2016 YAMAHA WR 250F Owners Manual

FRONT FORK
5-47
TIP
• Apply the lithium-soap-based grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat “a”
with fork oil applied to protect the oil seal lip.
15.Install:
• Inner tube bushing “1”
TIP
Install the inner tube bushing onto the slot on
inner tube.
16.Install:
• Outer tube “1”
(to the inner tube “2”)17.Install:
• Inner tube bushing “1”
• Washer “2”
(to the outer tube)
TIP
Press the inner tube bushing into the outer tube
with fork seal driver “3”.
18.Install:
• Oil seals “1”
TIP
Using a fork seal driver “2”, press the oil seal in
until the stopper ring groove fully appears.
LS
New
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948
New

FRONT FORK
5-48
19.Install:
• Oil seal clip “1”
TIP
Fit the oil seal clip correctly in the groove in the
outer tube.
20.Install:
• Dust seal “1”
TIP
Apply lithium-soap-based grease on the inner
tube.
21.Check:
• Inner tube smooth movement
Tightness/binding/rough spots  Repeat
the steps 14 to 20.22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
23.Install:
• Collar “1”
• Fork spring “2”
(to the damper assembly “3”)
TIP
Install the collar with its larger dia. end “a” fac-
ing the fork spring.
New
Distance “a”
16 mm (0.63 in) or more
Between the damper assembly
“1” bottom and locknut “2” bot-
tom.
1 2a
12
3
a

FRONT FORK
5-49
24.Install:
• Damper assembly “1”
(to the inner tube “2”)
ECA
NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
25.Loosen:
• Rebound damping force adjuster “1”
TIP
• Before loosening the damping force adjuster,
record the setting position.
• Unless the damping force adjuster is fully
loosened, correct damping characteristic can-
not be obtained after installation.
26.Install:
• Damper adjusting rod “1”
• Copper washer “2”
• Adjuster “3”
(to the damper assembly “4”)
TIP
• While compressing the inner tube “5”, set the
cap bolt ring wrench “7” between the inner
tube and locknut “6”.
• Fully finger tighten the adjuster onto the
damper assembly.27.Measure:
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and read-
just the locknut.
TIP
If it is installed with a gap out of specification,
correct damping force cannot be obtained.
28.Tighten:
• Adjuster (locknut) “1”
TIP
Hold the locknut “2” and tighten the adjuster.
1
2
1
New
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
Gap “a” between the adjuster and
the locknut
0.5–1.0 mm (0.02–0.04 in)
Adjuster (locknut)
29 Nm (2.9 m·kgf, 21 ft·lbf)
1
2a
T R..

FRONT FORK
5-50
29.Install:
• Adjuster “1”
(to the inner tube)
30.Fill:
• Front fork leg
ECA
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.31.Install:
• Damper assembly “1”
(to the outer tube)
TIP
Temporarily tighten the damper assembly.
32.Install:
• Protector guide “1”
EAS2GB7202INSTALLING THE FRONT FORK LEGS
1. Install:
• Front fork “1”
TIP
• Temporarily tighten the pinch bolts (lower
bracket).
• Do not tighten the pinch bolts (upper bracket)
yet. Adjuster
55 Nm (5.5 m·kgf, 40 ft·lbf)
LOCTITE®
Recommended oil
Suspension oil S1
Standard oil amount
340 cm
3 (11.50 US oz, 11.99
lmp.oz)
Extent of adjustment
300–365 cm
3 (10.14–12.34 US
oz, 10.58–12.87 lmp.oz)
T R..
1LT
1

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
EAS2GB7203
STEERING HEAD
Removing the lower bracket
Order Part name Q’ty Remarks
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-36.
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
2
4
5
7
3
(2)(2)
(2)
(2) (2)
1
6
8
9
10
LS
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
T
.R.38 Nm (3.8 mlbf) kgf, 27 ft
7 Nm (0.7 m
lbf) kgf, 5.1 ft
*
*

STEERING HEAD
5-54
For installation, reverse the removal proce-
dure.
Removing the lower bracket
Order Part name Q’ty Remarks
2
4
5
7
3
(2)(2)
(2)
(2) (2)
1
6
8
9
10
LS
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
T
.R.38 Nm (3.8 mlbf) kgf, 27 ft
7 Nm (0.7 m
lbf) kgf, 5.1 ft
*