2007 YAMAHA WR 250F brake

5 - 111
ENGCLUTCH
EC4A0000
CLUTCH
Extent of removal:
1 Push rod 1, 2 and push lever shaft removal
2 Push rod 1 disassembly
3 Friction plate and clutch plate removal
4 Primary driven gear removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in
the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8Ball 1
9 Push rod 2 1
1
1
2
34

5 - 129
ENGOIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
Extent of removal:
1 Oil filter element removal
2 Water pump removal
3 Right crankcase cover removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER
REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in
the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the
CHAPTER 3.
Radiator hose 3 Disconnect at water pump side.
Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section
in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Engine guard
1 Oil filter element cover 1
2 Oil filter element 1
13

5 - 211
ENGENGINE REMOVAL
Extent of removal:
1 Engine removal
Extent of removal Order Part name Q’ty Remarks
Ignition coil
Disconnect the AC magneto lead.
Starter motor lead Disconnect at the starter motor side.
Negative battery lead Disconnect at the engine side.
1 Engine guard 1
2 Neutral switch 1
3 Drive chain sprocket cover 1
4 Nut (drive sprocket) 1
Refer to “REMOVAL POINTS”. 5 Lock washer 1
6 Drive sprocket 1
7 Clip 1
8 Bolt (brake pedal) 1
9 Brake pedal 1
10 Upper engine bracket 2
11 Lower engine bracket 2
12 Engine mounting bolt 3
13 Pivot shaft 1
Refer to “REMOVAL POINTS”.
14 Engine 1
1

5 - 215
ENGENGINE REMOVAL
EC4M3000REMOVAL POINTSEC4F3100Drive sprocket
1. Remove:
Nut (drive sprocket)
1
Lock washer
2
NOTE:Straighten the lock washer tab.
Loosen the nut while applying the
rear brake.
2. Remove:
Drive sprocket
1
Drive chain
2
NOTE:Remove the drive sprocket together
with the drive chain.
EC4M3301Engine removal
1. Remove:
Pivot shaft
1
NOTE:If the pivot shaft is pulled all the way
out, the swingarm will come loose. If
possible, insert a shaft of similar
diameter into the other side of the
swingarm to support it.
2. Remove:
Engine
1
From right side.
NOTE:Make sure that the couplers, hoses
and cables are disconnected.
1
POINTS DE DEPOSE
Couronne arrière
1. Déposer:
Ecrou (couronne arrière) 1
Rondelle-frein 2
N.B.:
Redresser l’onglet de la rondelle-frein.
Desserrer l’écrou tout en actionnant le
frein arrière.
2. Déposer:
Couronne arrière 1
Chaîne de transmission 2
N.B.:
Déposer la couronne arrière et la chaîne
de transmission.
Dépose du moteur
1. Déposer:
Boulon-pivot 1
N.B.:
Si l’on extrait entièrement le boulon-
pivot, le bras oscillant n’est plus sup-
porté. Si possible, insérer un axe de dia-
mètre équivalent dans l’autre extrémité
du bras oscillant pour le supporter.
2. Déposer:
Moteur 1
Du côté droit.
N.B.:
S’assurer que les fiches rapides, les
tuyaux et les câbles sont déconnectés.
DEPOSE DU MOTEUR

5 - 217
ENGENGINE REMOVAL
EC4M5000ASSEMBLY AND INSTALLATION
Engine installation
1. Install:
Engine
1
Install the engine from right
side.
Pivot shaft
2
Engine mounting bolt (lower)
3
Lower engine bracket
4
Bolt (lower engine bracket)
5
Patch
6
Engine mounting bolt (front)
7
Upper engine bracket
8
Bolt (upper engine bracket)
9
Engine mounting bolt (upper)
0
Lower engine guard
A
Bolt (lower engine guard)
B
NOTE:Apply the molybdenum disulfide
grease on the pivot shaft.
Install the patch with the claw
a
facing outside the chassis.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
Brake pedal
1. Install:
Spring
1
Brake pedal
2
O-ring
3
Bolt (brake pedal)
4
Clip
5
NOTE:Apply the lithium soap base grease
on the bolt, O-rings and brake pedal
bracket.
T R..26 Nm (2.6 m · kg, 19 ft · lb)
New
Drive sprocket
1. Install:
Drive sprocket
1
Drive chain
2
NOTE:Install the drive sprocket together
with the drive chain.
ASSEMBLAGE ET MONTAGE
Montage du moteur
1. Monter:
Moteur 1
Monter le moteur par le côté
droit.
Boulon-pivot 2
Boulon d’ancrage du moteur
(inférieur) 3
Support de moteur inférieur 4
Boulon (support de moteur infé-
rieur) 5
Rondelle 6
Boulon d’ancrage du moteur
(avant) 7
Support de moteur supérieur 8
Boulon (support de moteur supé-
rieur) 9
Boulon d’ancrage du moteur
(supérieur) 0
Protège-carter inférieur A
Boulon (protège-carter inférieur)
B
N.B.:
Appliquer de la graisse au bisulfure de
molybdène sur le boulon-pivot.
Monter la rondelle en orientant la
griffe a vers l’extérieur du châssis.
Pédale de frein
1. Monter:
Ressort 1
Pédale de frein 2
Joint torique 3
Boulon (pédale de frein) 4
Clip 5
N.B.:
Appliquer de la graisse à savon de
lithium sur le boulon, les joints toriques
et le support de pédale de frein.
T R..85 Nm (8,5 m · kg, 61 ft · lb)
T R..53 Nm (5,3 m · kg, 38 ft · lb)
T R..34 Nm (3,4 m · kg, 24 ft · lb)
T R..53 Nm (5,3 m · kg, 38 ft · lb)
T R..34 Nm (3,4 m · kg, 24 ft · lb)
T R..55 Nm (5,5 m · kg, 40 ft · lb)
T R..7 Nm (0,7 m · kg, 5,1 ft · lb)
T R..26 Nm (2,6 m · kg, 19 ft · lb)
New
Couronne arrière
1. Monter:
Couronne arrière 1
Chaîne de transmission 2
N.B.:
Monter en même temps la couronne
arrière et la chaîne de transmission.
DEPOSE DU MOTEUR

5 - 219
ENGENGINE REMOVAL
2. Install:
Lock washer
1
Nut (drive sprocket)
2
NOTE:Tighten the nut while applying the
rear brake.
T R..75 Nm (7.5 m · kg, 54 ft · lb)
New
3. Bend the lock washer tab to lock
the nut.
4. Install:
Drive chain sprocket guide
1
Drive chain sprocket cover
2
Screw
(drive chain sprocket cover)
3
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
Neutral switch
1. Install:
Spring
1
Pin
2
O-ring
3
Neutral switch
4
Screw (neutral switch)
5
NOTE:Apply the lithium soap base grease
on the O-ring.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
New
2. Monter:
Rondelle-frein 1
Ecrou (couronne arrière) 2
N.B.:
Serrer l’écrou tout en actionnant le frein
arrière.
T R..75 Nm (7,5 m · kg, 54 ft · lb)
New
3. Plier l’onglet de la rondelle-frein
pour bloquer l’écrou.
4. Monter:
Patin de chaîne de transmission
1
Couvercle de pignon de chaîne de
transmission 2
Vis (couvercle de pignon de
chaîne de transmission) 3
T R..8 Nm (0,8 m · kg, 5,8 ft · lb)
Contacteur de point mort
1. Monter:
Ressort 1
Goupille 2
Joint torique 3
Contacteur de point mort 4
Vis (contacteur de point mort) 5
N.B.:
Appliquer de la graisse à savon de
lithium sur le joint torique.
T R..4 Nm (0,4 m · kg, 2,9 ft · lb)
New
DEPOSE DU MOTEUR

6 - 1
CHASFRONT WHEEL AND REAR WHEEL
EC500000
CHASSIS
EC590000
FRONT WHEEL
AND REAR WHEEL
EC598000FRONT WHEEL
NOTE:This section is intended for those who have basic knowledge and skill concerning the
servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.)
Those who have little knowledge and skill concerning servicing are requested not to
undertake inspection, adjustment, disassembly, or reassembly only by reference to
this manual. It may lead to servicing trouble and mechanical damage.
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

6 - 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