2012 YAMAHA WR 250F clutch

2-13
TIGHTENING TORQUES
Throttle cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable (pull) M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable (return) M12 1 11 Nm (1.1 m•kg, 8.0 ft•lb)
Throttle cable cover M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Hot starter plunger M12 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Hot starter cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
△Air filter case M6 2 8 Nm (0.8 m•kg, 5.8 ft•lb)
Air filter joint and air filter case M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Exhaust pipe M8 2 20 Nm (2.0 m•kg, 14 ft•lb)
△Exhaust pipe protector M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
△Silencer M8 2 30 Nm (3.0 m•kg, 22 ft•lb)
Silencer clamp M8 1 16 Nm (1.6 m•kg, 11 ft•lb)
Spark arrester M5 4 7 Nm (0.7 m•kg, 5.1 ft•lb)
Silencer cap M5 6 5 Nm (0.5 m•kg, 3.6 ft•lb)
Air induction pipe M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Air induction pipe clamp M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Air cut-off valve assembly and bracket M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Bracket (air cut-off valve) and frame M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Crankcase M6 11 12 Nm (1.2 m•kg, 8.7 ft•lb)
Crankcase bearing stopper M6 11 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase bearing stopper (crankshaft) M6 4 14 Nm (1.4 m•kg, 10 ft•lb) Stake.
Left crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Idle gear cover (starter motor)M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Idle gear plate M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Right crankcase cover M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch cover M6 7 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase oil drain bolt M10 1 20 Nm (2.0 m•kg, 14 ft•lb)Copper
washer
△Crankshaft end accessing screw M32 1 —
△Timing mark accessing screw M14 1 —
Drive chain sprocket cover M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Kick shaft ratchet wheel guide M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb) Lock washer
Kickstarter crank M8 1 33 Nm (3.3 m•kg, 24 ft•lb)
Primary drive gear M18 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Clutch spring M6 5 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch boss M16 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Clutch cable locknut M8 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Push lever shaft M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Drive sprocket M18 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Drive axle oil seal stopper M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Segment M8 1 30 Nm (3.0 m•kg, 22 ft•lb)
Shift guide M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Stopper lever M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Shift pedal M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)ItemThread
sizeQ'ty Tightening torque Remarks

2-14
TIGHTENING TORQUES
CHASSIS
△- marked portion shall be checked for torque tightening after break-in or before each race.
ItemThread
sizeQ'ty Tightening torque Remarks
△Upper bracket and outer tube M84 21 Nm (2.1 m•kg, 15 ft•lb)
△Lower bracket and outer tube M8 4 21 Nm (2.1 m•kg, 15 ft•lb)
△Upper bracket and steering stem M24 1 145 Nm (14.5 m•kg, 105 ft•lb)
△Handlebar upper holder and handlebar
lower holderM8 4 28 Nm (2.8 m•kg, 20 ft•lb)
△Handlebar lower holder and upper brack-
etM10 2 34 Nm (3.4 m•kg, 24 ft•lb)
△Steering stem and steering ring nut M28 1 Refer to TIP.
Front fork and front fork cap bolt M51 2 30 Nm (3.0 m•kg, 22 ft•lb)
Front fork and base valve M30 2 55 Nm (5.5 m•kg, 40 ft•lb)Copper
washer
Front fork cap bolt and damper rod M12 2 29 Nm (2.9 m•kg, 21 ft•lb)
Front fork bleed screw and front fork cap
boltM5 2 1 Nm (0.1 m•kg, 0.7 ft•lb)
△Front fork and front fork protector M6 6 7 Nm (0.7 m•kg, 5.1 ft•lb)
△Front fork protector and brake hose hold-
erM6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle grip cap M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
△Front brake master cylinder M6 29 Nm (0.9 m•kg, 6.5 ft•lb)
Brake lever mounting bolt M6 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Brake lever mounting nut M6 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Brake lever position locknut M6 1 5 Nm (0.5 m•kg, 3.6 ft•lb)
△Front brake hose guide and front brake
hose guide bracketM5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
△Front brake hose guide and lower bracket M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Clutch lever holder M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Clutch lever mounting nut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Hot starter lever holder M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Hot starter lever mounting nut M5 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Front brake master cylinder cap M4 2 2 Nm (0.2 m•kg, 1.4 ft•lb)
△
Front brake hose union bolt M10 2 30 Nm (3.0 m•kg, 22 ft•lb)Copper
washer
△Front brake caliper M8 2 23 Nm (2.3 m•kg, 17 ft•lb)
△Front brake caliper and brake hose holder M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Pad pin plug M10 2 3 Nm (0.3 m•kg, 2.2 ft•lb)
△Front brake caliper and pad pin M10 1 18 Nm (1.8 m•kg, 13 ft•lb)
△Rear brake caliper and pad pin M10 1 18 Nm (1.8 m•kg, 13 ft•lb)
△Brake caliper and bleed screw M8 2 6 Nm (0.6 m•kg, 4.3 ft•lb)
△Front wheel axle and axle nut M16 1 90 Nm (9.0 m•kg, 65 ft•lb)
△Front wheel axle holder M8 4 21 Nm (2.1 m•kg, 15 ft•lb)
△Front brake disc M6 6 12 Nm (1.2 m•kg, 8.7 ft•lb)
△Rear brake disc M6 6 14 Nm (1.4 m•kg, 10 ft•lb)

2-21
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

2-22
CABLE ROUTING DIAGRAM
A. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Fasten the throttle cable, hot
starter cable and rectifier/regula-
tor lead onto the frame. Locate
the clamp under the throttle ca-
ble on the right side of the frame,
and face its ends, as well as the
tie ends, downward.
C. Fasten the diode (at the mark-
ing), throttle cable and hot start-
er cable onto the frame. Locate
the clamp end facing toward the
lower right of the frame and with
the tie end facing downward.
D. Fasten the wire harness, throttle
position sensor lead, starter mo-
tor lead and negative battery
lead onto the frame. Pass the
clamp through the hole in the
stay (air cut-off valve). Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
E. Pass the carburetor breather
hoses, carburetor overflow hose
and catch tank breather hose
between the connecting rod and
cross tube (frame).
F. Fasten the neutral switch lead
and oil hose together with the
plastic locking ties and cut off
the tie ends.
G. Fasten the neutral switch lead
and AC magneto lead onto the
frame. Locate the clamp end
facing toward the outside of the
frame and tie end facing toward
the rear of the frame.
H. Pass the clutch cable through
the cable guide.
I. Fasten the starter motor lead,
AC magneto lead and neutral
switch lead onto the frame. Lo-
cate the clamp end facing to-
ward the rear of the frame and
cut off the tie end.
J. Fasten the clutch cable, starter
motor lead, negative battery
lead, AC magneto lead and neu-
tral switch lead onto the frame.
Locate the clamp end facing to-
ward the rear of the frame and
cut off the tie end.
K. Pass the neutral switch lead and
AC magneto lead on the inside
of the wire harness.
L. Fasten the clutch cable, AC
magneto lead and neutral switch
lead onto the frame. Locate the
clamp end near the clutch cable
and cut off the tie end.M. Pass the clutch cable and wire
harness through the cable
guide.
N. Locate the couplers in the frame
recess.
O. Pass the carburetor breather
hoses, carburetor overflow hose
and catch tank breather hose so
that the hoses do not contact the
rear shock absorber.
P. Secure the coupler by pushing it
into the hole in the headlight
unit.
Q. Fasten the throttle position sen-
sor lead and the hot starter ca-
ble.
R. Locate the clamp between the
hot starter cable protector and
rubber cap.

2-27
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 bracket
11. Main switch12. 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

2-28
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.

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART (For
Canada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
1 ClutchCheck operation.

Adjust or replace cable.
2 * Cooling systemCheck 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 brakeCheck operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brakeCheck operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hosesCheck for cracks or damage.
Replace. Every 4 years
7 * WheelsCheck runout, spoke tightness and for dam-
age.

Tighten spokes if necessary.
8*TiresCheck tread depth and for damage.
 Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearingsCheck bearings for smooth operation.

Replace if necessary.
10 * Swingarm pivot bearingsCheck bearing assemblies for looseness.

Moderately repack with lithium-soapbased
grease.
11 Drive chainCheck chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearingsCheck bearing assemblies for looseness.
 Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13Brake and clutch lever pivot
shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.
14 Brake pedal pivot shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.
3

3-4
MAINTENANCE INTERVALS FOR COMPETITION USE
VALVE LIFTERS
Inspect●Check for scratches and wear.
Replace●
CAMSHAFTS Inspect the camshaft surface.
Inspect●Inspect the decompression system.
Replace●
CAMSHAFT SPROCKETS
Inspect●Check for wear on the teeth and for
damage.
Replace●
PISTON
Inspect●●Inspect crack.
Clean●Inspect carbon deposits and eliminate
them.
Replace●It is recommended that the piston pin
and ring are also replaced at the same
time.
PISTON RING
Inspect●Check ring end gap.
Replace●●
PISTON PIN
Inspect●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean●Change gasket.
CYLINDER
Inspect and clean●Inspect score marks.
Replace●Inspect wear.
CLUTCH
Inspect and adjust●●Inspect housing, friction plate, clutch
plate and spring.
Replace●
TRANSMISSION
Inspect●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BAR
Inspect●Inspect wear.
ROTOR NUT
Retighten●●
MUFFLER
Inspect and retighten●●
Clean●
Replace● ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks