2004 YAMAHA WR 250F light

GENERAL SPECIFICATIONS
2 - 3
SPEC
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI
Generator system AC magneto
Battery type YTX5L-BS
Battery voltage/capacity 12 V/4 AH
Specific gravity 1.320
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Taillight 12 V 21/5 W × 1

MAINTENANCE SPECIFICATIONS
2 - 16
SPEC
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Headlight stay (lower) and lower bracket M8 × 1.25 2 7 0.7 5.1
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
Drive chain stopper and sidestand bracket M6 × 1.0 1 7 0.7 5.1
Sidestand M8 × 1.25 1 25 2.5 18 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

MAINTENANCE SPECIFICATIONS
2 - 17
SPEC
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5UM-50/YAMAHA (For USA) ----
5UM-60/YAMAHA (Except for USA) ----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5UM-00/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH712AA/SHINDENGEN ----
Regulated voltage (AC) 13.0 ~ 14.0 V ----
Regulated voltage (DC) 14.1 ~ 14.9 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM01/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.0189 ~ 0.0231 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----

SPEC
2 - 107
CABLE ROUTING DIAGRAM
1Brake master cylinder
2Brake hose holder
3Brake hoseÈInstall the brake hose so that its pipe portion directs as shown
and lightly touches the projection on the brake caliper.
ÉPass the brake hose into the brake hose holders.
ÊIf the brake hose contacts the spring (rear shock absorber),
correct its twist.
ËInstall the brake hose so that its pipe portion directs as shown
and lightly touches the projection on the brake master cylinder.

SPEC
2 - 109
CABLE ROUTING DIAGRAM
1Starter motor lead
2Negative battery lead
3Wire harness
4Clamp
5Taillight lead
6Coolant reservoir breather hose
7Coolant reservoir hose
8Positive battery lead
9Starting circuit cut-off relay
0BatteryÈPosition the starter motor lead, negative battery lead and wire
harness in the tank damper slit.
ÉFasten the wire harness.
ÊDo not allow the taillight lead to slacken.
ËFasten the coolant reservoir breather hose and coolant reser-
voir hose.
ÌPass the coolant reservoir hose on the outside of the coolant
reservoir breather hose.

3 - 39
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for
several minutes, and then turn
off the engine and wait for five
minutes.
2. Place the machine on a level
place and hold it up on upright
position by placing the suitable
stand under the engine.
3. Remove:
Oil tank cap
1
1
4. Inspect:
Oil level
Oil level should be between
maximum
a and minimum b
marks.
Oil level is low → Add oil to
proper level.
NOTE:When inspecting the oil level, do not
screw the oil tank cap into the oil
tank. Insert the gauge lightly.
(For USA and CDN)
CAUTION:
Do not add any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
Do not allow foreign material to
enter the crankcase.
Recommended oil:
At 5 °C (40 °F) or
higher È Yamalube 4
(20W-40) or SAE 20W-
40 type SG motor oil
(Non-Friction
modified)
At 15 °C (60 °F) or
lower É Yamalube 4
(10W-30) or SAE 10W-
30 type SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
a
b
CONTROLE DU NIVEAU D’HUILE
MOTEUR
1. Mettre le moteur en marche, le faire
chauffer pendant quelques minutes,
puis le couper et attendre cinq
minutes.
2. Placer le véhicule sur un plan hori-
zontal et le dresser à la verticale en
plaçant un support adéquat sous le
moteur.
3. Déposer:
Bouchon du réservoir d’huile 1
4. Contrôler:
Niveau d’huile
Le niveau d’huile doit se trouver
entre les repères maximum a et
minimum b.
Bas niveau d’huile → Ajouter de
l’huile jusqu’au niveau requis.
N.B.:
Pour mesurer le niveau d’huile, intro-
duire la jauge dans le réservoir en
veillant à ne pas la visser.
(USA et CDN)
ATTENTION:
Ne pas ajouter d’additifs chimiques.
L’huile moteur lubrifie également
l’embrayage et des additifs risquent
de provoquer le patinage de
l’embrayage.
Empêcher toute pénétration de
crasses ou d’objets dans le carter.
Huile recommandée:
Min. 5 °C (40 °F) È:
Yamalube 4 (20W40) ou
SAE 20W-40 de type SG
(Sans additifs anti-
friction)
Max. 15 °C (60 °F) É:
Yamalube 4 (10W-30) ou
SAE 10W-30 de type SG
(Sans additifs anti-
friction)
et/ou
Yamalube 4-R (15W-50)
(Sans additifs anti-
friction)
ENGINE
MOTEUR

3 - 47
INSP
ADJ
OIL PRESSURE INSPECTION
1. Check:
Oil pressure
Checking steps:
Slightly loosen the oil pressure
check bolt
1.
Start the engine and keep it
idling until oil starts to seep from
the oil pressure check bolt. If no
oil comes out after one minute,
turn the engine off so it will not
seize.
Check oil passages and oil
pump for damage or leakage.
Start the engine after solving
the problem(s) and recheck the
oil pressure.
Tighten the oil pressure check
bolt.
T R..
Oil pressure check bolt:
10 Nm
(1.0 m  kg, 7.2 ft  lb)
PILOT SCREW ADJUSTMENT
1. Adjust:
Pilot screw
1
* Except for USAAdjustment steps:
NOTE:To optimize the fuel flow at a
smaller throttle opening, each
machine’s pilot screw has been
individually set at the factory.
Before adjusting the pilot screw,
turn it in fully and count the num-
ber of turns. Record this number
as the factory-set number of turns
out.
Turn in the pilot screw until it is
lightly seated.
Turn out the pilot screw by the
factory-set number of turns.
Pilot screw:
2 turns out (example)
* 1-1/2 turns out
CONTROLE DE LA PRESSION
D’HUILE
1. Contrôler:
Pression d’huile
REGLAGE DE LA VIS DE
RICHESSE
1. Régler:
Vis de richesse 1
* Excepté USA Etapes du contrôle:
Desserrer légèrement le boulon 1
de contrôle de la pression d’huide.
Lancer le moteur et le laisser tour-
ner au ralenti jusqu’à ce que l’huile
commence à suinter au niveau du
boulon de la rampe de graissage. Si
l’huile ne sort pas après une
minute, arrêter le moteur pour évi-
ter qu’il ne grippe.
Vérifier les passages d’huile et la
pompe à huile pour voir s’il y a des
fuites ou des dégâts.
Mettre le moteur en marche après
avoir remédié au(x) problème(s) et
vérifier à nouveau la pression
d’huile.
Serrer le boulon de contrôle de la
pression d’huile au couple indiqué.
T R..
Boulon de contrôle de la
pression d’huile:
10 Nm
(1,0 m  kg, 7,2 ft  lb)
Etapes de réglage:
N.B.:
Afin d’optimiser le flux de carburant
à plus petite ouverture des gaz, la vis
de richesse de chaque véhicule a été
réglée individuellement à l’usine.
Avant de régler la vis de richesse, la
visser complètement en comptant le
nombre de tours exact. Noter ce chif-
fre et dévisser la vis de ce nombre de
tours.
Visser la vis de richesse jusqu’à ce
qu’elle touche légèrement son
siège.
Dévisser la vis de richesse du nom-
bre de tour réglé à l’usine.
Vis de richesse:
2 tours en arrière
(exemple)
* 1-1/2 tours en arrière
ENGINE
MOTEUR

3 - 63
INSP
ADJ
SPARK ARRESTER CLEANING
(For USA)
WARNING
Be sure the exhaust pipe and
muffler are cool before cleaning
the spark arrester.
Do not start the engine when
cleaning the exhaust system.
1. Remove:
Bolt (spark arrester)
1
1
1
2. Remove:
Spark arrester
1
Pull the spark arrester out of
the muffler.
1
3. Clean:
Spark arrester
Tap the spark arrester lightly,
then use a wire brush to
remove any carbon deposits.
4. Install:
Spark arrester
Insert the spark arrester into
the muffler and align the bolt
holes.
Bolt (spark arrester)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
NETTOYAGE DU PARE-
ETINCELLES (USA)
AVERTISSEMENT
Le tuyau et le pot d’échappement
doivent être froids au moment du
nettoyage du pare-étincelles.
Ne pas mettre le moteur en marche
pendant le nettoyage du système
d’échappement.
1. Déposer:
Boulon (pare-étincelles) 1
2. Déposer:
Pare-étincelles 1
Extraire le pare-étincelles du pot
d’échappement.
3. Nettoyer:
Pare-étincelles
Tapoter légèrement le pare-étin-
celles, puis éliminer tout dépôt de
calamine à l’aide d’une brosse
métallique.
4. Monter:
Pare-étincelles
Insérer le pare-étincelles dans le
pot d’échappement et aligner les
orifices de boulon.
Boulon (pare-étincelles)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
ENGINE
MOTEUR