2001 YAMAHA WR 250F brake pads

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
c
Inspect wear
ROTOR NUT
Retighten
c

c

EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace
c

c

c

c
* Whichever comes first
*SPARK ARRESTER
Clean
(Every six
months)
c
CRANK
Inspect and clean
c

c

CARBURETOR
Inspect, adjust and clean
c

c
When using a high-pres-
sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace
c

c

c

DRIVE CHAIN
Lubricate, slack, alignment
Replace
c

c

c
Use chain lube
Chain slack: 40 ~ 50 mm
(1.6 ~ 2.0 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
c

c

c

c

c
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
c

c
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
c

c

c
Use foam air-filter oil
FRAME
Clean and inspect
c

c

FUEL TANK, COCK
Clean and inspect
c

c

BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
c

c

c

c

c

c

c

c

c

c

c

c
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
c

c

c

c

c
Suspension oil “01” ItemAfter
break-inEvery
race
Every
third race
or
500 km
(300 mi)Every
fifth race
or
1,000 km
(600 mi)
As re-
quiredRemarks


3

3 - 29
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
lLoosen the pad pin 2.
lRemove the brake hose holder 3 and
brake caliper 4 from the front fork.
lRemove the pad pin and brake pads 5.
lConnect the transparent hose 6 to the
bleed screw 7 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake pads 8 and pad pin.
NOTE:
lInstall the brake pads with their projec-
tions a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this
point.
lInstall the brake hose holder 9 and brake
caliper 0 and tighten the pad pin A.
NOTE:
Fit the brake hose holder cut c over the
projection d on the front fork and clamp the
brake hose.
T R..
Bolt (brake caliper):
23 Nm (2.3 m • kg, 17 ft • lb)
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)

3 - 31
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
lRemove the pad pin 6 and brake pads 7.
lConnect the transparent hose 8 to the
bleed screw 9 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake pad 0 and pad pin A.
NOTE:
lInstall the brake pads with their projec-
tions a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this
point.
lInstall the brake caliper B and rear wheel
C.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.
lTighten the pad pin D.
T R..
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)
lInstall the pad pin plug E and protector F.
T R..
Pad pin plug:
3 Nm (0.3 m • kg, 2.2 ft • lb)
Bolt (protector):
7 Nm (0.7 m • kg, 5.1 ft • lb)

5 - 6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
lWheel
NOTE:
lInstall the brake disc between the brake
pads correctly.
lMake sure that the projections a in the trip
meter gear unit fits over the stopper b on
the front fork outer tube.
6. Install:
lWheel axle 1
NOTE:
Apply the lithium soap base grease on the
wheel axle.
7. Install:
lNut (wheel axle) 1
T R..105 Nm (10.5 m · kg, 75 ft · lb)
8. Tighten:
lBolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork sev-
eral times with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)

5 - 9
CHASFRONT WHEEL AND REAR WHEEL
4. Install:
lCollar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5. Install:
lWheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
6. Install:
lDrive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
7. Install:
lLeft drive chain puller 1
lWheel axle 2
NOTE:
lInstall the left drive chain puller, and insert
the wheel axle from left side.
lApply the lithium soap base grease on the
wheel axle.
8. Install:
lRight drive chain puller 1
lWasher 2
lNut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.

5 - 18
CHAS
2. Install:
lPiston seal 1
lDust seal 2
WARNING
Always use new piston seals and dust
seals.
NOTE:
Fit the piston seals and dust seals onto the slot
on brake caliper correctly.
Front
õRear

õ
3. Install:
lBrake caliper piston 1
NOTE:
Apply the brake fluid on the piston wall.
CAUTION:
lFor the front brake caliper, install the pis-
ton with its depressed side a facing the
brake caliper. For the rear brake caliper,
install the piston with its shallow
depressed side b facing the caliper.
lNever force to insert.
Front
õRear
Front brake caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pads with their projections
a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this point.

õ
FRONT BRAKE AND REAR BRAKE

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lCopper washer 1
lUnion bolt 2
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake caliper.
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
lBrake hose holder 1
lBrake caliper 2
lBolt (brake caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
4. Tighten:
lPad pin 4
5. Install:
lPad pin plug 5
Rear brake caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pads with their projections
a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this point.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)