2003 YAMAHA WR 250F torque

E0A0000
CONTENTS
CHAPTER 1
GENERAL
INFORMATION
DESCRIPTION............................ 1-1
MACHINE IDENTIFICATION...... 1-3
IMPORTANT INFORMATION..... 1-5
CHECKING OF CONNECTION... 1-9
SPECIAL TOOLS...................... 1-11
CONTROL FUNCTIONS........... 1-27
FUEL......................................... 1-35
STARTING AND BREAK-IN..... 1-37
TORQUE-CHECK POINTS....... 1-45
CLEANING AND STORAGE..... 1-51
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.... 2-1
MAINTENANCE
SPECIFICATIONS....................... 2-4
GENERAL TORQUE
SPECIFICATIONS..................... 2-19
DEFINITION OF UNITS............. 2-19
CABLE ROUTING DIAGRAM... 2-97
CHAPTER 3
REGULAR
INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS..... 3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE................ 3-16
ENGINE..................................... 3-21
CHASSIS................................... 3-65
ELECTRICAL.......................... 3-107
TABLES DES
MATIERES
CHAPITRE 1
RENSEIGNEMENTSG
ENERAUX
DESCRIPTION................................ 1-1
IDENTIFICATION DE LA
MACHINE........................................ 1-3
INFORMATIONS
IMPORTANTES.............................. 1-5
VERIFICATION DES
CONNEXIONS................................ 1-9
OUTILS SPECIAUX..................... 1-14
FONCTIONS DES
COMMANDES.............................. 1-27
CARBURANT................................ 1-35
MISE EN MARCHE ET
RODAGE........................................ 1-37
POINTS DE VERIFICATION
DE COUPLE DE SERRAGE....... 1-46
NETTOYAGE ET
RANGEMENT............................... 1-51
CHAPITRE 2
CARACTERISTIQUES
CARACTERISTIQUES
GENERALES................................. 2-20
CARACTERISTIQUES
D’ENTRETIEN.............................. 2-23
CARACTERISTIQUES
GENERALES DE COUPLE......... 2-38
DEFINITION DES UNITES......... 2-38
CHEMINEMENT DES
CABLES......................................... 2-98
CHAPITRE 3
CONTROLES ET
REGLAGES
COURANTS
PROGRAMME D’ENTRETIEN... 3-4
CONTROLE ET ENTRETIEN
AVANT UTILISATION................ 3-17
MOTEUR....................................... 3-21
PARTIE CYCLE........................... 3-65
PARTIE ELECTRIQUE............. 3-107

1 - 43
GEN
INFO
BREAK-IN PROCEDURES
1. Before starting the engine, fill the
fuel tank with the fuel.
2. Perform the pre-operation
checks on the machine.
3. Start and warm up the engine.
Check the idle speed, and check
the operation of the controls and
the engine stop switch. Then,
restart the engine and check its
operation within no more than 5
minutes after it is restarted.
4. Operate the machine in the
lower gears at moderate throttle
openings for five to eight min-
utes.
5. Check how the engine runs
when the machine is ridden with
the throttle 1/4 to 1/2 open (low
to medium speed) for about one
hour.
6. Restart the engine and check
the operation of the machine
throughout its entire operating
range. Restart the machine and
operate it for about 10 to 15
more minutes. The machine will
now be ready to race.
CAUTION:
After the break-in or before each
race, you must check the entire
machine for loose fittings and
fasteners as per “TORQUE-
CHECK POINTS”.
Tighten all such fasteners as
required.
When any of the following parts
have been replaced, they must
be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in
operation is necessary.
PISTON, RING, VALVES, CAM-
SHAFTS AND GEARS:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.PROCEDURE DE RODAGE
1. Avant de mettre le moteur en mar-
che, faire le plein d’essence.
2. Effectuer les contrôles avant utilisa-
tion de la machine.
3. Lancer le moteur et le laisser se
réchauffer. Vérifier le régime de
ralenti, le fonctionnement des com-
mandes et l’efficacité du coupe-cir-
cuit. Remettre ensuite le moteur en
marche et vérifier son fonctionne-
ment dans les 5 minutes maximum.
4. Piloter la machine sur les rapports
inférieurs et à régime modéré durant
les cinq à huit premières minutes.
5. Vérifier le fonctionnement du
moteur en roulant pendant environ 1
heure à une ouverture des gaz de 1/4
à 1/2 (petite à moyenne vitesse) .
6. Remettre le moteur en marche et
vérifier son fonctionnement à tous
les régimes. Relancer le moteur et
piloter la machine pendant 10 à 15
minutes supplémentaires. Elle sera
alors prête pour la course.
ATTENTION:
Après le rodage ou avant chaque
course, il faut vérifier toutes les fixa-
tions et serrages comme indiqué
dans “POINTS DE VERIFICA-
TION DE COUPLE DE SER-
RAGE”.
Serrer toutes ces fixations comme
requis.
Après avoir remplacé les pièces sui-
vantes, un nouveau rodage est
nécessaire.
CYLINDRE ET VILEBREQUIN:
Une heure environ de rodage est
nécessaire.
PISTONS, SEGMENTS, SOUPAPES,
ARBRES A CAMES ET PIGNONS:
Ces pièces nécessitent un rodage de
30 minutes environ à une ouverture
des gaz de maximum 1/2. Surveiller
attentivement l’état du moteur pen-
dant la marche.
STARTING AND BREAK-IN
MISE EN MARCHE ET RODAGE

1 - 45
GEN
INFO
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Rear Installation of rear
shock absorberRear shock absorber to frame
Rear Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp
NOTE:Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” sec-
tion in the CHAPTER 2.
TORQUE-CHECK POINTS

MAINTENANCE SPECIFICATIONS
2 - 10
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 37 3.7 27
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 10 1.0 7.2
Oil hose clamp—220.21.4
Oil strainer and frame M14 × 1.5 1 70 7.0 50
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

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 - 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

MAINTENANCE SPECIFICATIONS
2 - 15
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—72 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 6 50 5.0 36
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
Drive chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
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 23 2.3 17
Regulator bracket and frame M6 × 1.0 2 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
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 (upper) M8 × 1.25 1 32 3.2 23
Rear frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 19 1.9 13
Lower drive chain tensioner M8 × 1.25 1 20 2.0 14
Drive chain support 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
Air scoop and fuel tank M6 × 1.0 6 4 0.4 2.9
Air scoop and radiator guard (lower) M6 × 1.0 2 4 0.4 2.9
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 10 1.0 7.2
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
Trip meter M6 × 1.0 2 7 0.7 5.1
Meter cable holder and front fork protector M5 × 0.8 2 4 0.4 2.9
Headlight stay (lower) and lower bracket M8 × 1.25 2 7 0.7 5.1

MAINTENANCE SPECIFICATIONS
2 - 16
SPEC
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1
Headlight (left and right) M6 × 1.0 2 10 1.0 7.2
Headlight (lower) M6 × 1.0 1 7 0.7 5.1
Taillight M6 × 1.0 3 4 0.4 2.9
Taillight lead clamp and rear fender M4 × 1.59 2 0.5 0.05 0.36
Coolant reservoir M6 × 1.0 2 7 0.7 5.1
Sidestand bracket and frame M10 × 1.25 2 66 6.6 48
Sidestand M10 × 1.25 1 64 6.4 46 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb