2009 YAMAHA WR 250F check oil

6-20
FRONT FORK
7. Install:• Piston metal "1"
Install the piston metal onto the slot
on inner tube.
8. Install:• Outer tube "1"To inner tube "2".
9. Install: • Slide metal "1"
• Oil seal washer "2"To outer tube slot.
Press the slide metal into the outer
tube with fork seal driver "3".
10. Install:
• Oil seal "1"
Press the oil seal into the outer tube
with fork seal driver "2".
11. Install:• Stopper ring "1"
Fit the stopper ring correctly in the
groove in the outer tube.
12. Install:• Dust seal "1"
Apply the lithium soap base grease
on the inner tube.
13. Check:• Inner tube smooth movementTightness/binding/rough spots →
Repeat the steps 2 to 12. 14. Compress the front fork fully.
15. Fill:
• Front fork oilUntil outer tube top surface with
recommended fork oil "1".
• Be sure to use recommended
fork oil. If other oils are used,
they may have an excessively ad-
verse effect on the front fork per-
formance.
• Never allow foreign materials to
enter the front fork.
16. After filling, pump the damper rod "1" slowly up and down more than
10 times to distribute the fork oil.
17. Fill: • Front fork oil
Until outer tube top surface with
recom-mended fork oil once
more.
18. After filling, pump the outer tube "1" slowly up and down (about
200 mm (7.9 in) stroke) to distrib-
ute the fork oil once more.
Be careful not to excessive full stroke.
A stroke of 200 mm (7.9 in) or more
will cause air to enter. In this case, re-
peat the steps 15 to 18.
Fork seal driver:YM-A0948/90890-01502
Fork seal driver:YM-A0948/90890-01502
Recommended oil:
Suspension oil "S1"

6-21
FRONT FORK
19. Wait ten minutes until the air bub-bles have been removed from the
front fork, and the oil has dis-
pense evenly in system before
setting recommended oil level.
Fill with the fork oil up to the top end
of the outer tube, or the fork oil will not
spread over to every part of the front
forks, thus making it impossible to ob-
tain the correct level.
B e s u r e t o f i l l w i t h t h e f o r k o i l u p t o t h e
top of the outer tube and bleed the
front forks.
20. Measure:• Oil level (left and right) "a"
Out of specification →Adjust.
Be sure to install the spring guide "2"
when checking the oil level.
Never fail to make the oil level ad-
justment between the maximum
and minimum level and always ad-
just each front fork to the same
setting. Uneven adjustment can
cause poor handling and loss of
stability.
21. Measure:
• Distance "a"Out of specification →Turn into
the locknut.
22. Loosen: • Rebound damping adjuster "1"
• Loosen the rebound damping ad-
juster finger tight.
• Record the set position of the ad- juster (the amount of turning out the
fully turned in position).
23. Install:• Push rod "1"
• Fork spring "2"
• Install the fork spring with the
damper rod "3" pulled up.
• After installing the fork spring, hold
the damper rod end so that it will not
go down.
24. Install:• Spring seat "1"
• Front fork cap bolt "2"
Fully finger tighten the front fork cap
bolt onto the damper rod.
25. Tighten:• Front fork cap bolt (locknut) "1"
Hold the locknut "2" and tighten the
front fork cap bolt with specified
torque.
26. Install:• Front fork cap bolt "1"To outer tube.
Temporarily tighten the cap bolt.
27. Install:
• Protector guide "1"
Install the protector guide with its wid-
er side "a" facing downward.
Standard oil level: 132 mm (5.20 in)
Extent of adjustment:
95–150 mm (3.74–5.91
in)
From top of outer tube
with inner tube and
damper rod "1" fully
compressed without
spring.
Distance "a":18 mm (0.71 in) or more
Between damper rod
"1" top and locknut "2"
top.
Front fork cap bolt (lock-
nut):29 Nm (2.9 m•kg, 21
ft•lb)

6-24
HANDLEBAR
REMOVING THE BRAKE MASTER
CYLINDER
1. Remove:• Brake master cylinder bracket "1"
• Brake master cylinder "2"
• Do not let the brake master cylin-
der hang on the brake hose.
• Keep the brake master cylinder
cap side horizontal to prevent air
from coming in.
REMOVING THE GRIP
1. Remove:•Grip "1"
Blow in air between the handlebar or
tube guide and the grip. Then remove
the grip which has become loose.
CHECKING THE HANDLEBAR
1. Inspect:• Handlebar "1"
Bends/cracks/damage →Re-
place.
Do not attempt to straighten a bent
handlebar as this may dangerous-
ly weaken the handlebar.
INSTALLING THE HANDLEBAR
1. Install: • Handlebar lower holder "1"
•Washer "2"
• Nut (handlebar lower holder) "3"
• Install the handlebar lower holder with its side having the greater dis-
tance "a" from the mounting bolt
center facing forward.
• Apply the lithium soap base grease on the thread of the handlebar low-
er holder.
• Installing the handlebar lower hold- er in the reverse direction allows the
front-to-rear offset amount of the
handlebar position to be changed.
• Do not tighten the nut yet.
2. Install:
• Handlebar "1"
• Handlebar upper holder "2"
• Bolt (handlebar upper holder) "3"
• The handlebar upper holder should be installed with the punched mark
"a" forward.
• Install the handlebar so that the marks "b" are in place on both
sides.
• Install the handlebar so that the pro- jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• First tighten the bolts on the front side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
3. Tighten:
• Nut (handlebar lower holder) "1"
4. Install: • Left grip "1"Apply the adhesive to the handle-
bar "2".
• Before applying the adhesive, wipe off grease or oil on the handlebar
surface "a" with a lacquer thinner.
• Install the left grip to the handlebar
so that the line "b" between the two
arrow marks faces straight upward.
Bolt (handlebar upper
holder): 28 Nm (2.8 m•kg, 20
ft•lb)
Nut (handlebar lower
holder):
34 Nm (3.4 m•kg, 24
ft•lb)

6-25
HANDLEBAR
5. Install:•Right grip "1"
•Collar "2"Apply the adhesive on the tube
guide "3".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark "b" and
tube guide slot "c" form the angle as
shown.
6. Install:• Grip cap cover "1"
• Throttle grip "2"
Apply the lithium soap base grease
on the throttle grip sliding surface.
7. Install:
• Throttle cables "1"To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
8. Install:• Throttle cable cap "1"
• Screw (throttle cable cap) "2"
After tightening the screws, check
that the throttle grip "3" moves
smoothly. If it does not, retighten
the bolts for adjustment.
9. Install:• Grip cap cover "1"
• Cover (throttle cable cap) "2" 10. Install:
• Start switch "1"
• Brake master cylinder "2"
• Brake master cylinder bracket "3"
• Bolt (brake master cylinder brack-et) "4"
•Clamp "5"
• The start switch and brake master cylinder bracket should be installed
according to the dimensions
shown.
• Install the bracket so that the arrow mark "a" faces upward.
• First tighten the bolt on the upper
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
11. Install:• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
•Clamp "6"
Screw (throttle cable
cap): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (clutch lever holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (hot starter lever
holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)

6-33
SWINGARM
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE CAP
1. Remove:• Left cap "1"
Remove with a slotted-head screw-
driver inserted under the mark "a" on
the left cap.
REMOVING THE BEARING
1. Remove:• Bearing "1"
Remove the bearing by pressing its
outer race.
CHECKING THE SWINGARM
1. Inspect:
• Bearing "1"
• Bushing "2"Free play exists/unsmooth revolu-
tion/rust →Replace bearing and
bushing as a set.
2. Inspect:
•Oil seal "3"Damage →Replace. CHECKING THE RELAY ARM
1. Inspect:
• Bearing "1"
•Collar "2"Free play exists/unsmooth revolu-
tion/rust → Replace bearing and
collar as a set.
2. Inspect: • Oil seal "3"Damage →Replace.
CHECKING THE CONNECTING
ROD
1. Inspect: • Bearing "1"
•Collar "2"Free play exists/unsmooth revolu-
tion/rust →Replace bearing and
collar as a set.
2. Inspect:
• Oil seal "3"Damage →Replace.
INSTALLING THE BEARING AND
OIL SEAL
1. Install: • Bearing "1"
• Oil seal "2"
To 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.
• First install the outer and then the inner bearings to a specified depth
from inside.
2. Install:
• Bearing "1"
• Washer "2"
•Oil seal "3"To relay arm.
• 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.
• Apply the molybdenum disulfide grease on the washer.
3. Install:• Bearing "1"
•Oil seal "2"To connecting rod.
Installed depth of bear-
ings: Outer "a": Zero mm
(Zero in)
Inner "b": 6.5 mm (0.26
in)
Installed depth of bear-
ings "a":Zero mm (Zero in)

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)

6-38
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.

7-3
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*1 marked: Refer to "CHECKING THE FUSE" section in the CHAPTER 3.
*2 marked: Refer to "CHECKING AND CHARGING THE BATTERY" section in the CHAPTER 3.
*3 marked: Only when the ignition checker is used.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
*1 Check fuse. No good→Replace fuse and check wire harness.
OK ↓
*2 Check battery. No good→Recharge or replace.
OK ↓
Spark gap test Spark→ *3 Clean or replace spark plug.
No spark ↓
Check entire ignition system for connection.
(couplers, leads and ignition coil) No good
→
Repair or replace.
OK ↓
Check engine stop switch. No good→Replace.
OK ↓
Check main switch. No good→Replace.
OK ↓
Check ignition coil. (primary coil and secondary
coil) No good
→
Replace.
OK ↓
Check AC magneto. (pickup coil) No good→Replace.
OK ↓
Check neutral switch. No good→Repair or replace.
OK ↓
Replace CDI unit.
Dynamic spark tester: YM-34487
Ignition checker: 90890-06754
Pocket tester: YU-3112-C/90890-03112