2004 YAMAHA WR 250F width

GENERAL SPECIFICATIONS
2 - 1
SPEC
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR250FS (USA)
WR250F (EUROPE)
WR250F(S) (CDN, AUS, NZ, ZA)
Model code number: 5UM5 (USA)
5UM6 (EUROPE)
5UM7 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,165 mm (85.2 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 998 mm (39.3 in)
Wheelbase 1,475 mm (58.1 in)
Minimum ground clearance 382 mm (15.0 in)
Dry weight:
Without oil and fuel 105.5 kg (232.6 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
3 (8.76 Imp oz, 8.42 US oz)
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 12.5 : 1
Starting system Kick and electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
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)
(Except for USA and CDN)
API “SG” or higher grade
-20
-4-10
140
3010
5020
6830
8640 50
104
122˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40
2

MAINTENANCE SPECIFICATIONS
2 - 5
SPEC
Timing chain:
Timing chain type/No. of links 92RH2010-114M/114 ----
Timing chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)----
EX 0.17 ~ 0.22 mm
(0.0067 ~ 0.0087 in)----
Valve dimensions:
“A” head diameter IN 22.9 ~ 23.1 mm
(0.9016 ~ 0.9094 in)----
EX 24.4 ~ 24.6 mm
(0.9606 ~ 0.9685 in)----
“B” face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089 in) ----
“C” seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
“D” margin thickness IN 0.8 mm (0.0315 in) ----
EX 0.7 mm (0.0276 in) ----
Stem outside diameter IN 3.975 ~ 3.990 mm
(0.1565 ~ 0.1571 in)3.945 mm
(0.1553 in)
EX 4.460 ~ 4.475 mm
(0.1756 ~ 0.1762 in)4.430 mm
(0.1744 in)
Guide inside diameter IN 4.000 ~ 4.012 mm
(0.1575 ~ 0.1580 in)4.050 mm
(0.1594 in)
EX 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)4.550 mm
(0.1791 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)0.08 mm
(0.003 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)0.10 mm
(0.004 in) Item Standard Limit
BC
DA
Head diameter Face width Seat width Margin thickness

MAINTENANCE SPECIFICATIONS
2 - 6
SPEC
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 37.81 mm (1.49 in) 36.81 mm
(1.45 in)
EX 37.54 mm (1.48 in) 36.54 mm
(1.44 in)
Set length (valve closed) IN 29.13 mm (1.15 in) ----
EX 29.30 mm (1.15 in) ----
Compressed force (installed) IN 99 ~ 114 N at 29.13 mm
(9.9 ~ 11.4 kg at 29.13 mm,
22.27 ~ 25.57 lb at 1.15 in)----
EX 126 ~ 144 N at 29.30 mm
(12.6 ~ 14.4 kg at 29.30 mm,
28.44 ~ 32.41 lb at 1.15 in)----
Tilt limit IN ----
2.5°/ 1.7 mm
(2.5°/0.067 in)
EX ----2.5°/1.6 mm
(2.5°/0.063 in)
Direction of winding (top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”76.955 ~ 76.970 mm
(3.0297 ~ 3.0303 in)----
Measuring point “H”8 mm (0.31 in) ----
Piston off-set 0.5 mm (0.020 in)/IN-side ----Item Standard Limit
*
H
D

MAINTENANCE SPECIFICATIONS
2 - 7
SPEC
Piston pin bore inside diameter 16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)16.043 mm
(0.6316 in)
Piston pin outside diameter 15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ----
End gap (installed) 0.15 ~ 0.25 mm
(0.006 ~ 0.010 in)0.50 mm
(0.020 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ----
End gap (installed) 0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)0.80 mm
(0.031 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ----
End gap (installed) 0.10 ~ 0.40 mm
(0.004 ~ 0.016 in)----
Crankshaft:
Crank width “A”55.95 ~ 56.00 mm
(2.203 ~ 2.205 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F”0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in) Item Standard Limit
T
B
B
T
B
T

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

4 - 63
ENGCAMSHAFTS
4. Measure:
Camshaft-to-cap clearance
Out of specification
→ Mea-
sure camshaft outside diame-
ter.
5. Measure:
Camshaft outside diameter
a
Out of specification
→
Replace the camshaft.
Within specification
→
Replace camshaft case and
camshaft caps as a set.
Camshaft-to-cap
clearance:
0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)
:
0.08 mm (0.003 in)
Measurement steps:
Install the camshaft onto the
cylinder head.
Position a strip of Plastigauge
®
1 onto the camshaft.
Install the clip, dowel pins and
camshaft caps.
T R..
Bolt (camshaft cap):
10 Nm
(1.0 m  kg, 7.2 ft  lb)
NOTE:Tighten the bolts (camshaft
cap) in a crisscross pattern from
innermost to outer caps.
Do not turn the camshaft when
measuring clearance with the
Plastigauge®.
Remove the camshaft caps and
measure the width of the Plasti-
gauge
®
1.
Camshaft outside
diameter:
21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)
Camshaft sprocket
1. Inspect:
Camshaft sprocket
1
Wear/damage
→ Replace the
camshaft assembly and tim-
ing chain as a set.
4. Mesurer:
Jeu entre arbre à cames et cha-
peau
Hors spécifications → Mesurer le
diamètre extérieur de l’arbre à
cames.
5. Mesurer:
Diamètre extérieur d’arbre à
cames a
Hors spécifications → Remplacer
l’arbre à cames.
Dans les limites spécifiées →
Remplacer le carter d’arbre à
cames et les chapeaux d’arbre à
cames en un ensemble.
Jeu entre arbre à cames et
chapeau:
0,020 à 0,054 mm
(0,0008 à 0,0021 in)
:
0,08 mm (0,003 in)
Etapes de la mesure:
Installer l’arbre à cames sur la
culasse.
Placer une bande de Plastigauge
®
1 sur l’arbre à cames.
Installer le circlip, les goujons et
les chapeaux d’arbre à cames.
T R..
Boulon (chapeau d’arbre à
cames):
10 Nm
(1,0 m  kg, 7,2 ft  lb)
N.B.:
.Serrer les boulons (chapeau
d’arbre à cames) dans un ordre
entrecroisé, en commençant par
ceux situés au centre.
Ne pas faire tourner l’arbre à
cames pendant la mesure du jeu
avec le Plastigauge®.
Enlever les chapeaux d’arbre à
cames et mesurer la largeur 1 du
Plastigauge
®.
Diamètre extérieur d’arbre
à cames:
21,967 à 21,980 mm
(0,8648 à 0,8654 in)
Pignon d’arbre à cames
1. Contrôler:
Pignon d’arbre à cames 1
Usure/endommagement → Rem-
placer l’ensemble pignon d’arbre
à cames et chaîne de distribution.
ARBRES A CAMES

4 - 85
ENGVALVES AND VALVE SPRINGS
REMOVAL POINTS
Valve lifter and valve cotter
1. Remove:
Valve lifter
1
Pad
2
NOTE:Identify each lifter
1 and pad
2
position very carefully so that they
can be reinstalled in their original
place.
2. Check:
Valve sealing
Leakage at the valve seat
→
Inspect the valve face, valve
seat and valve seat width.
Checking steps:
Pour a clean solvent
1 into the
intake and exhaust ports.
Check that the valve seals
properly.
There should be no leakage at
the valve seat
2.
3. Remove:
Valve cotter
NOTE:Attach a valve spring compressor
1
between the valve spring retainer
and the cylinder head to remove the
valve cotters.
Valve spring
compressor:
YM-4019/90890-04019
POINTS DE DEPOSE
Poussoir de soupape et clavette de
soupape
1. Déposer:
Poussoir de soupape 1
Cale 2
N.B.:
Identifier minutieusement chacun des
poussoirs 1 et des cales de soupape 2
de façon à les remonter à leur position
d’origine.
2. Contrôler:
Joint d’étanchéité des soupapes
Fuite au siège de soupape → Exa-
miner la face de soupape, le siège
de soupape et la largeur du siège
de soupape.
Etapes de la contrôler:
Verser du dissolvant propre 1
dans les lumières d’admission et
d’échappement.
Vérifier l’étanchéité de la soupape.
Il ne doit pas y avoir de fuite au
niveau du siège de soupape 2.
3. Déposer:
Clavette de soupape
N.B.:
Fixer le compresseur de ressort de sou-
pape 1 entre la retenue de ressort de
soupape et la culasse pour déposer les
clavettes de soupape.
Compresseur de ressort de
soupape:
YM-4019/90890-04019
SOUPAPES ET RESSORTS DE SOUPAPE

4 - 91
ENGVALVES AND VALVE SPRINGS
5. Measure:
Runout (valve stem)
Out of specification
→
Replace.
NOTE:When installing a new valve
always replace the guide.
If the valve is removed or replaced
always replace the oil seal.
6. Eliminate:
Carbon deposits
(from the valve face and valve
seat)
7. Inspect:
Valve seat
Pitting/wear
→ Reface the
valve seat.
Runout limit:
0.01 mm (0.0004 in)
8. Measure:
Valve seat width
a
Out of specification
→ Reface
the valve seat.
Valve seat width:
Intake:
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
:
1.6 mm (0.0630 in)
Exhaust:
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
:
1.6 mm (0.0630 in)
Measurement steps:
Apply Mechanic’s blueing dye
(Dykem)
b to the valve face.
Install the valve into the cylinder
head.
Press the valve through the
valve guide and onto the valve
seat to make a clear pattern.
Measure the valve seat width.
Where the valve seat and valve
face made contact, blueing will
have been removed.
If the valve seat is too wide, too
narrow, or the seat is not cen-
tered, the valve seat must be
refaced.
5. Mesurer:
Ovalisation (queue de soupape)
Hors spécifications → Rempla-
cer.
N.B.:
Remplacer toujours le guide lors de
l’installation d’une nouvelle soupape.
Remplacer toujours la bague d’étan-
chéité si la soupape est déposée ou
remplacée.
6. Eliminer:
Dépôt de calamine
(de la face de soupape et du siège
de soupape)
7. Contrôler:
Siège de soupape
Piqûres/usure → Surfacer le siège
de soupape.
Limite de déformation:
0,01 mm (0,0004 in)
8. Mesurer:
Largeur de siège de soupape a
Hors spécifications → Surfacer le
siège de soupape.
Largeur du siège de
soupape:
Admission:
0,9 à 1,1 mm
(0,0354 à 0,0433 in)
:
1,6 mm (0,0630 in)
Echappement:
0,9 à 1,1 mm
(0,0354 à 0,0433 in)
:
1,6 mm (0,0630 in)
Etapes de la mesure:
Appliquer du bleu de mécanicien
(Dykem) b sur la face de la sou-
pape.
Installer la soupape dans la culasse.
Presser la soupape à travers le
guide de soupape et sur le siège de
soupape de manière à laisser une
trace nette.
Mesurer la largeur du siège de sou-
pape. Le bleu aura disparu aux
endroits où la soupape et son siège
entrent en contact.
Si le siège de soupape est trop
large, trop étroit ou si le siège n’est
pas centré, il faut le surfacer.
SOUPAPES ET RESSORTS DE SOUPAPE