2009 YAMAHA WR 250F steering wheel

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

1-5
SPECIAL TOOLS
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.
Damper rod holder
YM-01494, 90890-01494 Use this tool to remove and install
the damper rod.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Spoke nipple wrench
YM-01521, 90890-01521 This tool is used to tighten the
spoke.
Sheave holder
YS-1880-A, 90890-01701 This tool is used for when loosening
or tightening the flywheel magneto
securing nut.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Tool name/Part number How to use Illustration

1-16
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame constructionFrame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp

2-9
MAINTENANCE SPECIFICATIONS
CHASSISItem Standard Limit
Steering system: Steering bearing type Taper roller bearing----
Front suspension: Front fork travel 300 mm (11.8 in)----
Fork spring free length 460 mm (18.1 in)455 mm (17.9
in)
Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in)----
Optional spring/spacer Yes----
Oil capacity 648 cm
3 (22.8 lmp oz, 21.9 US oz)----
Oil level 132 mm (5.20 in)----
(From top of outer tube with inner
tube and damper rod fully compressed without
spring.) 95–150 mm (3.74–5.91 in)
----
Oil grade Suspension oil "S1"----
Inner tube outer diameter 48 mm (1.89 in)----
Front fork top end 5 mm (0.20 in)----
Rear suspension: USA, CDN AUS, NZ, ZA EUROPE
Shock absorber travel 130 mm (5.12
in) ←←
----
Spring free length 260 mm (10.24
in) ←←
----
Fitting length 249 mm (9.80
in) 245.0 mm (9.65
in) 248.5 mm (9.78
in)----
Preload length
1.5–13 mm
(0.06–0.51 in) ←←
----
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in) ←←
----
Optional spring Yes←← ----
Enclosed gas pressure 1,000 kPa (10
kg/cm
2, 142
psi) ←←
----
Swingarm: Swingarm free play limitEnd ---- 1.0 mm (0.04
in)
Wheel: USA, CDN, ZA AUS, NZ, EUROPE
Front wheel type Spoke wheel←----
Rear wheel type Spoke wheel←----
Front rim size/material 21 × 1.60/Aluminum←----
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum ----
Rim runout limit: Radial --------2.0 mm (0.08
in)
Lateral --------2.0 mm (0.08
in)

2-14
TIGHTENING TORQUES
CHASSIS
△- marked portion shall be checked for torque tightening after break-in or before each race.
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
△ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15
△ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15
△ Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
△ Handlebar upper holder and handlebar lower holder M8 × 1.25 4 28 2.8 20
△ Handlebar lower holder and upper bracket M10 × 1.25 2 34 3.4 24
△ Steering stem and steering ring nut M28 × 1.0 1Refer to TIP.
Front fork and front fork cap bolt M51 × 1.5 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 × 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
△ Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
△ Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
△ Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
△ Front brake hose guide and front brake hose guide bracket M5 × 0.8 1 4 0.4 2.9
△ Front brake hose guide and lower bracket M6 × 1.0 1 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting nut M5 × 0.8 1 2 0.2 1.4
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△ Front brake hose union bolt M10 × 1.25 2 30 3.0 22
△ Front brake caliper M8 × 1.25 2 23 2.3 17
△ Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Pad pin plug M10 × 1.0 2 3 0.3 2.2
△ Front brake caliper and pad pin M10 × 1.0 1 18 1.8 13
△ Rear brake caliper and pad pin M10 × 1.0 1 18 1.8 13
△ Brake caliper and bleed screw M8 × 1.25 2 6 0.6 4.3
△ Front wheel axle and axle nut M16 × 1.5 1 90 9.0 65
△ Front wheel axle holder M8 × 1.25 4 21 2.1 15
△ Front brake disc M6 × 1.0 6 12 1.2 8.7
△ Rear brake disc M6 × 1.0 6 14 1.4 10
△ Brake pedal M8 × 1.25 1 26 2.6 19
△ Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△ Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
△ Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90
△ Nipple (spoke) —72 3 0.3 2.2

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART (ForCanada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER
READINGS600 mi (1,000
km) or 1
month 1,800 mi
(3,000
km) or 3
months 3,000 mi
(5,000
km) or 6
months
1Clutch Check operation.
√√√
Adjust or replace cable.
2 * Cooling system Check hoses for cracks of damage.
√√√
Replace if necessary.
Replace with ethylene glycol anti-freeze cool-
ant every 1 year. Every 1 year
3 * Spark arrester Clean. √
4 * Front brake Check operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brake Check operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hoses Check for cracks or damage.
√√
Replace. Every 4 years
7*Wheels Check runout, spoke tightness and for dam-
age.
√√√
Tighten spokes if necessary.
8*Tires Check tread depth and for damage.
√√√
Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearings Check bearings for smooth operation.
√√√
Replace if necessary.
10 * Swingarm pivot bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease.
11 Drive chain Check chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13 Brake and clutch lever pivot
shafts Apply lithium-soap-based grease (all-purpose
grease) lightly.
√√√
14 Brake pedal pivot shafts Apply lithium-soap-based grease (all-purpose
grease) lightly. √√√
3

3-6
MAINTENANCE INTERVALS FOR COMPETITION USE
FRONT FORKSInspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
REAR SHOCK ABSORBER Inspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
SIDESTAND Lubricate ●Lithium base grease
STEERING HEAD Inspect free play and retighten ●●
Clean and lube ●Lithium base grease
Replace bearing ●
TIRE, WHEELS Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness ●●
Retighten sprocket bolt ●●
Inspect bearings ●
Replace bearings ●
Lubricate ●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection ●●
Lubricate ●● Yamaha cable lube or SAE 10W-30
motor oil
HOT STARTER, CLUTCH LEVER Inspect free play ●
BATTERY
Check terminal for looseness
and corrosion ●
Item
After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-7
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCEItem RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-11 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.
P.1-14
Engine oil Check that the oil level is correct. Check the crankcase and oil
line for leakage. P.3-14 – 16
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.
P.3-13
Brakes Check the play of front brake and effect of front and rear brake. P.3-19 – 22
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly. P.3-22 – 23
Wheels Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play. P.3-26 – 27
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play.
P.3-27
Front forks and rear shock
absorber Check that they operate smoothly and there is no oil leakage.
P.3-23 – 26
Cables (wires) Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.3-10 – 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are con-
nected tightly. P.1-3
Settings Is the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done? P.4-1 – 9