2001 YAMAHA WR 250F relay

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear brake disc M6 ´ 1.0 6 14 1.4 10
Brake pedal M8 ´ 1.25 1 26 2.6 19
Rear brake master cylinder M6 ´ 1.0 2 10 1.0 7.2
Rear brake reservoir tank M6 ´ 1.0 1 10 1.0 7.2
Rear brake reservoir tank cap M4 ´ 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 ´ 1.25 2 30 3.0 2.2
Rear wheel axle and axle nut M20 ´ 1.5 1 125 12.5 90
Nipple (spoke) — 72 3 0.3 2.2
Rear wheel sprocket M8 ´ 1.25 6 42 4.2 30
Rear brake disc cover M6 ´ 1.0 2 7 0.7 5.1
Rear brake caliper protector M6 ´ 1.0 2 7 0.7 5.1
Engine mounting:
Engine and engine bracket (front) M10 ´ 1.25 1 69 6.9 50
Engine and frame (lower) M10 ´ 1.25 1 69 6.9 50
Engine bracket and frame M8 ´ 1.25 6 34 3.4 24
Engine and engine bracket (upper) M10 ´ 1.25 1 55 5.5 40
Lower engine guard M6 ´ 1.0 3 10 1.0 7.2
Left engine guard M8 ´ 1.25 2 23 2.3 17
Right engine guard M8 ´ 1.25 2 10 1.0 7.2
Pivot shaft and nut M16 ´ 1.5 1 85 8.5 61
Relay arm and swingarm M14 ´ 1.5 1 80 8.0 58
Relay arm and connecting rod M14 ´ 1.5 1 80 8.0 58
Connecting rod and frame M14 ´ 1.5 1 80 8.0 58
Rear shock absorber and frame M10 ´ 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 ´ 1.25 1 53 5.3 38
Rear frame M8 ´ 1.25 3 29 2.9 21
Swingarm and brake hose holder M5 ´ — 4 4 0.4 2.9
Drive chain tensioner M8 ´ 1.25 2 19 1.9 13
Drive chain case M6 ´ 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 ´ 0.8 4 6 0.6 4.3
Fuel tank M6 ´ 1.0 2 10 1.0 7.2
Fuel cock M6 ´ 1.0 2 7 0.7 5.1
Seat set bracket and fuel tank M6 ´ 1.0 1 7 0.7 5.1
Hooking screw (fitting band) and fuel tank M6 ´ 1.0 1 7 0.7 5.1
Radiator cover M6 ´ 1.0 6 4 0.4 2.9
Front fender M6 ´ 1.0 4 7 0.7 5.1
Rear fender M6 ´ 1.0 4 7 0.7 5.1
Side cover M6 ´ 1.0 2 7 0.7 5.1
Seat M8 ´ 1.25 2 23 2.3 17

3 - 3
INSP
ADJ

MAINTENANCE INTERVALS
* marked : For USAFRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
c

c
Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
c

c

c

c

c c Molybdenum disulfide
grease
CHAIN GUARD AND ROLLERS
Inspect
c c
SWINGARM
Inspect and retighten
c c
RELAY ARM, CONNECTING ROD
Inspect and lube
c c Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
c c
c
c Lithium base grease
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate
c
c
c
c
c
c
c
Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Lubricate
c
c
c
c Yamaha cable lube or
SAE 10W-30 motor oil ItemAfter
break-inEvery
race
Every
third race
or
500 km
(300 mi)Every
fifth race
or
1,000 km
(600 mi)
As re-
quiredRemarks

5 - 53
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear brake caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Drive chain case 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

5 - 54
CHASSWINGARM
EC578000
SWINGARM DISASSEMBLY
Extent of removal:1 Swingarm disassembly2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Cap 2
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bushing 2
8 Oil seal 8
9 Bearing 8 Refer to “REMOVAL POINTS”.
1
2
32
3

5 - 55
CHASSWINGARM
EC573000
REMOVAL POINTS
EC573200
Bearing
1. Remove:
lBearing 1
NOTE:
Install the bearing by pressing its outer race.
INSPECTION
Wash the bearings, bushings, collars, and cov-
ers in a solvent.
Swingarm
1. Inspect:
lBearing 1
lBushing 2
Free play exists/unsmooth revolution/
rust ® Replace bearing and bushing as
a set.
2. Inspect:
lOil seal 3
Damage ® Replace.
EC574210
Relay arm
1. Inspect:
lBearing 1
lCollar 2
Free play exists/unsmooth revolution/rust
® Replace bearing and collar as a set.
2. Inspect:
lOil seal 3
Damage ® Replace.
EC574310
Connecting rod
1. Inspect:
lBearing 1
lCollar 2
Free play exists/unsmooth revolution/rust
® Replace bearing and collar as a set.
2. Inspect:
lOil seal 3
Damage ® Replace.

5 - 56
CHASSWINGARM
EC575000
ASSEMBLY AND INSTALLATION
EC575201
Bearing and oil seal
1. Install:
lBearing 1
lOil seal 2
To swingarm.
NOTE:
lApply the molybdenum disulfide grease on
the bearing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
lFirst install the outer and then the inner bear-
ings to a specified depth from inside.
Installed depth of bearings:
Outer a: Zero mm (Zero in)
Inner b: 8.5 mm (0.33 in)
2. Install:
lBearing 1
lOil seal 2
To relay arm.
NOTE:
lApply the molybdenum disulfide grease on
the bearing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
3. Install:
lBearing 1
lOil seal 2
To connecting rod.
NOTE:
lApply the molybdenum disulfide grease on
the bearing when installing.
lInstall the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings a:
5 mm (0.20 in)
Installed depth of bearings a:
5 mm (0.20 in)

5 - 57
CHASSWINGARM
Swingarm
1. Install:
lBushing 1
lThrust bearing 2
lOil seal 3
lCollar 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushings, thrust bearings and oil seal lips.
2. Install:
lCollar 1
To relay arm 2.
NOTE:
Apply the molybdenum disulfide grease on the
collars, bearings and oil seal lips.
3. Install:
lCollar 1
To connecting rod 2.
NOTE:
Apply the molybdenum disulfide grease on the
collar, bearings and oil seal lips.
4. Install:
lConnecting rod 1
lBolt (connecting rod) 2
lWasher 3
lNut (connecting rod) 4
To relay arm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
CAUTION:
Install the nut on the left side of the chas-
sis. If you make a mistake in its installation
position, the nut contacts the swingarm
when stroking the rear shock absorber.
T R..80 Nm (8.0 m · kg, 58 ft · lb)

5 - 58
CHASSWINGARM
5. Install:
lRelay arm 1
lBolt (relay arm) 2
lWasher 3
lNut (relay arm) 4
To swingarm.
NOTE:
lApply the molybdenum disulfide grease on
the bolt.
lDo not tighten the nut yet.
6. Install:
lSwingarm 1
lPivot shaft 2
NOTE:
lApply the molybdenum disulfide grease on
the pivot shaft.
lInsert the pivot shaft from right side.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
7. Check:
lSwingarm side play a
Free play exists ® Replace thrust bear-
ing.
lSwingarm up and down movement b
Unsmooth movement/binding/rough
spots ® Grease or replace bearings,
bushings and collars.
8. Install:
lBolt (connecting rod) 1
lWasher 2
lNut (connecting rod) 3
NOTE:
lApply the molybdenum disulfide grease on
the bolt.
lDo not tighten the nut yet.
9. Install:
lWasher 1
lBolt (rear shock absorber-relay arm) 2
NOTE:
lApply the molybdenum disulfide grease on
the bolt.
lInsert the bolt from right side.
T R..53 Nm (5.3 m · kg, 38 ft · lb)