2003 YAMAHA WR 250F clutch

MAINTENANCE SPECIFICATIONS
2 - 11
SPEC
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 19 1.9 13
Spark arrester (for USA) M6 × 1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6 × 1.0 1 10 1.0 7.2
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 3 10 1.0 7.2
Idle gear plate M6 × 1.0 2 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 8 0.8 5.8
Clutch boss M16 × 1.0 1 60 6.0 43
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Shift pedal M6 × 1.0 1 12 1.2 8.7 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

MAINTENANCE SPECIFICATIONS
2 - 13
SPEC
Wheel: USA, CDN, ZA EUROPE, AUS, NZ
Front wheel type Spoke wheel←----
Rear wheel type Spoke wheel←----
Front rim size/material 21 × 1.60/Aluminum←----
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- ---- 2.0 mm
(0.08 in)
Lateral ---- ---- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO ----
Number of links 113 links + joint ----
Chain slack 40 ~ 50 mm (1.6 ~ 2.0 in) ----
Chain length (10 links) ---- 150.1 mm
(5.91 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)
250 × 2.5 mm
(9.84
× 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)
245 × 3.5 mm
(9.65
× 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

MAINTENANCE SPECIFICATIONS
2 - 14
SPEC
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 upper 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
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
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting nut M5 × 0.8 1 2 0.2 1.4
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
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 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90

SPEC
2 - 97
CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Clamp
4Diode
5Wire harness
6Hot starter cable
7Throttle position sensor lead
8Neutral switch lead
9Oil hose
0Hose guideAAC magneto lead
BCylinder head breather hose
CStarter motor lead
DClutch cable
ERadiator hose 1
FRadiator pipe (radiator hose 4)
GCable guide
HNegative battery lead
ILight switch lead
JBrake hoseKCarburetor breather hose
LCarburetor overflow hose
MCoolant reservoir breather hose
ÈInsert the fuel tank breather hose into
the hole in the steering stem cap.
ÉPass the oil tank breather hose on the
outside of the AC magneto lead, neu-
tral switch lead, light switch lead, wire
harness, starter motor lead, negative
battery lead and cylinder head breather
hose.

SPEC
2 - 101
CABLE ROUTING DIAGRAM
ÖFasten the neutral switch lead and AC magneto lead.
×Pass the cylinder head breather hose on the inside of the radi-
ator hose 1 and on the outside of the radiator pipe (radiator
hose 4). Make sure that the cylinder head breather hose does
not go forward of the chassis.
ØPass the starter motor lead in front of the radiator hose 4.
ÙPass the clutch cable through the cable guide.
ÚPass the wire harness on the outside of the neutral switch lead
and AC magneto lead.
ÛFit the brake hose into the guides on the protector.
ÜPass the wire harness, clutch cable and light switch lead
through the cable guide.ÝFasten the AC magneto lead, neutral switch lead and light
switch lead to the cable guide at their protecting tube with a
plastic locking tie and cut off the tie end.
ÞPass the carburetor breather hoses, carburetor overflow hose
and coolant reservoir breather hose so that the hoses do not
contact the rear shock absorber.

SPEC
2 - 111
CABLE ROUTING DIAGRAM
1Throttle cable
2Brake hose
3Clamp
4Light switch lead
5Hot starter cable
6Clutch cable
7Hose guide
8Clutch switch lead
9Engine stop switch lead
0Trip meter cable
AMain switch lead
BTrip meter
CMain switchDLight switch
EStart switch lead
ÈFasten the start switch lead and light switch lead.
ÉFasten the engine stop switch lead and clutch switch lead.
ÊPass the brake hose through the hose guide.
ËPass the start switch lead in front of the main switch lead.
ÌFasten the start switch lead.
ÍPass the hot starter cable, clutch cable and light switch lead
between the upper bracket and coupler bracket.
ÎPass the throttle cables between the upper bracket and trip
meter.

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
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks
ENGINE OIL
Replace
Inspect
VALVES
Check the valve clearances The engine must be cold.
Check the valve seats and
valve stems for wear. Inspect
Replace
VALVE SPRINGS
InspectCheck the free length and
the tilt.
Replace
VALVE LIFTERS
InspectCheck for scratches and
wear.
Replace
CAMSHAFTSInspect the camshaft
surface.
Inspect the decompression
system. Inspect
Replace
TIMING CHAIN SPROCKETS, TIMING
CHAIN
InspectCheck for wear on the teeth
and for damage.
Replace
PISTON
InspectInspect crack
Inspect carbon deposits and
eliminate them. Clean
Replace
PISTON RING
InspectCheck ring end gap
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEADInspect carbon deposits and
eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect and adjust Inspect housing, friction
plate, clutch plate and spring
Replace
TRANSMISSION
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
*marked: For USAFRONT FORKS
Inspect and adjust
Replace oilSuspension oil “01”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
(After
rain
ride)Molybdenum disulfide
grease
Retighten
DRIVE CHAIN GUIDE AND ROLLERS
Inspect
SWINGARMMolybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD Molybdenum disulfide
grease
Inspect, lube and retighten
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out, tire
wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE Yamaha cable lube or SAE
10W-30 motor oil
Inspect dirt and wear on the
throttle cable on the
carburetor side. Check routing and connection
Lubricate
Inspect and clean (throttle cable)
HOT STARTER, CLUTCH LEVER
Inspect free play
BATTERY
Check terminal for looseness and
corrosionItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks