2016 YAMAHA WR 250F engine

EAS2GB7005
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-oper-
ation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme-
diately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.

EAS2GB7007
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Locking agent (LOCTITE®)
Engine oil Replace the part with a new one.
G
M
BF
B
T R..
LS
M
S
LT
E
New

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TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
TUNING
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING

1
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................ 1-1
DESCRIPTION.................................................................................................. 1-4
IDENTIFICATION............................................................................................. 1-5
VEHICLE IDENTIFICATION NUMBER ...................................................... 1-5
ENGINE SERIAL NUMBER ....................................................................... 1-5
VEHICLE EMISSION CONTROL INFORMATION LABEL......................... 1-5
INCLUDED PARTS.......................................................................................... 1-6
SPARK PLUG WRENCH ........................................................................... 1-6
NIPPLE WRENCH...................................................................................... 1-6
HANDLEBAR PROTECTOR ...................................................................... 1-6
FUEL HOSE JOINT COVER ...................................................................... 1-6
COUPLER FOR CONNECTING OPTIONAL PART................................... 1-6
IMPORTANT INFORMATION.......................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY............................ 1-7
REPLACEMENT PARTS............................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS ..................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS ...................................... 1-8
BEARINGS AND OIL SEALS ..................................................................... 1-8
CIRCLIPS ................................................................................................... 1-8
BASIC SERVICE INFORMATION.................................................................... 1-9
ELECTRICAL SYSTEM.............................................................................. 1-9
SPECIAL TOOLS........................................................................................... 1-13
CONTROL FUNCTIONS................................................................................ 1-19
INDICATOR LIGHTS AND WARNING LIGHTS ....................................... 1-19
ENGINE STOP SWITCH .......................................................................... 1-19
START SWITCH....................................................................................... 1-19
CLUTCH LEVER...................................................................................... 1-19
SHIFT PEDAL .......................................................................................... 1-20
KICKSTARTER LEVER............................................................................ 1-20
THROTTLE GRIP ..................................................................................... 1-20
FRONT BRAKE LEVER ........................................................................... 1-20
REAR BRAKE PEDAL.............................................................................. 1-20
SIDESTAND ............................................................................................. 1-21
STARTER KNOB/IDLE ADJUSTING SCREW ......................................... 1-21
FUEL TANK CAP ..................................................................................... 1-21

MULTI-FUNCTION DISPLAY......................................................................... 1-22
DESCRIPTION ......................................................................................... 1-22
BASIC MODE ........................................................................................... 1-22
CHANGEOVER TO BASIC MODE/RACE MODE.................................... 1-23
RACE MODE ............................................................................................ 1-24
FUNCTION DIAGRAM ............................................................................. 1-28
STARTING AND BREAK-IN.......................................................................... 1-30
FUEL ........................................................................................................ 1-30
HANDLING NOTE .................................................................................... 1-30
AIR FILTER MAINTENANCE ................................................................... 1-30
STARTING A COLD ENGINE .................................................................. 1-30
STARTING A WARM ENGINE ................................................................. 1-31
BREAK-IN PROCEDURES ...................................................................... 1-32
MAINTENANCE AFTER BREAK-IN.............................................................. 1-33
MAJOR MAINTENANCE .......................................................................... 1-33
TORQUE-CHECK POINTS............................................................................ 1-34
MOTORCYCLE CARE AND STORAGE........................................................ 1-36
CARE........................................................................................................ 1-36
STORAGE ................................................................................................ 1-37

DESCRIPTION
1-4
EAS2GB7009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.1. Clutch lever 12. Headlight
2. Multi-function display 13. Radiator
3. Front brake lever 14. Coolant drain bolt
4. Throttle grip 15. Rear brake pedal
5. Start switch 16. Air filter
6. Radiator cap 17. Drive chain
7. Fuel tank cap 18. Shift pedal
8. Engine stop switch 19. Oil level check window
9. Taillight 20. Starter knob/idle screw
10. Fuel tank 21. Front fork
11. Kickstarter lever
32 1
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10
91112 1376
54
15 14 21 20 19 18 1716

IDENTIFICATION
1-5
EAS2GB7010
IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive iden-
tification of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
EAS2GB7011VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the right side of the frame.
EAS2GB7012ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into
the elevated part of the right-side of the engine.
EAS2GB7013VEHICLE EMISSION CONTROL INFORMA-
TION LABEL
The Vehicle Emission Control Information label
“1” is affixed at the location in the illustration.
This label shows specifications related to ex-
haust emissions as required by federal law,
state law and Environment Canada.A: For Canada
B: For USA and Canada
1
1
1
1

IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS2GB7020PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment.
See “SPECIAL TOOLS”.
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them.4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS2GB7021REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.