Yamaha WR250FR Assembly Manual
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Yamaha WR250FR Assembly Manual

Yamaha WR250FR Assembly Manual

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  • Page 3: Assembly Manual

    WR250FR ASSEMBLY MANUAL LIT-11666-16-48 5UM-28107-10...
  • Page 4 Since some external parts of the machine have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled machine should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer.

  • Page 5: Symbols Used In Assembly Manual

    EAA00008 SYMBOLS USED IN ASSEMBLY MANUAL In order to simplify descriptions in this assembly manuals, the following symbols are used: (1) Coat with lithium-soap-based-grease. (2) Tighten to 10 Nm. (10 Nm = 1.0 mdkg = 7.2 ftdlb) (3) Towards the front of the machine. (4) Clearance required.
  • Page 6 EAA00040 PREPARATION To assemble the machine correctly, sup- plies (e.g. oils, greases, and shop rags) and sufficient working space are required. Workshop The workshop where the machine is assem- bled, should be clean, specious, and have a level floor. Self-protection Protect your eyes with suitable safety glasses or goggles when using com- pressed air, when grinding or when doing...
  • Page 7 EAA00060 UNPACKING 1. Remove the frame cover (1). NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the carton boxes (2), front tire (3). 3. Remove the packing frame bolt (4), and handlebar holder bolts (5).

  • Page 8: Parts Location

    EAA00070 PARTS LOCATION 1. Front wheel 2. Front fender 3. Carton Box 1 4. Carton Box 2 - 2 -...
  • Page 9 Packing frame 1. Front wheel 2. Front fender EAA00080 Carton Box 1 3. Handlebar 4. Headlight 5. Plastic bag 6. Handlebar upper holder 7. Flange bolt [d=8 (0.31), l=35 (1.38)] 8. Master cylinder bracket 9. Flange bolt [d=6 (0.24), l=22 (0.87)] 10.Panhead screw (light switch) [d=4 (0.16), l=14 (0.55)] 11.Bracket (light switch)

  • Page 10: Setup Procedures

    EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown. - 4 -...

  • Page 11: Throttle Grip

    EAA00200* C: Connect the couplers. 1. HANDLEBAR CAUTION: Proper cable and lead routing A: Clean the right handlebar end. is essential to assure safe Apply light coat grease. machine operation. Refer to "CABLE ROUTING". B: First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side to speci-...
  • Page 12 I: Tighten the front wheel axle nut to specification. Front wheel axle: 105 Nm (10.5 mdkg, 75 ftdlb) J: Tighten the front axle bolts to specification. Front axle bolts: 23 Nm (2.3 mdkg, 17 ftdlb) 1 Front wheel 2 Front wheel axle 3 Collar (front wheel axle) d=20 (0.79) 4 Trip meter gear unit...
  • Page 13 EAA00030 C: Tighten the brake hose hold- 5. FRONT BRAKE HOSE er bolts to specification. HOLDER Bolt: 10 Nm (1.0 mdkg, 7.2 ftdlb) A: Remove the front fork cover D: Slide the front fork cover to its bolts to slide the front fork cover upwards.

  • Page 14: Front Fender

    EAA00109 7. FRONT FENDER A: Install the collars. B: Tighten the bolts to specifica- tion. Bolt: 7 Nm (0.7 mdkg, 5.1 ftdlb) CAUTION: Be careful not to scratch the front fender with the front fork outer tubes. 1 Front fender Hexagon bolt with plain d=6 (0.24), l =20 (0.79) Proper cable routing is essen-...

  • Page 15: Light Switch

    EAA00198* While releasing the lever, seat the outer cable into the lever 10. HOT STARTER (CHOKE) holder. CABLE D: Install the boot to the hot starter (choke) lever. A: Install the boot to the hot starter (choke) lever cable. NOTE: B: Lubricate the pivoting part of Check the hot starter (choke) the hot starter (choke) lever.

  • Page 16: Handlebar Clamp

    EAA00039* 13. HANDLEBAR CLAMP A: Secure the left handlebar switch lead with a cableclamp. B: Secure the right handlebar switch lead with a cableclamp. NOTE: Refer to “CABLE ROUTING”. 1 Handlebar clamp EAA00209* 14. CABLE CLAMP A: Clamp the hot starter (choke) cable and clutch cable.
  • Page 17 EAA00109* 16. AIR SCOOP (LEFT) A: Tighten the screws to specifi- cation. Screw: 4 Nm (0.4 mdkg, 2.9 ftdlb) B: Tighten the bolt to specifica- tion. Bolt: 4 Nm (0.4 mdkg, 2.9 ftdlb) 1 Air scoop (left) Panhead screw with plain washer (air scoop) Hexagon bolt with plain washer (air scoop)

  • Page 18: Cable Routing

    EAA00900 CABLE ROUTING CAUTION: Proper cable and lead routing are essential to insure safe machine operation. (1) Fuel tank breather hose (2) Hot starter (choke) cable (3) Negative battery lead (4) Lights switch lead (5) Brake hose (6) Hose guide (7) Cable guide (A)Pass the fuel tank breather hose into the hole in the steering shaft cap.
  • Page 19 (1) Hot starter (choke) cable (2) Cable guide (3) Throttle cable (return) (4) Throttle cable (pull) (A)Pass the throttle cables and hot starter (choke) cable through the cable guides. (B)Pass the throttle cables, and hot starter (choke) cable between the radiator and frame, then under the radiator mounting boss. (C)Pass the throttle cables on the outside of the ignition coil.
  • Page 20 (1) Negative battery lead (2) Positive battery lead (3) Battery (A)Position the start motor lead, negative battery lead and wire harness in the tank damper slit. - 14 -...
  • Page 21 (1) Throttle cable (A)Fasten the start switch lead and lights switch lead to the handle- (2) Brake hose bar with a plastic band. (3) Clamp (B)Fasten the "ENGINE STOP" button lead and clutch switch lead (4) Lights switch lead to the handlebar with the plastic bands. (5) Hot starter cable (C)Pass the brake hose though the hose guide.

  • Page 22: Adjustments And Predelivery Service

    EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown. - 16 -...

  • Page 23: Checking And Charging The Battery

    EAA01000 CAUTION: A. CHECKING AND CHARGING D D If the voltage is lower than 12.8 V the battery must be charged. If this THE BATTERY is not done, the life of the battery will be shortened drastically. Refer CAUTION: battery to the service manual for The battery used in this machine is a charging...

  • Page 24: Measuring The Tire Pressure

    EAA01009 Basic weight: C. MEASURING THE TIRE PRES- With oil,coolant and full fuel tank SURE 122.1 kg (269 lb) Cold tire pressure: 1. Measure: Front 100 kPa (1.0 kgf/cm , 15 psi) Dtire pressure Rear 100 kPa (1.0 kgf/cm , 15 psi) Out of specification>Adjust.

  • Page 25: Adjusting The Front Brake

    EAA01024 Locknut: F. ADJUSTING THE FRONT 5 Nm (0.5 mdkg, 3.6 ftdlb) BRAKE Direction (a): 1. Measure: Brake lever distance is increased. Dbrake lever position (a) Direction (b): (distance (a) from the throttle grip to Brake lever distance is decreased. the brake lever) Out of specification>Adjust.

  • Page 26: Checking The Brake Fluid Level

    EAA01032 H. CHECKING THE BRAKE FLUID D Use only designated brake fluid. LEVEL Other brake fluids may cause the rubber seals to deteriorate, causing 1. Stand the machine on a level surface. leakage and poor brake perfor- NOTE: mance. Make sure that the machine is upright. D Refill with the same type of brake fluid that is already in the system.

  • Page 27: Checking The Engine Oil Level

    EAA01013 NOTE: D Before checking the engine oil level, J. CHECKING THE ENGINE OIL wait a few minutes until the oil has set- LEVEL tled. D Do not screw the dipstick in when 1. Stand the machine on a level surface. inspecting the oil level.

  • Page 28: Adjusting The Drive Chain Slack

    2. Adjust: NOTE: Dclutch cable free play D Make minute adjustment on the lever a. Loosen the locknuts (1). side using the adjusting dial (2). D After adjustment, check proper b. Adjust the free play by changing their operation of clutch lever. tightening position.

  • Page 29: Adjusting The Rear Shock Absorber Assembly

    EAA01049 Direction (a): Spring preload is increased (sus- O. ADJUSTING THE REAR SHOCK pension is harder). ABSORBER ASSEMBLY Direction (b): Spring preload is decreased (sus- Spring preload pension is softer). Securely support the machine so that Adjusting length (l): there is no danger of it falling over. Standard: 245 mm (9.65 in) Minimum: 240.5 mm (9.47 in) 1.

  • Page 30: Adjusting The Front Fork Legs

    EAA01041 1. Adjust: Drebound damping P. ADJUSTING THE FRONT FORK a. Turn the adjusting screw (1) in direc- LEGS tion (a) or (b). The following procedure applies to both of Direction (a): the front fork legs. Rebound damping is increased (suspension is harder).

  • Page 31: Service Data

    EAA10000 APPENDICES SERVICE DATA Engine idling speed: 1,900~2,100r/min Spark plug: Type /Manufacturer CR8E/NGK (resistance type) 0.7~0.8 mm (0.028~0.031 in) Fuel: Recommended fuel Premium unleaded gasoline only with a research octane number of 95 or higher. Fuel tank capacity 10L (2.2 lmp gal, 2.64 US gal) Valve clearance (cold): 0.10~0.15 mm (0.0039~0.0059 in) 0.17~0.22 mm (0.0067~0.0087 in)

  • Page 32: Tightening Torque

    EAA10300 TIGHTENING TORQUE Tightening torque Item Thread size mdkg ftdlb Engine: Engine oil drain bolt (crankcase) M 6 x1.0 Spark plug M10Sx1.0 Chassis: Handle crown and outer tube M 8 x1.25 Under bracket and outer tube M 8 x1.25 Handle crown and steering shaft M24x1.0 14.5 Handlebar holder (upper)
  • Page 33 Tightening torque Item Thread size mdkg ftdlb Rear wheel axle and nut M20x1.5 12.5 Driven sprocket and wheel hub M 8 x1.25 Nipple (spoke) Disc cover and rear brake caliper M 6 x1.0 Protector and rear brake caliper M 6 x1.0 Chain puller adjust bolt and locknut M 8 x1.25 Engine mounting:...
  • Page 34 PRINTED IN U.S.A.

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