2002 YAMAHA WR 250F ABS

5 - 61
CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
9 Locknut 1 Only loosening.
10 Adjuster 1 Only loosening.
11 Lower spring guide 1
12 Upper spring guide 1
13 Spring (rear shock absorber) 1
14 Bearing 2 Refer to “REMOVAL POINTS”.
2

5 - 62
CHAS
HANDLING NOTE
WARNING
This rear shock absorber is provided with a
separate type tank filled with high-pressure
nitrogen gas. To prevent the danger of
explosion, read and understand the follow-
ing information before handling the shock
absorber.
The manufacturer can not be held respon-
sible for property damage or personal
injury that may result from improper han-
dling.
1. Never tamper or attempt to disassem-
ble the cylinder or the tank.
2. Never throw the rear shock absorber
into an open flame or other high heat.
The rear shock absorber may explode
as a result of nitrogen gas expansion
and/or damage to the hose.
3. Be careful not to damage any part of
the gas tank. A damaged gas tank will
impair the damping performance or
cause a malfunction.
4. Take care not to scratch the contact
surface of the piston rod with the cylin-
der; or oil could leak out.
5. Never attempt to remove the plug at
the bottom of the nitrogen gas tank. It
is very dangerous to remove the plug.
6. When scrapping the rear shock
absorber, follow the instructions on
disposal.
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve 1.
Wear eye protection to prevent eye damage
from escaping gas and/or metal chips.
WARNING
To dispose of a damaged or worn-out rear
shock absorber, take the unit to your
Yamaha dealer for this disposal procedure.
REAR SHOCK ABSORBER

5 - 63
CHAS
EC583000
REMOVAL POINTS
EC583320
Bearing
1. Remove:
Stopper ring (upper bearing) 1
NOTE:
Press in the bearing while pressing its outer
race and remove the stopper ring.
2. Remove:
Upper bearing 1
NOTE:
Remove the bearing by pressing its outer race.
3. Remove:
Lower bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC584000
INSPECTION
Rear shock absorber
1. Inspect:
Damper rod 1
Bends/damage → Replace rear shock
absorber assembly.
Shock absorber 2
Oil leaks → Replace rear shock
absorber assembly.
Gas leaks → Replace rear shock
absorber assembly.
Spring 3
Damage → Replace spring.
Fatigue → Replace spring.
Move spring up and down.
Spring guide 4
Wear/damage → Replace spring guide.
Bearing 5
Free play exists/unsmooth revolution/
rust → Replace.
REAR SHOCK ABSORBER

5 - 64
CHASREAR SHOCK ABSORBER
EC585000
ASSEMBLY AND INSTALLATION
EC585300
Bearing
1. Install:
Upper bearing 1
NOTE:
Install the bearing parallel until the stopper ring
groove appears by pressing its outer race.
CAUTION:
Do not apply the grease on the bearing
outer race because it will wear the rear
shock absorber surface on which the bear-
ing is press fitted.
2. Install:
Stopper ring (upper bearing) 1
NOTE:
After installing the stopper ring, push back the
bearing until it contacts the stopper ring.
3. Install:
Lower bearing 1
NOTE:
Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of the bearing a:
4 mm (0.16 in)
Spring (rear shock absorber)
1. Install:
Spring 1
Upper spring guide 2
Lower spring guide 3

5 - 65
CHASREAR SHOCK ABSORBER
2. Tighten:
Adjuster 1
3. Adjust:
Spring length (installed) a
* For EUROPE
** For AUS, NZ and ZA
NOTE:
The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
4. Tighten:
Locknut 1
Rear shock absorber
1. Install:
Dust seal 1
O-ring 2
Collar 3
NOTE:
Apply the molybdenum disulfide grease on
the bearing.
Apply the lithium soap base grease on the
dust seals, O-rings and collars.
Spring length (installed) a:
Standard
lengthExtent of
adjustment
244 mm (9.61 in)
* 247 mm (9.72 in)
** 243.5 mm (9.59 in)240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)

5 - 66
CHASREAR SHOCK ABSORBER
2. Install:
Bushing 1
Collar 2
Dust seal 3
NOTE:
Apply the molybdenum disulfide grease on
the bearing.
Apply the lithium soap base grease on the
bushing, collars and dust seals.
Install the dust seals with their lips facing
outward.
3. Install:
Rear shock absorber
4. Install:
Bolt (rear shock absorber-frame) 1
Nut (rear shock absorber-frame) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5. Install:
Bolt (rear shock absorber-relay arm) 1
Nut (rear shock absorber-relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..56 Nm (5.6 m · kg, 40 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
6. Install:
Rear frame 1
Bolt (rear frame) 2
Bolt (reservoir tank) 3
T R..29 Nm (2.9 m · kg, 21 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Tighten:
Screw (air filter joint) 1
1
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

5 - 67
CHASREAR SHOCK ABSORBER
8. Install:
Band 1
Taillight connector 2

–+ELEC
5. Einstellen:
Leerlaufdrehzahl
Siehe hierzu den Abschnitt
“LEERLAUFDREHZAHL
EINSTELLEN” in KAPITEL
3.
6. Die dünnen elektrischen Leiter
2 (Leitungsdrähte) in den
TPS-Kabelstecker 1 stecken,
wie in der Abbildung gezeigt,
und zur Prüfung das Prüfgerät
anschließen.
ACHTUNG:
Nicht die elektrischen Leiter wei-
ter als erforderlich einstecken,
da sonst die Wasserfestigkeit
des Steckers beeinträchtigt wer-
den kann.
Sicherstellen, daß sich kein
Kurzschluß zwischen den Kon-
takten entwickelt, da dadurch
Schäden an den elektrischen
Bauteilen verursacht werden
können. Positives (+) Kabel des Prüf-
gerätes → Gelbe Leitung 3
Negatives (–) Kabel des Prüfge-
rätes → Schwarze Leitung 4
7. Den Motor starten.
8. Einstellen:
TPS-Ausgangsspannung
Einstellschritte:
Den Einbauwinkel von TPS 1 ein-
stellen, um die vorgeschriebene
Ausgangsspannung zu erhalten.
HINWEIS:
Die Ausgangsspannung akkurat
mit einem digitalen elektronische
Voltmeter mesen, das leichte Able-
sung kleiner Spannungen erlaubt.
TPS-Ausgangs-
spannungnung Prüfgerät-
Stellung
0,58–0,78 V DCV
5. Ajuster:
Vitesse de ralenti
Voir la section “REGLAGE
DU REGIME DE RALENTI”
dans le CHAPITRE 3.
6. Insérer les conducteurs électri-
ques fins 2 (fils) dans le capteur
de position de papillon des gaz
1, comme illustré, et y connecter
le manomètre.
ATTENTION:
Ne pas insérer les conducteurs élec-
triques plus que nécessaire sinon
l’étanchéité du reccord en est
réduite.
S’assurer qu’il n’y a aucun court-
circuit entre les bornes, ce qui pour-
rait endommager les composants
électriques.Fil du manomètre (+) →
Fil jaune 3
Fil du manomètre (–) →
Fil noir 4
7. Démarrer le moteur.
8. Régler:
La tension de sortie du capteur
de position de papillon des gaz
Étapes de réglage :
Régler l’angle de montage du capteur
de position de papillon des gaz 1
pour obtenir la tension de sortie spéci-
fiée.
N.B.:
Mesurer précisément la tension de sor-
tie avec un voltmètre électronique à
affichage numérique qui permet de
mieux lire les faibles tensions.
Tension de sortie
du capteur de posi-
tion de papillon des
gaz Position du sélec-
teur du manomè-
tre
0,58 à 0,78 V DCV
5. Regolare:
Regime del minimo
Fare riferimento al paragrafo
“REGOLAZIONE DEL
MINIMO” nel CAPITOLO 3.
6. Inserire i conduttori elettrici sot-
tili 2 (cavo) nell’accoppiatore
del sensore di posizione valvo a
farfalla 1, come illustrato e col-
legarvi il tester.
ATTENZIONE:
Non inserire i conduttori elettrici
più del necessario perché questo
può ridurre la funzione di imperme-
abilità dell’accoppiatore.
Accertarsi che non si creino corto-
circuiti tra i terminali perché le
componenti elettriche possono
rimanere danneggiate.Conduttore (+) del tester →
Conduttore giallo 3
Conduttore (–) del tester →
Conduttore nero 4
7. Avviare il motore.
8. Regolare:
Tensione di uscita del sensore
di posizione valvola a farfalla
Fasi di regolazione:
Regolare l’angolo di installazione del
sensore di posizione valvola a farfalla
1 per ottenere la tensione in uscita
desiderata.
NOTA:
Misurare accuratamente la tensione in
uscita con un voltmetro elettronico
digitale che permette una facile lettura
di piccole tensioni.
Tensione in uscita
del sensore di
posizione valvola
a farfallaPosizione del
selettore sul
tester
0,58 ~ 0,78 V DCV
CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ
DROSSELKLAPPEN-POSITIONSSENSOR
SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA
6 - 10