2006 YAMAHA WR 250F brake sensor

SPEC
2 - 97
CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Clamp
4Diode
5Wire harness
6Hot starter cable
7Cylinder head breather hose
8Throttle position sensor lead
9Neutral switch lead
0Oil hoseAClutch cable
BStarter motor lead
CNegative battery lead
DCable guide
EBrake hose
FRectifier/regulator lead
GAC magneto lead
HRectifier/regulator
ICarburetor breather hoseJCarburetor overflow hose
KCoolant reservoir breather hose
ÈInsert the fuel tank breather hose into
the hole in the steering stem cap.
ÉPass the oil tank breather hose on the
outside of the AC magneto lead, neu-
tral switch lead, wire harness, starter
motor lead, negative battery lead and
cylinder head breather hose.
B
B
B-B
A
Ô3B
Ó3 Ö
C
× EF
9
GÙ
H
Ú
Û
1
È
3
Ê
4
Ë
5
6
7 Ì
ÍÎ
Ï
Ñ Ð
8
0 3
ÒÜ II
JK
9 A 2
É
0
9A
ØD ØD
Õ

SPEC
2 - 111
CABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Brake hose
4Hot starter cable
5Clutch cable
6Hose guide
7Speed sensor lead
8Main switch lead
9Main switch
0Multi-function display
AStart switch lead
BClutch switch lead
CEngine stop switch lead
DMulti-function display leadÈFasten the start switch lead to the han-
dlebar with the plastic bands.
ÉFasten the engine stop switch lead and
clutch switch lead to the handlebar with
the plastic bands.
ÊPass the brake hose through the hose
guides.
ËSecure the coupler by inserting it into
the multi-function display bracket.
ÌPass the main switch lead above the
multi-function display bracket.
ÍPass the throttle cables, clutch cable
and hot starter cable between the upper
bracket and multi-function display
bracket.ÎPass the multi-function display lead and
speed sensor lead between the multi-
function display and multi-function dis-
play bracket.
ÏSecure the coupler by pushing it into
the hole in the multi-function display
bracket.
ÐFasten the clutch switch lead and
engine stop switch lead to the multi-
function display bracket and cut off the
tie end. Fasten them at a location
where the tie end does not contact the
multi-function display.
ÑSecure the wire harness clip by pushing
it into the hole in the multi-function dis-
play bracket on the inside.
4
5
Î
Ê Ó
A
B
F-FE-E
CD
A
D
7 7
2
Ò Ë
A
12
È32
É
6
Ê
6
8
Ì0
9
ËÑ C
BÏ
2
Ð 8
8
1Í
4
5
4
5B2
C
DC BB A
F F
EE
EE
Ë
2

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 - 13
CHASFRONT WHEEL AND REAR WHEEL
EC595000ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
Bearing (left)
1
Spacer
2
Bearing (right)
3
Oil seal
4
NOTE:Apply the lithium soap base grease
on the bearing and oil seal lip
when installing.
Use a socket that matches the out-
side diameter of the race of the
bearing.
Left side of bearing shall be
installed first.
Install the oil seal with its manufac-
ture’s marks or numbers facing
outward.
CAUTION:
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
New
2. Install:
Brake disc
1
Bolt (brake disc)
2
NOTE:Tighten the bolts in stage, using a
crisscross pattern.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Collar
1
NOTE:Apply the lithium soap base grease
on the oil seal lip.
4. Install:
Speed sensor
1
NOTE:Apply the lithium soap base grease
on the oil seal lip of the speed sen-
sor.
Make sure the two projections
a in
the wheel hub are meshed with the
two slots
b in the speed sensor.
b a1
B
ASSEMBLAGE ET MONTAGE
Roue avant
1. Monter:
Roulement (gauche) 1
Entretoise 2
Roulement (droit) 3
Bague d’étanchéité 4
N.B.:
Appliquer de la graisse à savon de
lithium sur le roulement et la lèvre de
la bague d’étanchéité lors du montage.
Utiliser une douille de même diamètre
que le diamètre extérieur de la cage du
roulement.
Monter d’abord le roulement de gau-
che.
Monter la bague d’étanchéité en posi-
tionnant vers l’extérieur la marque ou
le numéro du fabricant.
ATTENTION:
Ne pas frapper sur la cage interne du
roulement. Le contact ne peut avoir
lieu qu’avec la cage externe.
New
2. Monter:
Disque de frein 1
Boulon (disque de frein) 2
N.B.:
Serrer les boulons par étapes et en procé-
dant en croix.
T R..12 Nm (1,2 m · kg, 8,7 ft · lb)
3. Monter:
Entretoise épaulée 1
N.B.:
Appliquer de la graisse à savon de
lithium sur la lèvre de la bague d’étan-
chéité.
4. Monter:
Capteur de vitesse 1
N.B.:
Appliquer de la graisse à base de
savon au lithium sur la lèvre de bague
d’étanchéité du capteur de vitesse.
Veiller à ce que les deux ergots a du
moyeu de roue s’engrènent dans les
deux fentes b du capteur de vitesse.
ROUE AVANT ET ROUE ARRIERE

5 - 15
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
Wheel
NOTE:Install the brake disc
1 between
the brake pads
2 correctly.
Make sure that the projections
a
in the speed sensor fits over the
stopper
b on the front fork inner
tube.
6. Install:
Wheel axle
1
NOTE:Apply the lithium soap base grease
on the wheel axle.
7. Install:
Nut (wheel axle)
1
T R..90 Nm (9.0 m · kg, 65 ft · lb)
8. Tighten:
Bolt (axle holder)
1
NOTE:Before tightening the bolt, fit the
wheel axle to the axle holder by
stroking the front fork several times
with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
5. Monter:
Roue
N.B.:
Monter correctement le disque de frein
1 entre les plaquettes de frein 2.
Veiller à ce que les ergots a du cap-
teur de vitesse se positionnent au-des-
sus de la butée b du tube plongeur de
la fourche.
6. Monter:
Axe de roue 1
N.B.:
Appliquer de la graisse à savon de
lithium sur l’axe de roue.
7. Monter:
Ecrou (axe de roue) 1
T R..90 Nm (9,5 m · kg, 65 ft · lb)
8. Serrer:
Boulon (support d’axe) 1
N.B.:
Avant de serrer le boulon, engager l’axe
de roue dans le support d’axe en pous-
sant plusieurs fois sur la fourche en ser-
rant le frein avant.
T R..23 Nm (2,3 m · kg, 17 ft · lb)
ROUE AVANT ET ROUE ARRIERE

5 - 117
CHASSTEERING
7. Install:
•Front fork
1
•Upper bracket
2
•Main switch
3
•Front brake hose guide
bracket
4
NOTE:•Temporarily tighten the pinch bolts
(lower bracket).
•Do not tighten the pinch bolts
(upper bracket) yet.
8. Install:
•Guide (speed sensor lead)
1
NOTE:After installing the guide as shown,
pass the speed sensor lead through
the guide.1
9. Install:
•Washer
1
•Steering stem nut
2
T R..145 Nm (14.5 m · kg, 105 ft · lb)
10. Install:
•Steering stem cap
1
11. After tightening the nut, check
the steering for smooth move-
ment. If not, adjust the steering
by loosening the steering ring
nut little by little.
12. Adjust:
•Front fork top end
a
Front fork top end
(standard) a:
5 mm (0.20 in)
7. Monter:
Fourche 1
Té supérieur 2
Contacteur à clé 3
Support du guide de durit de frein
avant 4
N.B.:
Serrer provisoirement les boulons de
pincement (té inférieur).
Ne pas encore serrer les boulons de
pincement (té supérieur).
8. Monter:
Guide (fil du capteur de vitesse)
1
N.B.:
Une fois le guide monté comme illustré,
passer le fil du capteur de vitesse par le
guide.
9. Monter:
Rondelle 1
Ecrou de la colonne de direction
2
T R..145 Nm (14,5 m · kg, 105 ft · lb)
10. Monter:
Capuchon de la colonne de direc-
tion 1
11. Après avoir serré l’écrou, vérifier si
le mouvement de la direction est
régulier. Sinon, régler la direction
en desserrant petit à petit l’écrou.
12. Régler:
Extrémité supérieure de la four-
che a
Sommet de bras de fourche
(standard) a:
5 mm (0,20 in)
DIRECTION