2010 YAMAHA WR 250F check engine

5-1
RADIATOR
ENGINE
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.
RADIATOR
REMOVING THE RADIATOR
Order Part name Q'ty Remarks Drain the coolant. Refer to "CHECKING THE COOLANT" sec-
tion in the CHAPTER 3.
Seat, fuel tank and left side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
1 Radiator guard 2
2 Radiator hose clamp 10 Only loosening.
3 Radiator hose 1 1
4 Left radiator 1
5 Radiator hose 3 1
6 Radiator pipe 2 1
7 Radiator hose 5 1

5-3
RADIATOR
HANDLING NOTE
Do not remove the radiator cap
when the engine and radiator are
hot. Scalding hot fluid and steam
may be blown out under pressure,
which could cause serious injury.
When the engine has cooled, open
the radiator cap by the following
procedure:
Place a thick rag, like a towel, over
the radiator cap, slowly rotate the
cap counterclockwise to the de-
tent. This procedure allows any re-
sidual pressure to escape. When
the hissing sound has stopped,
press down on the cap while turn-
ing counterclockwise and remove
it.
CHECKING THE RADIATOR
1. Inspect:• Radiator core "1"
Obstruction →Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin →Repair/replace.
INSTALLING THE RADIATOR
1. Install: • O-ring "1"
• Radiator pipe 1 "2"
• Bolt (radiator pipe) "3"
Apply the lithium soap base grease
on the O-ring.
2. Install:• Catch tank hose "1"
• Radiator hose 2 "2"
• Radiator hose 3 "3"
• Radiator pipe 2 "4"
• Radiator hose 5 "5"
• Radiator hose 4 "6"To right radiator "7".
3. Install: • Right radiator "1"
• Bolt (right radiator) "2"
• Radiator hose 5 "3"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
4. Install: • Left radiator "1"
• Bolt (left radiator) "2"
• Radiator hose 1 "3"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2. 5. Tighten:
• Radiator hose clamp "4"
6. Install: • Radiator guard "1"
First fit the inner hook portion "a" and
then the outer one "b" onto the radia-
tor.
7. Install:• Catch tank "1"
• Bolt (catch tank) "2"
• Bolt (catch tank) "3"
• Catch tank hose "4"
• Catch tank breather hose "5"Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
Bolt (radiator pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (right radiator):10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (left radiator): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 1: 2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose clamp: 2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (catch tank): 7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (catch tank): 16 Nm (1.6 m•kg, 11
ft•lb)

5-7
CARBURETOR
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
REMOVING THE PILOT SCREW
(For EUROPE)
1. Remove: • Pilot screw "1"
To optimize the fuel flow at a small
throttle opening, each machine's pilot
screw has been individually set at the
factory. Before removing the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
CHECKING THE CARBURETOR
1. Inspect:• Carburetor bodyContamination →Clean.
• Use a petroleum based solvent for
cleaning. Blow out all passages and
jets with compressed air.
• Never use a wire.
2. Inspect:
•Main jet "1"
• Pilot jet "2"
• Needle jet "3"
• Starter jet "4"
•Pilot air jet "5"
• Leak jet "6"
• Main air jet "7"Damage →Replace.
Contamination →Clean.
• Use a petroleum based solvent for
cleaning. Blow out all passages and
jets with compressed air.
• Never use a wire.
CHECKING THE NEEDLE VALVE
1. Inspect: • Needle valve "1"
• Valve seat "2"Grooved wear "a" →Replace.
Dust "b" →Clean.
• Filter "c" Clogged →Clean.
CHECKING THE THROTTLE
VALVE
1. Check: • Free movement
Stick →Repair or replace.
Insert the throttle valve "1" into the
carburetor body, and check for free
movement.
CHECKING THE JET NEEDLE
1. Inspect: • Jet needle "1"Bends/wear →Replace.
• Clip groove Free play exists/wear →Replace.
MEASURING AND ADJUSTING
THE FLOAT HEIGHT
1. Measure: • Float height "a"Out of specification →Adjust.
Measurement and adjustment
steps:
a. Hold the carburetor in an upside
down position.
• Slowly tilt the ca rburetor in the op-
posite direction, then take the mea-
surement when the needle valve
aligns with the float arm.
• If the carburetor is level, the weight of the float will push in the needle
valve, resulting in an incorrect mea-
surement.
b. Measure the distance between the mating surface of the float
chamber and top of the float using
a vernier calipers.
The float arm should be resting on the
needle valve, but not compressing
the needle valve.
c. If the float height is not within specification, inspect the valve
seat and needle valve.
d. If either is worn, replace them both.
Float height:
8.0 mm (0.31 in)

5-17
CAMSHAFTS
4. Measure:• Camshaft-to-cap clearanceOut of specification →Measure
camshaft outside diameter.
Measurement steps:
a. Install the camshaft onto the cylin- der head.
b. Position a strip of Plastigauge
®
"1" onto the camshaft.
c. Install the clip, dowel pins and camshaft caps.
• Tighten the bolts (camshaft cap) in a crisscross pattern from innermost
to outer caps.
• Do not turn the camshaft when
measuring clearance with the
Plastigauge
®.
d. Remove the camshaft caps and measure the width of the Plasti-
gauge
® "1".
5. Measure:• Camshaft outside diameter "a"
Out of specification →Replace the
camshaft.
Within specification →Replace
camshaft case and camshaft
caps as a set. CHECKING THE CAMSHAFT
SPROCKET
1. Inspect:
• Camshaft sprocket "1"Wear/damage →Replace the
camshaft assemb ly and timing
chain as a set.
CHECKING THE
DECOMPRESSION SYSTEM
1. Check: • Decompression system
Checking steps:
a. Check that the decompression
mechanism cam "1" moves
smoothly.
b. Check that the decompression
mechanism cam lever pin "2" proj-
ects from the camshaft.
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:• While pressing the tensioner rod lightly with fingers, use a thin
screwdriver "1" and wind the ten-
sioner rod up fully clockwise.
• When releasing the screwdriver
by pressing lightly with fingers,
make sure that the tensioner rod
will come out smoothly.
• If not, replace the tensioner as- sembly. INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock- wise with a wrench.
• Apply the molybdenum disulfide oil on the camshafts.
• Apply the engine oil on the decom- pression system.
• Squeezing the decompression le-
ver allows the crankshaft to be
turned easily.
b. Align the T.D.C. mark "a" on the rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
c. Fit the timing chain "3" onto both camshaft sprockets and install the
camshafts on the cylinder head.
Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
:0.08 mm (0.003
in)
Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Camshaft outside diame-
ter: 21.959–21.972 mm
(0.8645–0.8650 in)

5-24
VALVES AND VALVE SPRINGS
CHECKING THE VALVE SPRINGS
1. Measure:• Valve spring free length "a"Out of specification →Replace.
2. Measure: • Compressed spring force "a"Out of specification →Replace.
b. Installed length
3. Measure:
• Spring tilt "a"Out of specification →Replace. CHECKING THE
VALVE LIFTERS
1. Inspect:
• Valve lifterScratches/damage →Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply: • Molybdenum disulfide oil
Onto the valve stem and valve
stem seal.
2. Install:
• Valve "1"
• Valve spring seat "2"
• Valve stem seal "3"
• Valve spring "4"
• Valve spring retainer "5"To cylinder head.
• Make sure that each valve is in-
stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": Orange
Intake (right/left) "b": Green
Exhaust "c": Purple
• Install the valve springs with the larger pitch "d" facing upward.
e. Smaller pitch 3. Install:
• Valve cotter
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil on the valve stem end.
• Apply the engine oil on the valve lift-
ers.
• Valve lifter must turn smoothly when rotated with a finger.
• Be careful to reinstall valve lifters and pads in their original place.
Free length (valve
spring): Intake:36.58 mm (1.44 in)
: 36.81 mm
(1.45 in)
Exhaust:
35.58 mm (1.40 in)
: 36.54 mm
(1.44 in)
Compressed spring
force: Intake:103–118 N at 29.13
mm (10.50–12.09 kg at
29.13 mm, 23.15–
26.66 lb at 1.15 in)
Exhaust: 126–144 N at 29.30
mm (12.85–14.68 kg at
29.30 mm, 28.32–
32.37 lb at 1.15 in)
Spring tilt limit: Intake:
2.5°/1.6 mm (0.063 in)
Exhaust: 2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

5-27
CYLINDER AND PISTON
a. 10 mm (0.39 in)
3. Measure:
• Ring end gapOut of specification →Replace.
You cannot measure the end gap on
the expander spacer of the oil control
ring. If the oil control ring rails show
excessive gap, replace all three rings.
CHECKING THE PISTON PIN
1. Inspect:
• Piston pinBlue discoloration/grooves →Re-
place, then inspect the lubrication
system.
2. Measure:
• Piston pin-to-piston clearance
Measurement steps:
a. Measure the outside diameter (piston pin) "a".
If out of specification, replace the
piston pin. b. Measure the inside diameter (pis-
ton) "b".
c. Calculate the piston pin-to-piston clearance with the following for-
mula.
d. If out of specific ation, replace the
piston.
INSTALLING THE PISTON RING
AND PISTON
1. Install: •Piston ringOnto the piston.
• Be sure to install the piston rings so that the manufacturer's marks or
numbers are located on the upper
side of the rings.
• Lubricate the piston and piston
rings liberally with engine oil.
2. Position:•Top ring
• 2nd ring
• Oil ringOffset the piston ring end gaps as
shown. a. Top ring end
b. 2nd ring end
c. Oil ring end (upper)
d. Oil ring
e. Oil ring end (lower)
3. Install: • Piston "1"
• Piston pin "2"
• Piston pin clip "3"
• Apply engine oil onto the piston pin and piston.
• Be sure that the arrow mark "a" on
the piston points to the exhaust side
of the engine.
• Before installing the piston pin clip,
cover the crankcase with a clean
rag to prevent the piston pin clip
from falling into the crankcase.
• Install the piston pin clips with their ends facing downward.End gap:
Standard
Top
ring 0.15–0.25 mm
(0.006–0.010 in) 0.50
mm
(0.020
in)
2nd
ring 0.30–0.45 mm
(0.012–0.018 in) 0.80
mm
(0.031
in)
Oil
ring 0.10–0.40 mm
(0.004–0.016 in) —
Outside diameter (piston
pin): 15.991–16.000 mm
(0.6296–0.6299 in)
Inside diameter (piston):16.002–16.013 mm
(0.6300–0.6304 in)
Piston pin-to-pis ton clearance =
Inside diameter (piston) "b" -
Outside diameter (piston pin)
"a"
Piston pin-to-piston
clearance:0.002–0.022 mm
(0.0001–0.0009 in)
:0.07 mm (0.003
in)
New

5-31
CLUTCH
REMOVING THE CLUTCH BOSS
1. Remove:•Nut "1"
• Lock washer "2"
• Clutch boss "3"
Straighten the lock washer tab and
use the clutch holding tool "4" to hold
the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
CHECKING THE CLUTCH
HOUSING AND BOSS
1. Inspect: • Clutch housing "1"
Cracks/wear/damage →Replace.
• Clutch boss "2" Scoring/wear/damage →Replace.
CHECKING THE PRIMARY DRIVEN
GEAR
1. Check: • Circumferential play
Free play exists →Replace.
• Gear teeth "a" Wear/damage →Replace. CHECKING THE CLUTCH
SPRINGS
1. Measure:
• Clutch spring free length "a"
Out of specification →Replace
springs as a set.
CHECKING THE FRICTION
PLATES
1. Measure: • Friction plate thickness
Out of specification →Replace
friction plate as a set.
Measure at all four points.
CHECKING THE CLUTCH PLATES
1. Measure: • Clutch plate warpageOut of specification →Replace
clutch plate as a set.
Use a surface plate "1" and thick-
ness gauge "2". CHECKING THE PUSH LEVER
SHAFT
1. Inspect:
• Push lever shaft "1"
Wear/damage →Replace.
CHECKING THE PUSH ROD
1. Inspect: • Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
•Ball "5"Wear/damage/bend →Replace.
INSTALLING THE PUSH LEVER
SHAFT
1. Install: • Push lever shaft "1"
• Bolt (push lever shaft) "2"
• Apply the lithium soap base grease
on the oil seal lip.
• Apply the engine oil on the push le- ver shaft.
• Fit the seat plate "3" in the groove "a" of the push lever shaft and tight-
en the bolt (seat plate).
Clutch holding tool: YM-91042/90890-04086
Clutch spring free
length:
37.0 mm (1.46 in)
: 36.0 mm (1.42
in)
Friction plate thickness: 2.9–3.1 mm (0.114–
0.122 in)
: 2.7 mm (0.106
in)
Warp limit: 0.1 mm (0.004 in)
Bolt (push lever shaft): 10 Nm (1.0 m•kg, 7.2
ft•lb)

5-40
BALANCER
REMOVING THE BALANCER
1. Straighten the lock washer tab.
2. Loosen:• Nut (primary drive gear) "1"
• Nut (balancer shaft driven gear) "2"
Place an aluminum plate "a" between
the teeth of the balancer shaft drive
gear "3" and driven gear "4".
3. Remove:• Balancer shaft "1"
When removing the balancer shaft,
align the center "a" of the balancer
shaft weight along the line connecting
the centers of the crankshaft and bal-
ancer shaft.
CHECKING THE PRIMARY DRIVE
GEAR, BALANCER SHAFT DRIVE
GEAR AND BALANCER SHAFT
DRIVEN GEAR
1. Inspect:
• Primary drive gear "1"
• Balancer shaft drive gear "2"
• Balancer shaft driven gear "3"Wear/damage →Replace. CHECKING THE BALANCER
SHAFT
1. Inspect:
• Balancer shaft
Cracks/damage →Replace.
INSTALLING THE BALANCER
1. Install: • Balancer shaft "1"
• Apply the engine oil on the bearing.
• When installing the balancer shaft, align the center "a" of the balancer
shaft weight along the line connect-
ing the centers of the crankshaft
and balancer shaft.
2. Install:• Balancer shaft driven gear "1"
Install the balancer shaft driven gear
onto the balancer shaft while aligning
the punch mark "a" on the balancer
shaft driven gear with the lower spline
"b" on the balancer shaft end.
3. Install:• Balancer shaft drive gear "1"
• Align the punched mark "a" on the balancer shaft drive gear with the
punched mark "b" on the balancer
shaft driven gear "2".
• Align the punched mark "c" on the
balancer shaft drive gear with the
lower spline "d" on the crankshaft
end.
4. Install:• Lock washer "1"
• Nut (balancer shaft driven gear) "2"
• Primary drive gear "3"
• Lock washer "4"
• Nut (primary drive gear) "5"
• Install the primary drive gear with its stepped side "a" facing the engine.
• Place an aluminum plate "b" be-
tween the teeth of the balancer
shaft drive gear "6" and driven gear
"7".
5. Bend the lock washer tab.
Nut (balancer shaft driv-
en gear): 50 Nm (5.0 m•kg, 36
ft•lb)
Nut (primary drive gear): 75 Nm (7.5 m•kg, 54
ft•lb)