2016 YAMAHA WR 250F brake sensor

TIGHTENING TORQUES
2-18
Drive chain tensioner bolt (lower
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain support nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide bolt M5 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side) M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bolt M5 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel sender screw M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw — 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Headlight body and headlight stay
boltM6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Multi-function meter nut M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Multi-function meter bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose guide and head-
light stay boltM5 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 1 and front fork protector bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 2 and front fork protector
screw— 2 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Speed sensor lead holder and
speed sensor lead bracket boltM6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Speed sensor lead bracket and low-
er bracket boltM6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Starter relay and positive battery
lead boltM6 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks

LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GB7070CHASSISShift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
Starter idle gear inner surface, thrust surfaces
Starter clutch drive gear inner surface, thrust surfaces
Cylinder head cover gasketThree bond
No.1215®
Crankcase mating surfaceThree bond
No.1215®
Stator assembly lead grommetThree bond
No.1215®
Lubrication point Lubricant types
Upper bearings (steering head)
Upper bearings and bearing race cover (steering head)
Lower bearings and oil seal lip (steering head)
Steering stem threads and nut contacting surface
Pivot shaft bearing
Swingarm pivot portion (collar side surface and thrust bearing)
Swingarm pivot portion (collar outer surface)
Swingarm pivot portion (oil seal lip)
Pivot shaft outer surface
Relay arm bearing and oil seal lip
Relay arm thrust washer surface (both sides)
Relay arm collar outer surface and bolt outer surface
Relay arm bolt threads (swingarm side)
Connecting arm bearing and oil seal lip
Connecting arm collar outer surface and bolt outer surface
Rear shock absorber assembly collar outer surface and dust seal lip (upper
side)
Rear shock absorber assembly bearing and dust seal lip (lower side)
Brake pedal pivot portion (O-ring and bolt outer surface)
Front wheel oil seal lip
Front wheel axle outer surface
Speed sensor oil seal lip
Rear wheel oil seal lip
Rear wheel axle outer surface
Sidestand pivot portion and collar outer surface
Brake lever contacting portion (front brake master cylinder)
Front brake lever bolt outer surface
Clutch lever sliding surface and bolt outer surfaceLubrication point Lubricant types
E
E
E
E
LS
LS
LS
LS
M
M
M
M
M
M
M
M
M
M
M
M
M
LS
LS
LS
LS
LS
LS
LS
S
S
LS

CABLE ROUTING DIAGRAM
2-40
1. Clutch switch lead
2. Engine stop switch lead
3. Clutch cable
4. Brake hose guide
5. Headlight lead
6. Speed sensor lead
7. Indicator light coupler
8. Meter assembly optional switch coupler
9. Meter assembly coupler
10. Speed sensor coupler
11. Start switch lead
12. Plastic band
13. Throttle cable
14. Front brake hose
A. Route the throttle cable, clutch cable, clutch
switch lead, engine stop switch lead and start
switch lead between the cable guide of the meter
bracket and handle crown. The cables and leads
may be routed in any order.
B. Clamp the wire harness, clutch switch lead and
start switch lead to the meter bracket. The clamp
shall be located at a position where there is no
slack with the handle turned fully to the left.
C. Connect the headlight lead to the headlight.
D. Clamp the start switch lead to the handlebar by
the plastic band.
E. Clamp the engine stop switch lead and clutch
switch lead to the handlebar by the plastic band.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han-
dlebar.

FRONT WHEEL
5-4
EAS2GB7154
FRONT WHEEL
Removing the front wheel
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6Collar 1
7 Oil seal 1
8 Bearing 2
9 Brake disc 1
For installation, reverse the removal proce-
dure.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
New
LT
LS
LS
LS
8
7 8
(6)
9
12
1 3
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
4
90 Nm (9.0 m kgf, 65 ft lbf)T.R.
5
6

FRONT WHEEL
5-7
3. Install:
• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
4. Install:
• Speed sensor “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip of speed sensor.
Make sure the two projections “a” in the wheel
hub are meshed with the two slots “b” in the
speed sensor.
EAS2GB7159INSTALLING THE FRONT WHEEL
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly.2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the
front wheel axle.
3. Tighten:
• Front wheel axle nut “1”
ECA
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”1
a
b
LS
Front wheel axle nut
90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..

TROUBLESHOOTING
10-3
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
• Faulty coolant temperature sensor
EAS2GB7416OVERCOOLING
Cooling system
1. Coolant temperature sensor
• Faulty coolant temperature sensor
EAS2GB7417POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS2GB7418FRONT FORK OIL LEAKING
Chassis
1. Front fork
• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS2GB7419FAULTY FRONT FORK LEGS
Chassis
1. Front fork
• Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS2GB7420UNSTABLE HANDLING
Chassis
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel (s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race