2016 YAMAHA WR 250F Owners Manual

STEERING HEAD
5-55
EAS2GB7204REMOVING 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.
EAS2GB7205CHECKING 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.
EAS2GB7206INSTALLING 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
5-56
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
5-57
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
5-58
EAS2GB7207
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
5-59
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

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
Order Part name Q’ty Remarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
5
6
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf) kgf, 58 ft
M
M
M
M
M MM

REAR SHOCK ABSORBER ASSEMBLY
5-61
EAS2GB7208HANDLING THE REAR SHOCK ABSORBEREWA
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS2GB7209DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out
rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS2GB7210REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS2GB7211REMOVING THE BEARING
1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:
• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GB7212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.•Spring
Damage/wear  Replace.
• Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts
Bends/damage/wear  Replace.
EAS2GB7213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check:
• Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check:
• Oil seals
Damage/pitting  Replace.
EAS2GB7214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install:
• Bearing “1”
• Washer “2”
• Oil seals “3”
(to relay arm “4”)
1
Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0 mm (0 in)
New
3 3
43
2 2
22
a
1
11