2004 YAMAHA WR 250F torque

5 - 85
CHASFRONT FORK
23. Install:
Cushion rubber
1
Washer
2
Spacer
3
To front fork cap bolt
4.
NOTE:Install the cushion rubber with its
smaller dia.end
a facing the front
fork cap bolt.
24. Install:
Push rod
1
Fork spring
2
NOTE:Install the fork spring with the
damper rod
3 pulled up.
After installing the fork spring, hold
the damper rod end so that it will
not go down.
25. Install:
Front fork cap bolt
1
Fully tighten the front fork cap
bolt onto the damper rod by
hand.
26. Tighten:
Front fork cap bolt (locknut)
1
NOTE:While compressing the fork spring,
set the thin type spanners
2
between the spacer
3 and spring
guide
4.
Hold the locknut
5 and tighten the
front fork cap bolt with specified
torque.
T R..29 Nm (2.9 m · kg, 21 ft · lb)
23. Monter:
Garniture en caoutchouc 1
Rondelle 2
Entretoise 3
Au bouchon de tube de fourche
4.
N.B.:
Installer la garniture en caoutchouc avec
le côté de plus faible diamètre a face au
bouchon de tube de fourche.
24. Monter:
Tige de commade 1
Ressort de fourche 2
N.B.:
Installer le ressort de fourche tout en
tirant sus la tige d’amortisseur 3.
Après avoir installé le ressort de four-
che, maintenir la tige d’amortisseur de
façon à ce qu’elle ne redescende pas.
25. Monter:
Bouchon de tube de fourche 1
Serrer à fond manuellement le
bouchon de tube de fourche sur la
tige d’amortisseur.
26. Serrer:
Bouchon de tube de fourche
(contre-écrou) 1
N.B.:
Tout en comprimant le ressort de four-
che, placer la clé à ergots fine 2 entre
l’entretoise 3 et le guide de ressort
4.
Maintenir le contre-écrou 5 et serrer
le bouchon de tube de fourche au cou-
ple de serrage spécifié.
T R..29 Nm (2,9 m · kg, 21 ft · lb)
FOURCHE AVANT

5 - 87
CHASFRONT FORK
27. Install:
Front fork cap bolt
1
To outer tube.
NOTE:Temporarily tighten the cap bolt.
28. Install:
Protector guide
1
Installation
1. Install:
Front fork
1
NOTE:Temporarily tighten the pinch bolts
(lower bracket).
Do not tighten the pinch bolts
(upper bracket) yet.
2. Tighten:
Front fork cap bolt
1
3. Adjust:
Front fork top end
a
* For AUS, NZ and ZA
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Front fork top end
(standard) a
:
5 mm (0.20 in)
* 10 mm (0.39 in)
4. Tighten:
Pinch bolt (upper bracket)
1
Pinch bolt (lower bracket)
2
CAUTION:
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
27. Monter:
Bouchon de tube de fourche 1
Sur le fourreau.
N.B.:
Serrer le bouchon de tube de fourche de
quelques tours.
28. Monter:
Guide de protection 1
Montage
1. Monter:
Fourche avant 1
N.B.:
Serrer provisoirement les boulons de
bridage (té inférieur).
Ne pas encore serrer les boulons de
bridage (té supérieur).
2. Serrer:
Bouchon de tube de fourche 1
3. Régler:
Sommet de bras de fourche avant
a
* AUS, NZ et ZA
T R..30 Nm (3,0 m · kg, 22 ft · lb)
Sommet de bras de fourche
avant (standard) a:
5 mm (0,20 in)
* 10 mm (0,39 in)
4. Serrer:
Boulon de bridage (té supérieur)
1
Boulon de bridage (té inférieur)
2
ATTENTION:
Serrer le té inférieur au couple spéci-
fié. S’il est serré trop fort, cela peut
entraîner le mauvais fonctionnement
de la fourche.
T R..23 Nm (2,3 m · kg, 17 ft · lb)
T R..20 Nm (2,0 m · kg, 14 ft · lb)
FOURCHE AVANT

5 - 117
CHASSTEERING
12. Tighten:
Pinch bolt (upper bracket)
1
Pinch bolt (lower bracket)
2
CAUTION:
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
13. Install:
Trip meter
1
Bolt (trip meter)
2
NOTE:Install the trip meter over the coupler
bracket
3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
12. Serrer:
Boulon de bridage
(té supérieur) 1
Boulon de bridage
(té inférieur) 2
ATTENTION:
Resserrer le té inférieur au couple spé-
cifié. S’il est trop serré, la fourche
avant pourrait mal fonctionner.
T R..23 Nm (2,3 m · kg, 17 ft · lb)
T R..20 Nm (2,0 m · kg, 14 ft · lb)
13. Monter:
Compteur de vitesse 1
Boulon (compteur de vitesse) 2
N.B.:
Installer le compteur de vitesse sur le
support de raccord 3.
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
DIRECTION

7 - 41
TUNSETTING
EC72H002Suspension setting
Front fork
NOTE:If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire rangeCompression damping
Oil level (oil amount)
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with soft spring.
Unsmooth movement
over entire rangeOuter tube
Inner tube
Under bracket tightening
torqueCheck for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Retighten to specified torque.
Poor initial
movementRebound damping
Oil sealTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Apply grease in oil seal wall.
Soft over entire
range, bottoming outCompression damping
Oil level (oil amount)
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with stiff spring.
Stiff toward stroke
endOil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming outOil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial movement Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front postureCompression damping
Rebound damping
Balance with rear end
Oil level (oil amount)Turn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in)
when one passenger is astride seat (lower rear
posture).
Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front,
tending to upper front
postureCompression damping
Balance with rear end
Spring
Oil lever (oil amount)Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in)
when one passenger is astride seat (upper rear
posture).
Replace with soft spring.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).