2015 YAMAHA WR 250F Owners Manual

FRONT FORK
5-51
2. Tighten:
• Damper assembly “1”
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.
3. Adjust:
• Front fork top end “a”4. Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
• Speed sensor lead “1”
• Plate 1 “2”
(to the right front fork protector)
TIP
Install the speed sensor lead so that its paint “a”
directs as shown and align the bottom “b” of the
plate 1 with the same paint. Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
Front fork top end (standard) “a”
5 mm (0.20 in)
T R..
2
1
a
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Plate 1 bolt
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
T R..
21
T R..
1 2
a b

FRONT FORK
5-52
6. Install:
• Speed sensor lead “1”
• Plate 2 “2”
(to the right front fork protector)
TIP
Install the plate 2 in the direction as shown.
7. Install:
• Protector “1”
• Bolt (protector) “2”
8. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.9. Adjust:
• Compression damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
Plate 2 screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Bolt (protector)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
1
212
T R..
1
2
1
1

STEERING HEAD
5-53
EAS2GB2205
STEERING HEAD
Removing the lower bracket
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Headlight assembly/multi-function meter/front
fenderRefer to “GENERAL CHASSIS” on page 5-1.
Handlebar Refer to “HANDLEBAR” on page 5-33.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg (s) 2 Refer to “FRONT FORK” on page 5-40.
4 Upper bracket 1
5 Steering ring nut 1
6 Lower bracket 1
7 Bearing race cover 1
8 Upper bearing 1
9 Bearing (lower side) 1
10 Bearing races 2
For installation, reverse the removal proce-
dure.
2
4
5
7
3
(2)(2)
(2)
(2) (2)
1
6
8
9
10
LS
1st
2ndT.R.
LS
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.3.8 Nm (0.38 mlbf) kgf, 2.8 ft
T.R.3.8 Nm (0.38 mlbf) kgf, 2.8 ft
T.R.9 Nm (0.9 mlbf) kgf, 6.5 ft
T.R.7 Nm (0.7 mlbf) kgf, 5.1 ftT.R.7 Nm (0.7 mlbf) kgf, 5.1 ft
T.R.10 Nm (1.0 mlbf) kgf, 7.2 ft
T.R.145 Nm (14.5 mlbf) kgf, 105 ft
38 Nm (3.8 m
lbf) kgf, 27 ft
7 Nm (0.7 m
lbf) kgf, 5.1 ft

STEERING HEAD
5-54
EAS2GB2206REMOVING THE LOWER BRACKET
1. Use a suitable stand to raise the front wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rng nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS2GB2207CHECKING THE STEERING HEAD
1. Wash with kerosene:
• Bearing
• Bearing races
2. Check:
• Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering
head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
ECA
NOTICE
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
Always replace the bearing and the bearing
race as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS2GB2208INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium-soap-based grease on the
dust seal lip and bearing inner circumference.
2. Install:
• Bearing races
• Upper bearing “1”
• Bearing race cover “2” Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

STEERING HEAD
5-55
TIP
Apply the lithium-soap-based grease on the
bearing and bearing race cover lip.
3. Install:
• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.
4. Install:
• Steering ring nut “1”
TIP
Install the steering nut with its stepped side “a”
facing downward.
Tighten the steering ring nut with a steering
nut wrench “2”.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-36.5. Check the steering stem by turning this lock
to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.
6. Install:
• Washer “1”
7. Install:
• Front fork “1”
• Upper bracket “2”
TIP
• Temporarily tighten the pinch bolts (lower
bracket).
• Do not tighten the pinch bolts (upper bracket)
yet.
8. Install:
• Steering stem nut “1” Steering ring nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LS
1 a
LSLS
T R..
Steering stem nut
145 Nm (14.5 m·kgf, 105 ft·lbf)
T R..

STEERING HEAD
5-56
TIP
Apply the lithium-soap-based grease to the
contact surface of the steering stem nut when
installing.
9. After tightening the nut, check the steering
for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”
11.Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.12.Install:
• Speed sensor lead holder “1”
• Speed sensor lead clamp “2”
TIP
• Insert the end of the speed sensor lead holder
in the hole in the lower bracket “a”.
• Install so that the marking “b” on the speed
sensor lead aligns with the speed sensor lead
holder edge.
• Install the speed sensor lead clamp while in-
serting it in the hole “c” in the speed sensor
lead holder. Front fork top end (standard) “a”
5 mm (0.20 in)
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
a
T R..
T R..
Speed sensor lead holder bolt
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Speed sensor lead clamp bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
21
T R..

REAR SHOCK ABSORBER ASSEMBLY
5-57
EAS2GB2209
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
Order Part name Q’ty Remarks
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
1 Rear shock absorber assembly lower bolt 1
2 Rear shock absorber assembly upper bolt 1
3 Rear shock absorber assembly 1
4 Locknut 1
5 Adjusting nut 1
6 Lower spring guide 1
7 Upper spring guide 1
8Spring 1
9 Dust seal 2
10 Collars 2
11 Bushing 1
12 Collars 2
2
12
1615
1413
12
14
4
5
7
6
83
9
9 10
10 11
1
New
New
13New
LS
LS
M
M
M
M
M

REAR SHOCK ABSORBER ASSEMBLY
5-58
13 O-ring 2
14 Dust seal 2
15 Stopper ring 1
16 Bearing 1
For installation, reverse the removal proce-
dure.
Removing the rear shock absorber assembly
Order Part name Q’ty Remarks
2
12
1615
1413
12
14
4
5
7
6
83
9
9 10
10 11
1
New
New
13New
LS
LS
M
M
M
M
M