2001 YAMAHA WR 250F clutch

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 7 Nm (0.7 m • kg, 5.1 ft • lb).Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 ´ 1.25 4 23 2.3 17
Lower bracket and outer tube M8 ´ 1.25 4 20 2.0 14
Upper bracket and steering stem M24 ´ 1.0 1 145 14.5 105
Handlebar holder and upper bracket M8 ´ 1.25 4 28 2.8 20
Steering stem and steering ring nut M28 ´ 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M48 ´ 1.0 2 30 3.0 22
Front fork and base valve M30 ´ 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 ´ 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 ´ 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 ´ 1.0 6 10 1.0 7.2
Meter cable holder and front fork protector M5 ´ 0.8 2 4 0.4 2.9
Front fork and brake hose guide M5 ´ 0.8 2 4 0.4 2.9
Front fork and brake hose holder M6 ´ 1.0 2 10 1.0 7.2
Front fork and brake hose cover (M8) M8 ´ 1.25 1 16 1.6 11
(M6) M6 ´ 1.0 1 7 0.7 5.1
Throttle grip cap M5 ´ 0.8 2 4 0.4 2.9
Front brake master cylinder M6 ´ 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 ´ 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 ´ 1.0 1 6 0.6 4.3
Brake lever position locknut M6 ´ 1.0 1 5 0.5 3.6
Front brake hose guide M5 ´ 0.8 2 4 0.4 2.9
Clutch lever holder M5 ´ 0.8 2 4 0.4 2.9
Clutch lever mounting bolt M6 ´ 1.0 1 2 0.2 1.4
Decompression lever holder M5 ´ 0.8 2 4 0.4 2.9
Light switch M4 ´ 0.7 2 2 0.2 1.4
Front brake master cylinder cap M4 ´ 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 ´ 1.25 2 30 3.0 22
Front brake caliper M8 ´ 1.25 2 23 2.3 17
Pad pin plug M10 ´ 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 ´ 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 ´ 1.5 1 105 10.5 75
Front wheel axle holder M8 ´ 1.25 4 23 2.3 17
Front brake disc M6 ´ 1.0 6 12 1.2 8.7

2 - 19
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Hose guide
2
Brake hose
3
Voltage regulator
4
Light switch lead
5
Fuel tank breather hose
6
Clamp
7
Oil tank breather hose
8
Engine stop switch lead
9
Sub-wire harness
0
Taillight lead
A
Throttle position sensor lead
B
Neutral switch lead
C
Oil hose
D
Cylinder head breather hose
E
CDI magneto lead
F
Clutch cable
G
Cable guide
H
Carburetor breather hose
I
Carburetor overflow hose
J
Coolant reservoir breather hose
K
Decompression cable
L
CDI unit lead
M
Ignition coil lead
N
Voltage regulator lead

Pass the fuel tank breather hose
behind handlebar, then insert it
into the steering stem hole.
õ
Pass the decompression cable,
engine stop switch lead and light
switch lead under where the oil
hose is attached.
‚
Pass the voltage regulator lead,
engine stop switch lead and light
switch lead over the radiator
hose.
ë
Fasten the engine stop switch
lead and ignition coil lead of the
sub-wire harness.
ä
Fasten the sub-wire harness
and engine stop switch lead.
ì
Pass the cylinder head breather
hose along the right side of the
oil tank breather hose.
í
Fasten the sub-wire harness
and engine stop switch lead in
front of the upper engine brack-
ets.
î
Fasten the sub-wire harness.
é
Pass the sub-wire harness
between the upper engine
brackets.
ï
Fasten the sub-wire harness.
ð
Fasten the throttle position sen-
sor lead.

2 - 20
SPEC

CABLE ROUTING DIAGRAM
ñ
Pass the carburetor breather
hose and overflow hose
between the connecting rod
and cross tube (frame).
÷
Pass the cylinder head
breather hose through the hose
guide.
ö
Pass the clutch cable through
the cable guide.
¯
Fasten the neutral switch lead
and CDI magneto lead.
¸
Pass the clutch cable along the
inner side of the cylinder head
breather hose.
Î
Pass the cylinder head
breather hose along the inner
side of the radiator hose.
å
Pass the clutch cable in front of
the radiator mounting boss.
ê
Fit the brake hose into the
guides on the protector.
æ
Fasten the ground lead
together with the ignition coil
lead.
è
Do not allow the engine stop
switch leads and light switch
lead to slacken between the
two clamps.
×
Pass the decompression cable
along the right side of the cylin-
der head breather hose.
ã
Pass the clutch cable through
the cable guides.
ô
Pass the carburetor breather
hoses and overflow hose so
that all there hoses do not con-
tact the rear shock absorber.
ç
Position each lead at the lower
left of the main tube (frame).

2 - 24
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Light switch
3Light switch lead
4Clamp
5Decompression cable
6Clutch cable
7Hose guide
8Trip meter
9Brake hose
0Engine stop switch leadFasten the engine stop switch lead to the handlebar with the plastic
band.
õPass the decompression cable between the brake hose and clutch
cable.
‚Pass the throttle cables between the upper bracket and trip meter.
ëPass the light switch leads behind the engine stop switch lead, then
pass the headlight lead (of the light switch leads) in front of the head
pipe.
äInstall the trip meter cable so that its bent portion faces the chassis
rear.
ìInstall the brake hose so that it contacts the master cylinder projec-
tion and that its bent portion faces downward.

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third race
or
500 km
(300 mi)Every
fifth race
or
1,000 km
(600 mi)
As re-
quiredRemarks
ENGINE OIL
Replace
Inspect
c

cc

c
OIL FILTER ELEMENT, OIL STRAINER
Clean
c

VALVES
Check the valve clearances.
Inspect
Replace
c

c

c

c
The engine must be cold.
Check the valve seats
and valve stems for wear.
VALVE SPRINGS
Inspect
Replace
c

c
Check the free length and
the tilt.
VALVE LIFTERS
Inspect
Replace
c

c
Check for scratches and
wear.
CAMSHAFTS
Inspect
Replace
c

c
Inspect the camshaft sur-
face.
TIMING CHAIN SPROCKETS, TIMING
CHAIN
Inspect
Replace
c

c
Check for wear on the
teeth and for damage.
PISTON
Inspect
Clean
Replace
c

c

c

c
Inspect crack
Remove carbon
PISTON RING
Inspect
Replace
c

c

c
Check ring end gap
PISTON PIN
Inspect
Replace
c

c

CYLINDER HEAD
Inspect and clean
c
Remove carbon
Change gasket
CYLINDER
Inspect and clean
Replace
c

c
Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
c

c

c
Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Inspect
Replace bearing
c

c



3

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check that the coolant level is correct in the coolant reservoir.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-26 ~ 32
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-33 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 45
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 22

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
lDo not apply pressure more than specified
pressure.
lRadiator should be filled fully.
4. Inspect:
lPressure
Impossible to maintain the specified
pressure for 10 seconds ® Repair.
lRadiator 1
lRadiator hose joint 2
Coolant leakage ® Repair or replace.
lRadiator hose 3
Swelling ® Replace.
CLUTCH ADJUSTMENT
1. Check:
lClutch lever free play a
Out of specification ® Adjust.
Clutch lever free play a:
2 ~ 4 mm (0.08 ~ 0.16 in)
2. Adjust:
lClutch lever free play
NOTE:
lMake minute adjustment on the lever side
using the adjuster 2.
lAfter adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
lLoosen the locknuts 1.
lAdjust the free play by changing their
tightening position.
lTighten the locknuts.

3 - 15
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
(For USA and CDN)
CAUTION:
lDo not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
lDo not allow foreign material to enter the
crankcase.
Recommended oil:
At 5 ˚C (40 ˚F) or higher
Yamalube 4 (20W-40) or
SAE 20W-40 type SH motor oil
(Non-Friction modified)
At 15 ˚C (60 ˚F) or lower õ
Yamalube 4 (10W-30) or
SAE 10W-30 type SH motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
(Except for USA and CDN)
CAUTION:
lDo not add any chemical additives or use
oils with a grade of CD a or higher.
lDo not use oils labeled “ENERGY CON-
SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
lDo not allow foreign materials to enter the
crankcase.
5. Install:
lOil tank cap
6. Start the engine and let it warm up for
several minutes.
7. Turn off the engine and inspect the oil
level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SH” or higher grade
(Designed primarily for motor-
cycles)
-20
-4-10
140
3010
5020
6830
8640 50
104
122¡CTemp.
¡F
10W-30
10W-40
20W-40
20W-50
15W-40
a
b