2009 YAMAHA WR 250F brake sensor

CONTENTS
CHAPTER 1GENERAL
INFORMATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION .................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
MULTI-FUNCTION
DISPLAY .......................... 1-9
STARTING AND
BREAK-IN ...................... 1-14
TORQUE-CHECK
POINTS........................... 1-16
CLEANING AND
STORAGE ...................... 1-17
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-12
LUBRICATION
DIAGRAMS .................... 2-18
CABLE ROUTING
DIAGRAM ....................... 2-20
CHAPTER 3 REGULAR
INSPECTION AND ADJUSTMENTS
PERIODIC MAINTENANCE
CHART FOR THE EMISSION
CONTROL SYSTEM
(For Canada) .................... 3-1
GENERAL MAINTENANCE
AND LUBRICATION CHART
(For Canada) .................... 3-2
MAINTENANCE
INTERVALS FOR
COMPETITION USE ......... 3-3
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-7
ENGINE ............................ 3-8
CHASSIS ........................ 3-19
ELECTRICAL ................. 3-29
CHAPTER 4 TUNING
ENGINE
(Except for Canada) ........ 4-1
CHASSIS .......................... 4-5
CHAPTER 5ENGINE
RADIATOR ....................... 5-1
CARBURETOR................. 5-4
AIR INDICTOIN
SYSTEM ......................... 5-12
CAMSHAFTS.................. 5-14
CYLINDER HEAD........... 5-19
VALVES AND VALVE
SPRINGS ........................ 5-21
CYLINDER AND
PISTON ........................... 5-25
CLUTCH ......................... 5-29 OIL FILTER ELEMENT
AND WATER PUMP .......5-34
BALANCER ....................5-38
OIL PUMP .......................5-40
KICK SHAFT AND
SHIFT SHAFT ................. 5-43
AC MAGNETO AND
STARTER CLUTCH........5-48
ENGINE REMOVAL........ 5-53
CRANKCASE AND
CRANKSHAFT ...............5-57
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK ................... 5-63
CHAPTER 6
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................6-1
FRONT BRAKE AND
REAR BRAKE ..................6-6
FRONT FORK ................. 6-16
HANDLEBAR..................6-23
STEERING ......................6-27
SWINGARM ....................6-31
REAR SHOCK
ABSORBER ....................6-36
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-1
IGNITION SYSTEM...........7-3
ELECTRIC STARTING
SYSTEM............................7-5
CHARGING SYSTEM .....7-13
THROTTLE POSITION
SENSOR SYSTEM .........7-15
LIGHTING SYSTEM .......7-18
SIGNALING SYSTEM.....7-20

2-15
TIGHTENING TORQUES
△Rear wheel sprocket M8 × 1.25 6 50 5.0 36
△ Rear brake disc cover M6 × 1.0 2 10 1.0 7.2
△ Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
△ Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△ Upper engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Lower engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
△ Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
△ Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△ Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△ Connecting rod and frame M14 × 1.5 1 80 8.0 58
△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△ Rear frame (upper) M8 × 1.25 1 38 3.8 27
△ Rear frame (lower) M8 × 1.25 2 32 3.2 23
△ Swingarm and brake hose holder M5 × 0.8 4 3 0.3 2.2
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△ Fuel tank M6 × 1.0 2 9 0.9 6.5
△ Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
△ Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
△ Air scoop and radiator guard (lower) M6 × 1.0 2 6 0.6 4.3
△ Front fender M6 × 1.0 4 7 0.7 5.1
△ Rear fender (front) M6 × 1.0 2 7 0.7 5.1
△ Rear fender (rear) M6 × 1.0 2 11 1.1 8.0
△ Side cover M6 × 1.0 2 7 0.7 5.1
△ Seat M8 × 1.25 2 23 2.3 17
Multi-function display bracket and upper bracket M6 × 1.0 2 7 0.7 5.1
Multi-function display M5 × 0.8 2 4 0.4 2.9
Plate 1 and front fork protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and front fork protector — 2 0.5 0.05 0.36
Speed sensor lead holder and lower bracket M6 × 1.0 1 13 1.3 9.4
Speed sensor lead holder and clamp M6 × 1.0 1 7 0.7 5.1 Part to be tightened Thread size Q'ty
Tightening torque
Nm m•kg ft•lb

2-20
CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose
2. Clamp
3. Diode
4. Hot starter cable
5. Wire harness
6. Hump (frame)
7. Cylinder head breather hose
8. Throttle position sensor lead
9. Neutral switch lead10. Oil hose
11. Clutch cable
12. Starter motor lead
13. Cable guide
14. Negative battery lead
15. AC magneto lead
16. Brake hose
17. Rectifier/regulator lead
18. Carburetor breather hose19. Carburetor overflow hose
20. Catch tank breather hose
21. Hot starter cable protector
22. Rubber cap

2-26
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Brake hose
4. Clutch cable
5. Hose guide
6. Main switch coupler
7. Wire harness
8. Headlight coupler
9. Hot starter cable
10. Multi-function display bracket11. Main switch
12. Upper bracket
13. Clutch switch coupler
14. Engine stop switch coupler
15. Multi-function display coupler
16. Start switch coupler
17. Speed sensor coupler
18. Speed sensor lead

2-27
CABLE ROUTING DIAGRAM
A. Fasten the start switch lead to the handlebar with the plastic
bands.
B. Fasten the engine stop switch
lead and clutch switch lead to
the handlebar with the plastic
bands.
C. Pass the brake hose through the hose guides.
D. Secure the coupler by inserting
it into the multi-function display
bracket.
E. Pass the throttle cables, clutch
cable and hot starter cable be-
tween the upper bracket and
multi-function display bracket.
F. Fasten the multi-function display leads to the bracket. Cut off the
tie end.
G. Secure the coupler by pushing it into the hole in the multi-function
display bracket.
H. Secure the wire harness clip by pushing it into the hole in the
multi-function display bracket on
the inside.
I. Fasten the wire harness to the multi-function display bracket.
Cut off the tie end.
J. Fasten the main switch lead (wire harness side) to the multi-
function display bracket. Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
K. Pass the speed sensor lead through the guide on the outside
of the front fork.

6-1
FRONT WHEEL AND REAR WHEEL
CHASSIS
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 request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.
FRONT WHEEL AND REAR WHEEL
REMOVING THE FRONT WHEELOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
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
6Collar 1
7 Oil seal 1
8 Bearing 2 Refer to removal section.
9Brake disc 1
21 Nm (2.1 m kg, 15 ft lb)
21 Nm (2.1 m kg, 15 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)
90 Nm (9.0 m kg, 65 ft lb)

6-4
FRONT WHEEL AND REAR WHEEL
2. Install:•Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:•Collar "1"
Apply the lithium soap base grease
on the oil seal lip.
4. Install:• Speed sensor "1"
• 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.
5. Install:• Wheel
• Install the brake disc "1" between the brake pads "2" correctly.
• Make sure that the projections "a" in
the speed sensor fits over the stop-
per "b" on the front fork inner tube.
6. Install:• Wheel axle "1"
Apply the lithium soap base grease
on the wheel axle.
7. Install:• Nut (wheel axle) "1"
8. Tighten: • Bolt (axle holder) "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok-
ing the front fork several times with
the front brake applied.
INSTALLING THE REAR WHEEL
1. Install:• Bearing (right) "1"
• Circlip "2"
•Spacer "3"
• Bearing (left) "4"
•Oil seal "5"
• Apply the lithium soap base grease
on the bearing and oil seal lip when
installing.
• Install the bearing with seal facing outward.
• Use a socket that matches the out- side diameter of the race of the
bearing.
• Right side of bearing shall be in- stalled first.
• Install the oil seal with its manufac- ture's marks or numbers facing out-
ward.
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7
ft•lb)
Nut (wheel axle):
90 Nm (9.0 m•kg, 65
ft•lb)
Bolt (axle holder): 21 Nm (2.1 m•kg, 15
ft•lb)

6-30
STEERING
5. Check the steering stem by turn-ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
6. Install: • Washer "1"
•Collar "2"
Install the collar "2" with the larger in-
side diameter facing downward.
7. Install:
• Front fork "1"
• Upper bracket "2"
• Main switch "3"
• Front brake hose guide bracket "4"
• Temporarily tighten the pinch bolts (lowerbracket).
• Do not tighten the pinch bolts (up- per bracket)yet.
8. Install:• Guide (speed sensor lead) "1"
After installing the guide as shown,
pass the speed sensor lead through
the guide.
9. Install:•Washer "1"
• Steering stem nut "2"
10. After tightening the nut, check the steering for smooth movement. If
not, adjust the steering by loosen-
ing the steering ring nut little by lit-
tle.
11. Adjust: • Front fork top end "a"
12. Tighten: • Pinch bolt (upper bracket) "1"
• Pinch bolt (lower bracket) "2"
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
13. Install:
• Multi-function display bracket "1"
• Multi-function display "2"
Pass the throttle cables "3", clutch ca-
ble "4" and hot starter cable "5" be-
tween the multi-function display
bracket and upper bracket.
14. Install:• Holder "1"
•Clamp "2"
• Install so that the marking "a" on the
speed sensor lead aligns with the
holder edge.
• Fasten the speed sensor lead to the holder with the clamp.
Steering stem nut: 145 Nm (14.5 m•kg, 105
ft•lb)
Front fork top end (stan-
dard) "a": 5 mm (0.20 in)
Pinch bolt (upper brack-
et): 21 Nm (2.1 m•kg, 15
ft•lb)
Pinch bolt (lower brack-
et): 21 Nm (2.1 m•kg, 15
ft•lb)
Multi-function display
bracket:7 Nm (0.7 m•kg, 5.1
ft•lb)
Multi-function display: 4 Nm (0.4 m•kg, 2.9
ft•lb)
Holder: 13 Nm (1.3 m•kg, 9.4
ft•lb)
Clamp: 7 Nm (0.7 m•kg, 5.1
ft•lb)