-13218
5GS-25448-50
5NY-25448-00
Front fork setting
Change in level and characteristics of fork oil
Spring preload adjustment
Setting of spring after replacement
Mark
Part Number
Spring
Rate
Standard figure 90 ~ 100 mm 3.5 ~ 3.9
Rear suspension setting
Choosing set length
Setting of spring after replacement
Setting
Spring Free Extent
Rear shock absorber setting parts
Adjustment b
Suspension setting
One passenger is astride seat
Printed on Recycled Paper Shingai Iwata Shizuoka Japan