2001 YAMAHA WR 250F light

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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.

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AIR FILTER CLEANING
2. Adjust:
lDecompression lever free play
Adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 in or out until the
adjustment is suitable.
lTighten the locknut.
CAUTION:
After the adjustment, start the engine
and make sure that the engine does not
stop when the handlebar is turned fully
both ways. If the decompression cable is
too tense, the engine will stop by the
decompression system.
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
lSeat
2. Disconnect:
lTaillight lead connectors 1
3. Remove:
lAir filter case cover 2
4. Remove:
lFitting bolt 1
lWasher 2
lAir filter element 3
lAir filter guide 4

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10. Install:
lAir filter element 1
lWasher
lFitting bolt
NOTE:
Align the projection a on filter guide with the
hole b in air filter case.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
lOil tank cap 1
4. Inspect:
lOil level
Oil level should be between maximum
a and minimum b marks.
Oil level is low ® Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
oil tank cap into the oil tank. Insert the gauge
lightly.
ENGINE OIL LEVEL INSPECTION

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OIL PRESSURE INSPECTION
1. Check:
lOil pressure
Checking steps:
lSlightly loosen the oil pressure check bolt
1.
lStart the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt. If no oil comes out after one minute,
turn the engine off so it will not seize.
lCheck oil passages and oil pump for dam-
age or leakage.
lStart the engine after solving the prob-
lem(s) and recheck the oil pressure.
lTighten the oil pressure check bolt.
T R..
Oil pressure check bolt:
10 Nm (1.0 m • kg, 7.2 ft • lb)
PILOT SCREW ADJUSTMENT
1. Adjust:
lPilot screw 1
Adjustment steps:
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num-
ber as the factory-set number of turns out.
lTurn in the pilot screw until it is lightly
seated.
lTurn out the pilot screw by the factory-set
number of turns.
Pilot screw:
1-3/4 turns out (example)
OIL PRESSURE INSPECTION/
PILOT SCREW ADJUSTMENT

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SPARK ARRESTER CLEANING (For USA)
WARNING
lBe sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
lDo not start the engine when cleaning the
exhaust system.
1. Remove:
lBolt (spark arrester) 1 1
1
2. Remove:
lSpark arrester 1
Pull the spark arrester out of the muf-
fler.
1
3. Clean:
lSpark arrester
Tap the spark arrester lightly, then use
a wire brush to remove any carbon
deposits.
4. Install:
lSpark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
lBolt (spark arrester)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
SPARK ARRESTER CLEANING (For USA)

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STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
lBearing free play
Exist play ® Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
lSteering shaft
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play ® Adjust steering head.
3. Check:
lSteering smooth action
Turn the handlebar lock to lock.
Unsmooth action ® Adjust steering ring
nut.
4. Adjust:
lSteering ring nut
Steering ring nut adjustment steps:
lRemove the headlight.
lRemove the handlebar and upper bracket.
lLoosen the steering ring nut 1 using the
steering nut wrench 2.
Steering nut wrench:
YU-33975/90890-01403

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STEERING HEAD INSPECTION AND ADJUSTMENT
lTighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tighten-
ing):
38 Nm (3.8 m • kg, 27 ft • lb)
lLoosen the steering ring nut one turn.
lRetighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tighten-
ing):
7 Nm (0.7 m • kg, 5.1 ft • lb)
lCheck the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
lInstall the upper bracket 5, steering stem
nut 6, handlebar 7, handlebar holder 8
and headlight 9.
NOTE:
lThe upper handlebar holder should be
installed with the punched mark a for-
ward.
lInsert the end of fuel breather hose 0 into
the hole of the steering stem.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar upper holder:
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (handle crown):
23 Nm (2.3 m • kg, 17 ft • lb)
Headlight:
7 Nm (0.7 m • kg, 5.1 ft • lb)

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LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Decompression cable endUse Yamaha cable lube or equivalent on these
areas.
õUse SAE 10W-30 motor oil or suitable chain
lubricants.
‚Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC