2006 YAMAHA WR 250F warning

4 - 215
ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the suitable
stand under the frame.
WARNING
Support the machine securely so there is nodanger of it falling over.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in
the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”
section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section.
Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM” section.
Clutch cable Disconnect at the engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH”
section.
Cylinder head breather hose and oil tank
breather hoseRefer to “CAMSHAFTS” section.

5 - 1
CHASFRONT WHEEL AND REAR WHEEL
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000FRONT WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable
stand under the engine.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Oil seal 1
8 Bearing 2 Refer to “REMOVAL POINTS”.
9 Brake disc 1
1
2
3
3

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC598100REAR WHEEL
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable
stand under the engine.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10 Brake disc 1
1
2
3
3

5 - 11
CHASFRONT WHEEL AND REAR WHEEL
EC514200Wheel axle
1. Measure:
Wheel axle bends
Out of specification
→
Replace.
Use the dial gauge
1.
NOTE:The bending value is shown by one
half of the dial gauge reading.
WARNING
Do not attempt to straighten a
bent axle.
Wheel axle bending
limit:
0.5 mm (0.020 in)
EC594200Brake disc
1. Measure:
Brake disc deflection
(only rear brake disc)
Use the dial gauge
1.
Out of specification
→ Inspect
wheel runout.
If wheel runout is in good con-
dition, replace the brake disc.
2. Measure:
Brake disc thickness
a
Out of limit
→ Replace.
Brake disc deflection
limit:
Rear:
:
0.15 mm (0.006 in)
Brake disc thickness:
Front:
3.0 mm (0.12 in)
:
2.5 mm (0.10 in)
Rear:
4.0 mm (0.16 in)
:
3.5 mm (0.14 in)
Axe de roue
1. Mesurer:
Déformations de l’axe de roue
Hors spécifications → Rempla-
cer.
Utiliser le comparateur à cadran
1.
N.B.:
La valeur de flexion est égale à la moitié
de la valeur affichée sur le comparateur à
cadran.
AVERTISSEMENT
Ne pas tenter de redresser un axe
déformé.
Limite de flexion d’axe de
roue:
0,5 mm (0,020 in)
Disque de frein
1. Mesurer:
Déflexion du disque de frein
(disque de frein arrière unique-
ment)
Utiliser le comparateur à cadran
1.
Hors spécifications → Contrôler
le voile de roue.
Si le voile de roue est normal,
remplacer le disque de frein.
2. Mesurer:
Epaisseur du disque de frein a
Hors spécifications → Rempla-
cer.
Limite de déflexion du
disque de frein:
Arrière:
:
0,15 mm (0,006 in)
Epaisseur du disque de
frein:
Avant:
3,0 mm (0,12 in)
:
2,5 mm (0,10 in)
Arrière:
4,0 mm (0,16 in)
:
3,5 mm (0,14 in)
ROUE AVANT ET ROUE ARRIERE

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000FRONT BRAKE
Extent of removal:
1 Brake hose removal
2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
FRONT BRAKE REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable
stand under the engine.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake hose holder (protector) 2
2 Brake hose holder (brake caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6 Pad pin 1 Loosen when disassembling the brake caliper.
7 Brake caliper 1
8 Brake lever 1
9 Brake master cylinder bracket 1
10 Brake master cylinder 1
12
2
3
3

5 - 27
CHASFRONT BRAKE AND REAR BRAKE
EC5A8100REAR BRAKE
Extent of removal:
1 Brake master cylinder removal
2 Brake hose removal
3 Brake caliper removal
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable
stand under the engine.
Rear wheel Refer to “FRONT WHEEL AND REAR WHEEL”
section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the brake caliper.
8 Brake caliper 1
1
13
3
2

5 - 39
CHASFRONT BRAKE AND REAR BRAKE
EC5A3000REMOVAL POINTS
Brake fluid
1. Remove:
[Front]
Brake master cylinder cap
1
[Rear]
Brake master cylinder cap
1
Protector
NOTE:Do not remove the diaphragm.
ÈFront
ÉRear
È
É
2. Connect the transparent hose
2
to the bleed screw
1 and place a
suitable container under its end.
ÈFront
ÉRear
3. Loosen the bleed screw and
drain the brake fluid while pulling
the lever in or pushing down on
the pedal.
CAUTION:
Do not reuse the drained brake
fluid.
Brake fluid may erode painted
surfaces or plastic parts. Always
clean up spilled fluid immedi-
ately.
É È
Brake caliper piston
1. Remove:
Brake caliper piston
Use compressed air and pro-
ceed carefully.
WARNING
Cover piston with rag and use
extreme caution when expelling
piston from cylinder.
Never attempt to pry out piston.
ÈFront
ÉRear
Caliper piston removal steps:
Insert a piece of rag into the
brake caliper to lock one brake
caliper.
Carefully force the piston out of
the brake caliper cylinder with
compressed air.
È
É
POINTS DE DEPOSE
Liquide de frein
1. Déposer:
[Avant]
Couvercle de maître-cylindre de
frein 1
[Arrière]
Couvercle de maître-cylindre de
frein 1
Protection
N.B.:Ne pas déposer le diaphragme.
È
Avant
É
Arrière
2. Raccorder le tuyau transparent 2 à
la vis de purge 1 et placer un réci-
pient adéquat sous son extrémité.
È
Avant
É
Arrière
3. Desserrer la vis de purge et purger
le liquide de frein tout en pressant le
levier ou en appuyant sur la pédale.
ATTENTION:
Ne pas réutiliser le liquide de frein
purgé.
Le liquide de frein peut attaquer les
surfaces peintes et les pièces en plas-
tique. Toujours essuyer immédiate-
ment toute trace de liquide renversé.
Piston d’étrier de frein
1. Déposer:
Piston d’étrier de frein
Utiliser de l’air comprimé et pro-
céder prudemment.
AVERTISSEMENT
Recouvrir le piston d’un chiffon et
faire très attention au moment où le
piston est éjecté du cylindre.
Ne jamais chasser le cylindre du pis-
ton en faisant levier.
È
Avant
É
Arrière
Etapes de la dépose du piston
d’étrier:
Insérer un morceau de tissu dans
l’étrier de frein pour bloquer le pis-
ton.
Libérer prudemment le piston du
cylindre d’étrier de frein en insuf-
flant de l’air comprimé.
FREIN AVANT ET FREIN ARRIERE

5 - 41
CHASFRONT BRAKE AND REAR BRAKE
Brake caliper piston seal kit
1. Remove:
Dust seal
1
Piston seal
2
NOTE:Remove the piston seals and dust
seals by pushing them with a finger.
CAUTION:
Never attempt to pry out piston
seals and dust seals.
WARNING
Replace the piston seals and dust
seals whenever a caliper is disas-
sembled.
ÈFront
ÉRear
È
É
EC5A4000INSPECTION
Brake master cylinder
1. Inspect:
Brake master cylinder inner
surface
a
Wear/scratches
→ Replace
master cylinder assembly.
Stains
→ Clean.
WARNING
Use only new brake fluid.
ÈFront
ÉRear
É È
2. Inspect:
Diaphragm
1
Crack/damage
→ Replace.
ÈFront
ÉRear
É È
3. Inspect: (front brake only)
Reservoir float
1
Damage
→ Replace.
Kit de joint de piston d’étrier de frein
1. Déposer:
Joint antipoussière 1
Joint de piston 2
N.B.:
Déposer les joints de piston et antipous-
sière en les poussant avec le doigt.
ATTENTION:
Ne jamais chasser les joints de piston
et antipoussière hors du cylindre.
AVERTISSEMENT
En cas de démontage d’un étrier, tou-
jours remplacer les joints de piston et
antipoussière.
È
Avant
É
Arrière
CONTROLE
Maître-cylindre de frein
1. Contrôler:
Surface interne du maître-cylin-
dre de frein
a
Usure/rayures → Remplacer
l’ensemble maître-cylindre.
Taches → Nettoyer.
AVERTISSEMENT
Utiliser uniquement du liquide de
frein neuf.
È
Avant
É
Arrière
2. Contrôler:
Diaphragme 1
Craquelures/endommagement →
Remplacer.
È
Avant
É
Arrière
3. Contrôler: (frein avant seulement)
Flotteur du réservoir 1
Endommagement → Remplacer.
FREIN AVANT ET FREIN ARRIERE