2010 YAMAHA WR 250F relay

2-11
MAINTENANCE SPECIFICATIONS
Charging system:System type AC magneto ----
Model (stator)/manufacturer 5UM 30/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–Ground) ----
Lighting coil resistance (color) 0.224–0.336 Ω at 20 °C (68 °F) (Yellow–Ground) ----
Rectifier/regulator: Regulator type Semiconductor short circuit ----
Model/manufacture SH770AA/SHINDENGEN----
Regulated voltage (AC) 12.5–13.5 V ----
Regulated voltage (DC) 14.0–15.0 V ----
Rectifier capacity (AC) 12 A----
Rectifier capacity (DC) 8 A----
Electric starting system: Type Constant mesh----
Starter motor: Model/manufacturer 5UM01/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.0189–0.0231 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14
in)
Brush quantity 2 pcs. ----
Spring force 3.92–5.88 N (400–600 g, 14.1–21.2 oz) ----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65
in)
Mica undercut (depth) 1.5 mm (0.06 in) ----
Starter relay: Model/manufacturer RC19-042/MITSUBA ----
Amperage rating 180 A ----
Coil winding resistance 4.2–4.6 Ω at 20 °C (68 °F) ----
Starting circui t cut-off relay:
Model/manufacturer ACM33221 M38/MATSUSHITA ----
Coil winding resistance 75.69–92.51 Ω at 20 °C (68 °F) ----
Fuse (amperage×quantity): Main fuse 10 A × 1----
Reserve fuse 10 A × 1----
Item
StandardLimit

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 22 2.2 16
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
Headlight body and headlight unit —2 1 0.1 0.7
Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-16
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL
Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m •kg, 47 ft•lb).
△Headlight M6 × 1.0 2 7 0.7 5.1
Taillight — 3 1 0.1 0.7
Taillight lead clamp and rear fender — 3 0.5 0.05 0.36
△ Catch tank (upper) M6 × 1.0 1 16 1.6 11
△ Catch tank (lower) M6 × 1.0 1 7 0.7 5.1
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
Sidestand M10 × 1.25 1 25 2.5 18
Front reflector (For CDN) M6 × 1.0 2 4 0.4 2.9
Rear reflector (For CDN) M5 × 0.8 3 2 0.2 1.4 Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5× 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1Refer to TIP.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Negative lead and cylinder head M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2

2-26
CABLE ROUTING DIAGRAM
A. Fasten the wire harness, nega-tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side) . Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame.
B. Fasten the wire harness, nega- tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side). Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame. Clamp the wire harness
and negative lead at the mark-
ing.
C. Pass the starter motor lead
through the hole in the relay
holder.
D. Fit the cover securely.
E. Connect the wire harness to the starter relay.
F. Fasten the catch tank breather
hose and catch tank hose to the
rear frame. Clamp them close to
where they are joined to the
frame. Fasten the pipe tightly
enough not to crush it. Locate
the clamp end facing toward the
rear of the frame with the tie end
facing downward.
G. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the upper side of
the frame and cut off the tie end.
H. Connect the negative battery
lead to the battery negative ter-
minal.
I. Connect the negative battery
lead to the wire harness.
J. Fasten the wire harness to the rear frame. Locate the clamp
end facing toward the upper side
of the frame and the tie end to-
ward the inside of the frame.
Clamp the wire harness at the
marking.
K. Pass the wire harness, starter
relay lead, starting circuit cut-off
relay lead and negative battery
lead through the hole in the relay
holder.
L. Fasten the (three) CDI unit leads and taillight lead to the rear
frame. Locate the clamp end
facing toward the lower side of
the frame and cut off the tie end. M. Fasten the taillight lead to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and cut off the tie
end.
N. Do not allow the taillight lead to slacken.
O. Locate the CDI unit lead be- tween the CDI unit and rear
fender.
P. Locate the CDI unit coupler in the clearance between the up-
per side of the CDI unit and low-
er side of the catch tank stay.
Q. Locate the CDI unit lead be- tween the CDI unit and rear
frame.

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-40
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

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
5 Pivot shaft 1
6 Swingarm 1

6-32
SWINGARM
DISASSEMBLING THE SWINGARMOrder Part name Q'ty Remarks1 Cap 2 Refer to removal section.
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bushing 2
8 Oil seal 8
9 Bearing 10 Refer to removal section.

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)