2004 YAMAHA WR 250F radiator

CHAPTER 4
ENGINE
SEAT, FUEL TANK AND SIDE
COVERS..................................... 4-1
EXHAUST PIPE AND
SILENCER.................................. 4-7
RADIATOR............................... 4-13
CARBURETOR........................ 4-21
CAMSHAFTS........................... 4-51
CYLINDER HEAD.................... 4-73
VALVES AND VALVE
SPRINGS.................................. 4-81
CYLINDER AND PISTON...... 4-101
CLUTCH................................. 4-117
OIL FILTER ELEMENT,
WATER PUMP AND RIGHT
CRANKCASE COVER........... 4-135
BALANCER............................ 4-151
OIL PUMP.............................. 4-159
KICK SHAFT AND
SHIFT SHAFT........................ 4-169
AC MAGNETO AND STARTER
CLUTCH................................. 4-185
ENGINE REMOVAL............... 4-207
CRANKCASE AND
CRANKSHAFT....................... 4-221
TRANSMISSION, SHIFT CAM
AND SHIFT FORK................. 4-245
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR
WHEEL....................................... 5-1
FRONT BRAKE AND
REAR BRAKE.......................... 5-23
FRONT FORK.......................... 5-61
HANDLEBAR........................... 5-91
STEERING............................. 5-103
SWINGARM........................... 5-119
REAR SHOCK ABSORBER.. 5-139
CHAPITRE 4
MOTEUR
SELLE, RESERVOIR DE
CARBURANT ET CACHES
LATERAUX..................................... 4-2
TUYAU D’ECHAPPEMENT ET
SILENCIEUX................................... 4-8
RADIATEUR................................. 4-14
CARBURATEUR.......................... 4-22
ARBRES A CAMES...................... 4-52
CULASSE....................................... 4-74
SOUPAPES ET RESSORTS DE
SOUPAPE....................................... 4-82
CYLINDRE ET PISTON............ 4-102
EMBRAYAGE............................. 4-118
ELEMENT DE FILTRE A
HUILE, POMPE A EAU ET
DEMI-CARTER DROIT............ 4-136
BALANCIER............................... 4-152
POMPE A HUILE....................... 4-160
ARBRE DE KICK ET
ARBRE DE SELECTEUR.......... 4-170
MAGNETO CA ET
ROCHET DE DEMARRAGE ... 4-186
DEPOSE DU MOTEUR.............. 4-208
CARTER ET VILEBREQUIN... 4-222
BOITE A VITESSES,
TAMBOUR ET FOURCHETTES
DE SELECTION.......................... 4-246
CHAPITRE 5
PARTIE CYCLE
ROUE AVANT ET ROUE
ARRIERE......................................... 5-2
FREIN AVANT ET FREIN
ARRIERE....................................... 5-24
FOURCHE AVANT...................... 5-62
GUIDON......................................... 5-92
DIRECTION................................ 5-104
BRAS OSCILLANT.................... 5-120
AMORTISSEUR ARRIERE...... 5-140

KAPITEL 4
MOTOR
SITZBANK, KRAFTSTOFFTANK
UND SEITENABDECKUNGEN... 4-2
KRÜMMER UND
SCHALLDÄMPFER.................... 4-8
KÜHLER.................................... 4-14
VERGASER............................... 4-22
NOCKENWELLE....................... 4-52
ZYLINDERKOPF....................... 4-74
VENTILE UND
VENTILFEDERN....................... 4-82
ZYLINDER UND KOLBEN...... 4-102
KUPPLUNG............................. 4-118
ÖLFILTEREINSATZ,
WASSERPUMPE UND
RECHTE KURBELWELLENAB-
DECKUNG............................... 4-136
AUSGLEICHSWELLE............. 4-152
ÖLPUMPE............................... 4-160
KICKSTARTER UND
KICKSTARTERWELLE.......... 4-170
AC-MAGNETZÜNDER UND
STARTERKUPPLUNG ........... 4-186
MOTOR DEMONTIEREN........ 4-208
KURBELGEHÄUSE UND
KURBELWELLE..................... 4-222
GETRIEBE, SCHALTWALZE
UND SCHALTGABELN.......... 4-246
KAPITEL 5
FAHRWERK
VORDER- UND HINTERRAD..... 5-2
VORDER- UND
HINTERRADBREMSE.............. 5-24
TELESKOPGABEL................... 5-62
LENKER.................................... 5-92
LENKKOPF............................. 5-104
SCHWINGE............................. 5-120
FEDERBEIN............................ 5-140
CAPITOLO 4
MOTORE
SELLA, SERBATOIO
CARBURANTE E
CARENATURA LATERALE....... 4-3
TUBO DI SCARICO E
SILENZIATORE............................ 4-9
RADIATORE................................ 4-15
CARBURATORE.......................... 4-23
ALBERI A CAMME..................... 4-53
TESTATA DEL CILINDRO....... 4-75
VALVOLE E MOLLE
VALVOLE..................................... 4-83
CILINDRO E PISTONE............ 4-103
FRIZIONE................................... 4-119
ELEMENTO FILTRANTE
DELL’OLIO, POMPA
DELL’ACQUA E COPERCHIO
CARTER DESTRO ................... 4-137
BILANCIERE............................. 4-153
POMPA DELL’OLIO................ 4-161
ALBERO PEDALE E
ALBERO DEL CAMBIO........... 4-171
MAGNETE CA E FRIZIONE
DELLO STARTER..................... 4-187
RIMOZIONE DEL MOTORE.. 4-209
CARTER E ALBERO
MOTORE..................................... 4-223
TRASMISSIONE, CAMMA
DEL CAMBIO E FORCELLA
DEL CAMBIO............................. 4-247
CAPITOLO 5
PARTE CICLISTICA
RUOTA ANTERIORE E
RUOTA POSTERIORE................. 5-3
FRENO ANTERIORE E
POSTERIORE............................... 5-25
FORCELLA ANTERIORE......... 5-63
MANUBRIO.................................. 5-93
STERZO....................................... 5-105
FORCELLONE
OSCILLANTE............................. 5-121
AMMORTIZZATORE
POSTERIORE............................. 5-141
CAPÍTULO 4
MOTOR
ASIENTO, DEPÓSITO DE
COMBUSTIBLE Y CUBIERTAS
LATERALES............................... 4-4
TUBO DE ESCAPE Y
SILENCIADOR.......................... 4-10
RADIADOR................................ 4-16
CARBURADOR......................... 4-24
ÁRBOLES DE LEVAS.............. 4-54
CULATA.................................... 4-76
VÁLVULAS Y MUELLES DE
VÁLVULA.................................. 4-84
CILINDRO Y PISTÓN.............. 4-104
EMBRAGUE............................ 4-120
ELEMENTO DEL FILTRO DE
ACEITE, BOMBA DE AGUA Y
CUBIERTA DEL CÁRTER
DERECHA............................... 4-138
COMPENSADOR.................... 4-154
BOMBA DE ACEITE............... 4-162
EJE DEL PEDAL Y EJE DE
CAMBIOS................................ 4-172
MAGNETO DE CA Y
EMBRAGUE DEL
ARRANCADOR ...................... 4-188
EXTRACCIÓN DEL MOTOR... 4-210
CÁRTER Y CIGÜEÑAL........... 4-224
CAJA DE CAMBIOS,
LEVA DE CAMBIOS Y
HORQUILLA DE CAMBIOS.... 4-248
CAPÍTULO 5
CHASIS
RUEDA DELANTERA Y
RUEDA TRASERA...................... 5-4
FRENO DELANTERO Y
FRENO TRASERO.................... 5-26
HORQUILLA DELANTERA...... 5-64
MANILLAR................................ 5-94
DIRECCIÓN............................. 5-106
PALANCA OSCILANTE.......... 5-122
AMORTIGUADOR
TRASERO............................... 5-142

1 - 1
GEN
INFODESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Engine stop switch
4Trip meter
5Main switch
6Start switch
7Front brake lever
8Throttle grip
9Radiator cap
0Fuel tank cap
ATaillight
BKickstarter crank
CFuel tank
DHeadlight
ERadiator
FCoolant drain bolt
GRear brake pedal
HValve joint
IFuel cock
JCold starter knob
KAir cleaner
LDrive chain
MShift pedal
NOil dipstick
OFront 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.
A
BCD
E
F G
HIJK
L M
N O
1234
5
6
7
8
9 0
RENSEIGNEMENTS GENERAUX
DESCRIPTION
1Levier d’embrayage
2Levier de démarreur à chaud
3Coupe-circuit du moteur
4Compteur de vitesse
5Commutateur principal
6Commutateur de démarrage
7Levier de frein avant
8Poignée des gaz
9Bouchon de radiateur
0Bouchon de réservoir de carburant
ALampe arrière
BPedale de kick
CRéservoir de carburant
DPhare
ERadiateur
FBoulon de vidange du liquide de refroidissement
GPédale de frein arrière
HClapet de durit de mise a liair
IRobinet de carburant
JBouton de démarrage à froid
KFiltre à air
LChaîne de transmission
MPédale de sélecteur
NJauge de niveau d’huile
OFourche 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

1 - 2
GEN
INFO
ALLGEMEINE
ANGABEN
FAHRZEUGBESCHREI-
BUNG
1Kupplungshebel
2Heißstarterhebel
3Motorstoppschalter
4Tageskilometerzähler
5Zündschalter
6Startschalter
7Handbremshebel
8Gasdrehgriff
9Kühlerverschlußdeckel
0Kraftstoffankverschluß
ARücklicht
BKickstarterhebel
CKraftstofftank
DScheinwerfer
EKühler
FKühlmittel-Ablaßschraube
GFußbremshebel
HAuslaufschutzventil
IKraftstoffhahn
JKaltstarterknopf
KLuftfilter
LAntriebskette
MFußschalthebel
NÖlmeßstab
OTeleskopgabel
HINWEIS:
Leichte Modell-Abweichungen
möglich.
Änderungen an Design und techni-
schen Daten jederzeit vorbehalten.
INFORMAZIONI
GENERALI
DESCRIZIONE
1Leva della frizione
2Leva dell’avviamento a caldo
3Interruttore di arresto motore
4Contachilometri parziale
5Interruttore principale
6Interruttore di avviamento
7Leva del freno anteriore
8Manopola dell’acceleratore
9Tappo del radiatore
0Tappo del serbatoio del carburante
AFanalino posteriore
BPedivella di avviamento
CSerbatoio del carburante
DFaro
ERadiatore
FBullone di scarico del refrigerante
GPedale del freno posteriore
HGiunto a valvola
IRubinetto del carburante
JManopola di avviamento a freddo
KFiltro aria
LCatena di trasmissione
MPedale del cambio
NAstina dell’olio
OForcella anteriore
NOTA:
Il veicolo acquistato potrebbe differire
leggermente da quelli illustrati qui di
seguito.
I modelli e le specifiche sono soggetti
a variazioni senza preavviso.
INFORMACIÓN
GENERAL
DESCRIPCIÓN
1Palanca del embrague
2Palanca de arranque en caliente
3Botón de parada del motor
4Medidor de trayecto
5Interruptor principal
6Interruptor de arranque
7Palanca del freno delantero
8Empuñadura del acelerador
9Tapa del radiador
0Tapa del depósito de combustible
APiloto trasero
BPedal de arranque
CDepósito de combustible
DFaro
ERadiador
FPerno de drenaje del refrigerante
GPedal del freno trasero
HJunta de la válvula
IGrifo de combustible
JPomo de arranque en frío
KDepurador de aire
LCadena de la caja de cambios
MPedal de cambios
NVarilla del nivel de aceite
OHorquilla delantera
NOTA:
El vehículo que ha adquirido
puede diferir ligeramente de los
que se muestran a continuación.
Los diseños y las especificaciones
están sujetos a modificaciones sin
previo aviso.
FAHRZEUGBESCHREIBUNG
DESCRIZIONE
DESCRIPCIÓN
1
2
3
4
5
6
7

1 - 11
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool
will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used
for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an
order.
NOTE:For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1135-A, 90890-01135 Crankcase separating tool
These tool is used to remove the crankshaft from
either case.
YU-3097, 90890-01252
YU-1256Dial gauge and stand
Stand
These tools are used to check each part for runout or
bent.
YU-90050, 90890-01274
YU-90050, 90890-01275
YM-91044, 90890-04081
YU-90063, 90890-01278Crankshaft installing tool
Crankshaft installing pot
Crankshaft installing bolt
Spacer (crankshaft installer)
Adapter (M12)
These tools are used to install the crankshaft.
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.
YU-24460-01, 90890-01325
YU-33984, 90890-01352Radiator cap tester
Radiator cap tester adapter
These tools are used for checking the cooling
system.
YU-33975, 90890-01403 Steering nut wrench
This tool is used when tighten the steering ring nut to
specification.
YM-1423, 90890-01423 Damper rod holder
Use this tool to remove and install the damper rod.
YM-01442, 90890-01442 Fork seal driver
This tool is used when install the fork oil seal.

1 - 20
GEN
INFO
UTENSILI SPECIALI
Sono necessari idonei utensili speciali per una messa a punto e un assemblaggio completi e accurati. L’impiego dell’attrezzo speciale
adatto aiuterà a prevenire eventuali danni causati dall’impiego di utensili non idonei o di tecniche improvvisate. La forma e il numero
di pezzo utilizzato per l’attrezzo speciale differiscono da paese a paese, pertanto ne vengono indicati due tipi. Fare riferimento
all’elenco fornito onde evitare errori quando si effettua un’ordinazione.
NOTA:
Per USA e CDN, utilizzare il numero di pezzo che comincia con “YM-”, “YU-” o “ACC-”.
Per gli altri, utilizzare il numero di pezzo che comincia con “90890-”.
Numero di pezzo Nome dell’attrezzo/Come utilizzarlo Figura
YU-1135-A, 90890-01135 Utensile per la separazione del carter
Questo attrezzo è utilizzato per disaccoppiare i due
semicarter.
YU-3097, 90890-01252
YU-1256Comparatore e supporto
Supporto
Questi strumenti sono usati per controllare ciascuna parte
per usura o deviazioni.
YU-90050, 90890-01274
YU-90050, 90890-01275
YM-91044, 90890-04081
YU-90063, 90890-01278Utensile per il montaggio dell’albero motore
Contenitore per il montaggio dell’albero motore
Bullone per il montaggio dell’albero motore
Distanziatore (dispositivo di installazione dell’albero motore)
Adattatore (M12)
Questi utensili sono utilizzati per installare l’albero motore.
YU-1304, 90890-01304 Kit estrattore dello spinotto pistone
Questo attrezzo è utilizzato per rimuovere gli spinotti.
YU-24460-01, 90890-01325
YU-33984, 90890-01352Tester del tappo radiatore
Adattatore del tester tappo radiatore
Questi utensili sono utilizzati per il controllo del sistema di
raffreddamento.
YU-33975, 90890-01403 Chiave per ghiere
Questo attrezzo è utilizzato per serrare le ghiere fino ai
valori indicati nelle specifiche.
YM-1423, 90890-01423 Utensile di blocco dell’asta ammortizzatore
Utilizzare questo attrezzo per rimuovere ed installare l’asta
dell’ammortizzatore.
YM-01442, 90890-01442 Utensile per il paraolio della forcella
Questo attrezzo è utilizzato per installare il paraolio della
forcella.
UTENSILI SPECIALI

MAINTENANCE SPECIFICATIONS
2 - 9
SPEC
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 220 mm (8.7 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

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 28 2.8 20
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 8 0.8 5.8
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