2003 YAMAHA WR 250F fuel cap

1 - 1
GEN
INFODESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Engine stop switch
4Trip meter
5Main switch
6Light switch
7Start switch
8Front brake lever
9Throttle grip
0Radiator cap
AFuel tank cap
BTaillight
CKickstarter crank
DFuel tank
EHeadlight
FRadiator
GCoolant drain bolt
HRear brake pedal
IValve joint
JFuel cock
KCold starter knob
LAir cleaner
MDrive chain
NShift pedal
OOil dipstick
PFront fork
NOTE:The machine you have purchased may differ slightly
from those shown in the following.
Designs and specifications are subject to change with-
out notice.
B
CDE
F
G H
1234
5
6
7
8
9
0 A
IJ
K
L
M N
O P
RENSEIGNEMENTS GENERAUX
DESCRIPTION
1Levier d’embrayage
2Levier de démarreur à chaud
3Coupe-circuit du moteur
4Compteur de vitesse
5Commutateur principal
6Interrupteur lumiêres
7Commutateur de démarrage
8Levier de frein avant
9Poignée des gaz
0Bouchon de radiateur
ABouchon de réservoir de carburant
BLampe arrière
CPedale de kick
DRéservoir de carburant
EPhare
FRadiateur
GBoulon de vidange du liquide de refroidissement
HPédale de frein arrière
IClapet de durit de mise a liair
JRobinet de carburant
KBouton de démarrage à froid
LFiltre à air
MChaîne de transmission
NPédale de sélecteur
OJauge de niveau d’huile
PFourche avant
N.B.:
Votre machine diffère peut-être partiellement de celle mon-
trée sur ces photos.
La conception et les caractéristiques peuvent êtres changées
sans préavis.
DESCRIPTION

GENERAL SPECIFICATIONS
2 - 2
SPEC
Oil capacity:
Engine oil
Periodic oil change 1.2 L (1.06 Imp qt, 1.27 US qt)
With oil filter replacement 1.3 L (1.14 Imp qt, 1.37 US qt)
Total amount 1.4 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
(Except for ZA)
Premium gasoline (For ZA)
Tank capacity 10 L (2.2 Imp gal, 2.64 US gal)
Reserve 1.2 L (0.26 Imp gal, 0.32 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 52/13 (4.000)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 31/13 (2.385)
2nd 28/16 (1.750)
3rd 28/21 (1.333)
4th 25/24 (1.042)
5th 22/27 (0.815)
Chassis:
Frame type Semi double cradle
Caster angle 27.1°
Trail 117.4 mm (4.62 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)
90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)
130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
1
2
3
4
5
6
7

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.

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
ROTOR NUT
Retighten
EXHAUST PIPE, SILENCER,
PROTECTOR
Inspect and retighten
Clean
Replace* Whichever comes first
*SPARK ARRESTER
Clean
(Every
six
months)
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAINUse chain lube
Chain slack:
40 ~ 50 mm (1.6 ~ 2.0 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolantEvery two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING AND
BREAK-IN” section in the
CHAPTER 1. Retighten
AIR FILTER
Clean and lubricate Use foam air-filter oil or
equivalent oil
Replace
OIL FILTER
Replace
OIL STRAINER (frame)
Clean
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
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 Every one yearItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks
1
2
3
4
5
6
7

3 - 16
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-21 ~ 29
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-35
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-39 ~ 47
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-29 ~ 31
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-31 ~ 33
Brakes Check the play of front brake and effect of front and rear brake. P.3-65 ~ 77
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-79 ~ 83
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-99 ~ 101
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-101 ~ 103
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-83 ~ 97
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-7 ~ 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-77
Lubrication Check for smooth operation. Lubricate if necessary. P.3-105
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-45
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are
connected tightly.P.1-9
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 42

3 - 23
INSP
ADJ
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap
when the engine is hot.
CAUTION:
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the
engine.
2. Remove:
Seat
Refer to “SEAT, FUEL TANK
AND SIDE COVERS” section
in the CHAPTER 4.
3. Disconnect:
Coolant reservoir hose
1
Drain the coolant completely.
4. Connect:
Coolant reservoir hose
LOWFULLCOOLANT1
5. Remove:
Engine guard
1
Coolant drain bolt
2
6. Remove:
Radiator cap
Drain the coolant completely.
7. Clean:
Cooling system
Thoroughly flush the cooling
system with clean tap water.
8. Install:
Copper washer
Coolant drain bolt
Engine guard
Bolt [engine guard (front)]
Bolt [engine guard (rear)]
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
New
CHANGEMENT DU LIQUIDE DE
REFROIDISSEMENT
AVERTISSEMENT
Ne jamais enlever le bouchon du
radiateur quand le moteur est chaud.
ATTENTION:
Prendre garde à ne pas verser de
liquide de refroidissement sur les sur-
faces peintes. Si cela devait se pro-
duire, nettoyer à l’eau.
1. Mettre un récipient sous le moteur.
2. Déposer:
Selle
Se reporter à la section “SELLE,
RESERVOIR DE CARBURANT
ET CACHES LATERAUX” au
CHAPITRE 4.
3. Déconnecter:
Durit du vase d’expansion 1
Vidanger complètement le liquide
de refroidissement.
4. Connecter:
Durit du vase d’expansion
5. Déposer:
Protège-carter 1
Boulon de vidange de refroidisse-
ment 2
6. Déposer:
Bouchon du radiateur
Vidanger complètement le liquide
de refroidissement.
7. Nettoyer:
Circuit de refroidissement
Bien rincer le circuit de refroidis-
sement avec de l’eau du robinet.
8. Monter:
Rondelle en cuivre
Boulon de vidange de refroidisse-
ment
Protège-carter
Boulon [protège-carter (avant)]
Boulon [protège-carter (arrière)]
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..34 Nm (3,4 m · kg, 24 ft · lb)
T R..23 Nm (2,3 m · kg, 17 ft · lb)
New
ENGINE
MOTEUR

3 - 103
INSP
ADJ
Loosen the steering ring nut
one turn.
Retighten the steering ring nut
using the steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut
(final tightening):
7 Nm
(0.7 m  kg, 5.1 ft  lb)
Check the steering stem by
turning it lock to lock. If there is
any binding, remove the steer-
ing stem assembly and inspect
the steering bearings.
Install the washer
5, upper
bracket
6, washer
7, steering
stem nut
8, steering stem cap
9, handlebar
0, handlebar
upper holder
A and headlight
B.
NOTE:The handlebar upper holder
should be installed with the
punched mark
a forward.
Insert the end of the fuel
breather hose
C into the hole in
the steering stem cap.
CAUTION:
First tighten the bolts on the
front side of the handlebar
upper 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 (upper
bracket):
23 Nm
(2.3 m  kg, 17 ft  lb)
Headlight (left and right):
10 Nm
(1.0 m  kg, 7.2 ft  lb)
Headlight (lower):
7 Nm
(0.7 m  kg, 5.1 ft  lb)
Desserrer l’écrou crénelé de direc-
tion.
Resserrer l’écrou crénelé de direc-
tion à l’aide de la clé pour écrou
crénelé de direction.
AVERTISSEMENT
Prendre garde de ne pas serrer
excessivement.
T R..
Ecrou crénelé de direction
(serrage final):
7 Nm
(0,7 m  kg, 5,1 ft  lb)
Vérifier l’arbre de direction en le
tournant d’une position bloquée à
l’autre. S’il y a une gêne quelcon-
que, retirer l’ensemble colonne de
direction et inspecter le support de
direction.
Remettre en place le demi-palier
6, la rondelle 7, la rondelle 5,
l’écrou d’arbre de direction 8, le
capuchon de colonne de direction
9, le guidon 0, le demi-palier
supérieur du guidon A et le phare
B.
N.B.:
Le demi-palier supérieur du guidon
doit être monté avec son poinçon
a à l’avant.
Introduire l’extrémité de la durit de
mise à l’air de carburant C dans
l’orifice du capuchon de la colonne
de direction.
ATTENTION:
Premièrement, serrer les boulons
côté avant du demi-palier de gui-
don, puis serrer les boulons du côté
arrière.
T R..
Ecrou d’arbre de direction:
145 Nm
(14,5 m  kg, 105 ft  lb)
Demi-palier supérieur du
guidon:
28 Nm
(2,8 m  kg, 20 ft  lb)
Boulon de bridage
(support supérieur):
23 Nm
(2,3 m  kg, 17 ft  lb)
Phare (gauche et droit):
10 Nm
(1,0 m  kg, 7,2 ft  lb)
Phare (bas):
7 Nm
(0,7 m  kg, 5,1 ft  lb)
CHASSIS
PARTIE CYCLE

4 - 33
ENGCARBURETOR
HANDLING NOTE
CAUTION:
Do not loosen the screws (throttle
position sensor) 1
except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
1
REMOVAL POINTS
Pilot screw
1. Remove:
Pilot screw
1
NOTE:To optimize the fuel flow at a small
throttle opening, each machine’s pilot
screw has been individually set at the
factory. Before removing the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
INSPECTION
Carburetor
1. Inspect:
Carburetor body
Contamination
→ Clean.
NOTE:Use a petroleum based solvent for
cleaning. Blow out all passages
and jets with compressed air.
Never use a wire.
REMARQUE CONCERNANT LES
MANIPULATIONS
ATTENTION:
Ne pas desserrer les vis (capteur de
position du papillon des gaz) 1 sauf
lors du changement de capteur de
position du papillon des gaz en cas de
panne pour éviter les diminutions de
performance du moteur.
POINTS DE DEPOSE
Vis de richesse
1. Déposer:
Vis de richesse 1
N.B.:
Afin d’optimiser le flux de carburant à
petite ouverture des gaz, la vis de
richesse de chaque véhicule a été réglé
individuellement à l’usine. Avant de
remonter la vis de richesse, la visser
complètement en comptant le nombre de
tours exact. Retenir et noter ce chiffre et
dévisser la vis de ce nombre de tours.
CONTROLE
Carburateur
1. Contrôler:
Corps du carburateur
Encrassé → Nettoyer.
N.B.:
Pour le nettoyage, employer un dissol-
vant à base de pétrole. Passer tous les
conduits et gicleurs à l’air comprimé.
Ne jamais utiliser de fil.
CARBURATEUR