2009 YAMAHA WR 250F ABS

4-9
CHASSIS
SUSPENSION SETTING (REAR SHOCK ABSORBER)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Symptom Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff, tending to sink ○○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spongy and unsta-
ble ○○Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Low compression
damping Turn adjuster clockwise (about 1 click) to increase
damping.
Spring Replace with stiff spring.
Heavy and dragging ○○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring Replace with soft spring.
Poor road gripping ○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low compression
damping Turn adjuster clockwise (about 1 clicks) to in-
crease damping.
High compression
damping Turn adjuster clockwise (about 1/6 turn) to in-
crease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spring Replace with soft spring.
Bottoming out ○○ High compression
damping
Turn adjuster clockwise (about 1/6 turn) to in-
crease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger in astride seat.
Spring Replace with stiff spring.
Bouncing ○○ Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Spring Replace with soft spring.
Stiff travel ○○ High compression
damping
Turn adjuster counterclockwise (about 1/6 turn) to
decrease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spring Replace with soft spring.

5-4
CARBURETOR
CARBURETOR
REMOVING THE CARBURETOROrder Part name Q'ty Remarks Seat and fuel tank Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Rear shock absorber Refer to "REAR SHOCK ABSORBER" sec-
tion in the CHAPTER 6.
1Clamp 2
2 Throttle position sensor lead coupler 1
3 Throttle cable cover 1
4 Throttle cable 2
5 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
6 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).
7 Hot starter plunger 1
8 Carburetor assembly 1
9 Carburetor joint 1
4 Nm (0.4 m kg, 2.9 ft lb)
2 Nm (0.2 m kg, 1.4 ft lb)
11 Nm (1.1 m kg, 8.0 ft lb)
4 Nm (0.4 m kg, 2.9 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
3 Nm (0.3 m kg, 2.2 ft lb)
3 Nm (0.3 m kg, 2.2 ft lb)

6-14
FRONT BRAKE AND REAR BRAKE
INSTALLING THE FRONT BRAKE
HOSE
1. Install:• Copper washer "1"
•Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:
• Brake hose holder "1"
• Bolt (brake hose holder) "2"
3. Install: • Brake hose holder "1"
• Nut (brake hose holder) "2"
Align the top "a" of the brake hose
holder with the paint "b" of the brake
hose.
4. Pass the brake hose through the front brake hose guides "1".
5. Install: • Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that it
contacts the brake master cylinder
projection "a" and that its bent
portion "b" faces downward.
INSTALLING THE REAR BRAKE
HOSE
1. Install:• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:• Brake hose holder "1"
• Screw (brake hose holder) "2"
After installing the brake hose
holders, make sure the brake hose
does not contact the spring (rear
shock absorber). If it does, correct
its twist.
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Bolt (brake hose holder): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Nut (brake hose holder): 7 Nm (0.7 m•kg, 5.1 ft
•lb)
Union bolt:30 Nm (3.0 m•kg, 22
ft•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Screw (brake hose hold-
er):3 Nm (0.3 m•kg, 2.2
ft•lb)

6-31
SWINGARM
SWINGARM
REMOVING THE SWINGARMOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Brake hose holder Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Rear brake caliper Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (connecting rod) 1
5Pivot shaft 1
6 Swingarm 1

6-34
SWINGARM
• Apply the molybdenum disulfide grease on the bearing when install-
ing.
• Install the bearing by pressing it on the side having the manufacture's
marks or numbers.
INSTALLING THE SWINGARM
1. Install:• Bushing "1"
• Thrust bearing "2"
•Oil seal "3"
•Collar "4"
To swingarm "5"
Apply the molybdenum disulfide
grease on the bushings, thrust bear-
ings, oil seal lips and contact surfaces
of the collar and thrust bearing.
2. Install:•Collar "1"
• Washer "2"To relay arm "3".
Apply the molybdenum disulfide
grease on the collars and oil seal lips.
3. Install:•Collar "1"To connecting rod "2".
Apply the molybdenum disulfide
grease on the collar and oil seal lips.
4. Install:• Connecting rod "1"
• Bolt (connecting rod) "2"
•Washer "3"
• Nut (connecting rod) "4"
To relay arm "5".
Apply the molybdenum disulfide
grease on the bolt.
5. Install:• Relay arm"1"
• Bolt (relay arm) "2"
•Washer "3"
• Nut (relay arm) "4"To swingarm.
• Apply the molybdenum disulfide grease on the bolt circumference
and threaded portion.
• Do not tighten the nut yet.
6. Install: • Swingarm "1"
• Pivot shaft "2"
• Apply the molybdenum disulfide grease on the pivot shaft.
• Insert the pivot shaft from right side.
7. Check: • Swingarm side play "a"
Free play exists →Replace thrust
bearing.
• Swingarm up and down move-
ment "b"
Unsmooth movement/binding/
rough spots →Grease or replace
bearings, bushings and collars.
8. Install: • Bolt (connecting rod) "1"
• Washer "2"
• Nut (connecting rod) "3"
• Apply the molybdenum disulfide grease on the bolt.
• Do not tighten the nut yet.
9. Install: • Bolt (rear shock absorber-relay
arm) "1"
• Nut (rear shock absorber-relay arm) "2"
Apply the molybdenum disulfide
grease on the bolt.
Installed depth of bear-
ings "a": Zero mm (Zero in)
Nut (connecting rod):80 Nm (8.0 m•kg, 58
ft•lb)
Pivot shaft: 85 Nm (8.5 m•kg, 61
ft•lb)
Nut (rear shock absorb-
er-relay arm):
53 Nm (5.3 m•kg, 38
ft•lb)

6-36
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER
REMOVING THE REAR SHOCK ABSORBEROrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Seat and side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Silencer Refer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING THE COOLANT" sec-
tion in the CHAPTER 3.
Catch tank breather hose Disconnect at the catch tank side.
Catch tank hose Disconnect at the catch tank side.
Air induction hose (air cut-off valve-air filter case) Disconnect at the air filter case side.
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to "CHECKING AND CHARGING THE
BATTERY" section in the CHAPTER 3.
Disconnect the starter relay coupler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 4

6-37
REAR SHOCK ABSORBER
2 Taillight coupler1
3 CDI unit coupler 3
4 Plastic band 1
5 Clamp (air filter joint) 1 Only loosening.
6 Rear frame 1
7 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
9 Rear shock absorber 1
10 Locknut 1 Only loosening.
11 Adjuster 1 Only loosening.
12 Lower spring guide 1
13 Upper spring guide 1
14 Spring (rear shock absorber) 1
15 Bearing 2 Refer to removal section.
Order
Part name Q'tyRemarks

6-38
REAR SHOCK ABSORBER
HANDLING NOTE
• Support the machine securely so there is no danger of it falling
over.
• This rear shock absorber is pro-
vided with a separate type tank
filled with high-pressure nitro-
gen gas. To prevent the danger
of explosion, read and under-
stand the following information
before handling the shock ab-
sorber. The manufacturer can
not be held responsible for prop-
erty damage or personal injury
that may result from improper
handling.
• Never tamper or attempt to dis-assemble the cylinder or the
tank.
• Never throw the rear shock ab-
sorber into an open flame or
other high heat. The rear shock
absorber may explode as a re-
sult of nitrogen gas expansion
and/ or damage to the hose.
• Be careful not to damage any
part of the gas tank. A damaged
gas tank will impair the damp-
ing performance or cause a
malfunction.
• Take care not to scratch the contact surface of the piston
rod with the cylinder; or oil
could leak out.
• Never attempt to remove the plug at the bottom of the nitro-
gen gas tank. It is very danger-
ous to remove the plug.
• When scrapping the rear shock
absorber, follow the instruc-
tions on disposal.
NOTES ON DISPOSAL (YAMAHA
DEALERS ONLY)
Before disposing the rear shock ab-
sorber, be sure to extract the nitrogen
gas from valve "1". Wear eye protec-
tion to prevent eye damage from es-
caping gas and/or metal chips.
To dispose of a damaged or worn-
out rear shock absorber, take the
unit to your Yamaha dealer for this
disposal procedure.
REMOVING THE BEARING
1. Remove:• Stopper ring (upper bearing) "1"
Press in the bearing while pressing its
outer race and remove the stopper
ring.
2. Remove:• Upper bearing "1"
Remove the bearing by pressing its
outer race.
3. Remove:• Lower bearing "1"
Remove the bearing by pressing its
outer race.
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:• Damper rod "1"
Bends/damage →Replace rear
shock absorber assembly.
• Shock absorber "2"
Oil leaks →Replace rear shock
absorber assembly.
Gas leaks →Replace rear shock
absorber assembly.
• Spring "3" Damage →Replace spring.
Fatigue →Replace spring.
Move spring up and down.
• Spring guide "4"
Wear/damage →Replace spring
guide.
• Bearing "5"
Free play exists/unsmooth revolu-
tion/rust →Replace.
INSTALLING THE BEARING
1. Install: • Upper bearing "1"
Install the bearing parallel until the
stopper ring groove appears by
pressing its outer race.
Do not apply the grease on the
bearing outer race because it will
wear the rear shock absorber sur-
face on which the bearing is press
fitted.