2016 YAMAHA WR 250F wheel

REAR BRAKE
5-29
EAS2GB7187INSTALLING THE BRAKE CALIPER PISTON
1. Clean:
• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper piston
Use brake fluid for cleaning.
2. Install:
• Brake caliper piston seals “1”
• Brake caliper piston dust seal “2”
EWA
WARNING
Always use new brake caliper piston seal
and brake caliper piston dust seal.
TIP
• Apply the silicone grease on the brake caliper
piston seal and brake caliper piston dust seal.
• Fit the brake caliper piston seals and brake
caliper piston dust seals onto the slot on
brake caliper correctly.
3. Install:
• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing
the brake caliper.
• Never force to insert.
EAS2GB7188INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Rear brake caliper
• Rear brake caliper bracket
2. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 5-9.
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that a bend in its pipe portion “a”
is directed as shown and the brake hose
touches the projection “b” on the brake cal-
iper.
3. Install:
• Brake pad springs
• Brake pads
• Brake pad pin
• Brake pad pin plug
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-28.
4. Pour brake fluid to the brake fluid reservoir
up to the specified level.
New
New
2
1
1
a1
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Specified brake fluid
DOT 4
New
T R..
b
b
a
T R..

FRONT FORK
5-40
EAS2GB7197
FRONT FORK
Removing the front fork legs
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Front wheel Refer to “FRONT WHEEL” on page 5-4.
Front brake caliper Refer to “FRONT BRAKE” on page 5-13.
1 Brake hose holder 2
2 Protector 1
3 Upper bracket pinch bolts 2 Loosen.
4 Damper assembly 1 Loosen.
5 Lower bracket pinch bolts 2 Loosen.
6 Front fork leg 1
7 Reflector/Stay/Nut 1 For Canada
For installation, reverse the removal proce-
dure.

FRONT FORK
5-42
EAS2GB7198REMOVING THE FRONT FORK LEGS
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.
TIP
Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.
2. Loosen:
• Upper bracket pinch bolts
• Damper assembly
• Lower bracket pinch bolts
EWA
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.
3. Remove:
• Front fork leg (s)
EAS2GB7199DISASSEMBLING THE FRONT FORK LEGS
1. Drain:
• Fork oil
2. Remove:
• Adjuster “1”
(from the inner tube)
TIP
• While compressing the inner tube “2”, set the
cap bolt ring wrench “4” between the inner
tube and locknut “3”.
• Hold the locknut and remove the adjuster.
ECA
NOTICE
Do not scratch the inner tube.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA
NOTICE
Do not scratch the inner tube.
4. Remove:
• Inner tube “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push in slowly “a” the inner tube just before
it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be
pulled out from the outer tube. Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
12
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
1
234
1
2

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
5-55
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

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

SWINGARM
5-65
EAS2GB7216
SWINGARM
Removing the swingarm
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 5-23.
Rear brake caliper Refer to “REAR BRAKE” on page 5-23.
Bolt (brake pedal)
Drive chain
1Collars 2
2Oil seals 2
3Thrust bearing 2
4Bushing 2
5Oil seals 2
6Bearing 4
For installation, reverse the removal proce-
dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf) kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf) kgf, 2.9 ft

SWINGARM
5-66
EAS2GB7217REMOVING THE SWINGARM
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. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GB7218REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GB7219CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..