Yamaha WR250FR 2003 Owner's Service Manual
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Yamaha WR250FR 2003 Owner's Service Manual

Yamaha WR250FR 2003 Owner's Service Manual

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OWNER'S SERVICE MANUAL
WR250FR
5UM-28199-10
LIT-11626-16-48

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Summary of Contents for Yamaha WR250FR 2003

  • Page 1 OWNER’S SERVICE MANUAL WR250FR 5UM-28199-10 LIT-11626-16-48...
  • Page 2 EC090000 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC REGULAR INSPECTION AND ADJUSTMENTS INSP ENGINE CHASSIS CHAS – ELECTRICAL ELEC TUNING...

  • Page 3: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-14 STARTING AND BREAK-IN ....1-15 TORQUE-CHECK POINTS ..... 1-19 CLEANING AND STORAGE ....
  • Page 4 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .......... 4-1 EXHAUST PIPE AND SILENCER .... 4-3 RADIATOR ..........4-5 CARBURETOR ......... 4-8 CAMSHAFTS .......... 4-22 CYLINDER HEAD ........4-31 VALVES AND VALVE SPRINGS ... 4-34 CYLINDER AND PISTON ....... 4-43 CLUTCH ..........
  • Page 5 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 ELECTRIC STARTING SYSTEM ....6-8 CHARGING SYSTEM ......6-17 THROTTLE POSITION SENSOR SYSTEM ..........6-19 LIGHTING SYSTEM ........ 6-24 CHAPTER 7 TUNING ENGINE .............

  • Page 6: General Information

    DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Hot starter lever • The machine you have purchased may differ 3 Engine stop switch slightly from those shown in the following. 4 Trip meter • Designs and specifications are subject to 5 Main switch change without notice.

  • Page 7: Machine Identification

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

  • Page 8: Important Information

    IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts follows. • Silencer exhaust port •...

  • Page 9: All Replacement Parts

    IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
  • Page 10 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.

  • Page 11: Checking Of Connection

    CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 13 SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YM-01442, 90890-01442 Fork seal driver This tool is used when install the fork oil seal. YU-3112-C, 90890-03112 Pocket tester Use this tool to inspect the coil resistance, output voltage and amperage. YU-8036-B Inductive tachometer 90890-03113...
  • Page 14 YM-34487 Dynamic spark tester 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components.  ACC-QUICK-GS-KT Quick gasket 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating sur- face, etc. 1 - 9...

  • Page 15: Control Functions

    CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indica- tor light 2 to avoid forgetting to turn it off.
  • Page 16 CONTROL FUNCTIONS INFO EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch.

  • Page 17: Rear Brake Pedal

    CONTROL FUNCTIONS INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel.

  • Page 18: Light Switch

    CONTROL FUNCTIONS INFO LIGHT SWITCH The light switch 1 is located on the handlebar. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward.

  • Page 19: Fuel

    FUEL INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION:...

  • Page 20: Starting And Break-In

    STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: •...
  • Page 21 STARTING AND BREAK-IN INFO NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

  • Page 22: Starting A Warm Engine

    STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick- ing the kickstarter crank forcefully with a firm stroke.

  • Page 23: Break-In Procedures

    STARTING AND BREAK-IN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.

  • Page 24: Torque-Check Points

    TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to Steering stem to frame Steering stem to upper bracket...

  • Page 25: Cleaning And Storage

    CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
  • Page 26 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the car- buretor float bowl.

  • Page 27: Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FR (USA) WR250F (EUROPE) WR250F(R) (CDN, AUS, NZ, ZA) Model code number: 5UM1 (USA) 5UM2 (EUROPE) 5UM4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,165 mm (85.2 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in)
  • Page 28 SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.2 L (1.06 Imp qt, 1.27 US qt) With oil filter replacement 1.3 L (1.14 Imp qt, 1.37 US qt) Total amount 1.4 L (1.23 Imp qt, 1.48 US qt) Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt) Air filter:...
  • Page 29 SPEC GENERAL SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper...

  • Page 30: Maintenance

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm ---- (3.0315 ~ 3.0319 in) Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ----...

  • Page 31: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm ---- (0.0067 ~ 0.0087 in) Valve dimensions:...
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 37.81 mm (1.49 in)
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings: Top ring: Type Barrel...
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.7 mm (0.106 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 in)
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Side clearance 0.09 ~ 0.17 mm 0.24 mm (0.0035 ~ 0.0067 in) (0.009 in)
  • Page 36 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 × 1.25 (stud bolt) M9 ×...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Silencer M8 × 1.25 Silencer clamp M6 × 1.0 Spark arrester (for USA) M6 × 1.0 Silencer end pipe (for USA) M6 × 1.0 Crankcase M6 ×...
  • Page 38 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← ← Front fork travel 460 mm (18.1 in) ← ← Fork spring free length Spring rate, STD K = 4.31 N/mm K = 4.12 N/mm...
  • Page 39 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: USA, CDN, ZA EUROPE, AUS, NZ ← Front wheel type Spoke wheel ---- ← Rear wheel type Spoke wheel ---- 21 × 1.60/Aluminum ← Front rim size/material ---- 18 × 1.85/Aluminum 18 × 2.15/Aluminum ---- Rear rim size/material Rim runout limit: Radial...
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 M8 × 1.25 Handlebar upper holder and upper bracket M28 ×...
  • Page 41 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Nipple (spoke) — M8 × 1.25 Rear wheel sprocket M6 × 1.0 Rear brake disc cover M6 × 1.0 Rear brake caliper protector M8 × 1.25 Drive chain puller adjust bolt and locknut Engine mounting: M10 ×...
  • Page 42 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M6 × 1.0 Headlight (left and right) M6 × 1.0 Headlight (lower) M6 × 1.0 Taillight M4 × 1.59 Taillight lead clamp and rear fender 0.05 0.36 M6 ×...

  • Page 43: Electrical

    248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (color) ---- (White – Red) CDI unit-model/manufacturer 5UM-00/YAMAHA (For USA) ---- 5UM-10/YAMAHA (Except for USA) ---- Ignition coil: Model/manufacturer 5UL-00/DENSO ---- Minimum spark gap 6 mm (0.24 in) ---- 0.08 ~ 0.10 Ω...
  • Page 44 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter relay: Model/manufacturer 2768090-A/JIDECO ---- Amperage rating 180 A ---- 4.2 ~ 4.6 Ω at 20 °C (68 °F) Coil winding resistance ---- Starting circuit cut-off relay: Model/manufacturer ACM33221 M06/MATSUSHITA ---- 75.69 ~ 92.51 Ω at 20 °C (68 °F) Coil winding resistance ---- Fuse (amperage ×...

  • Page 45: General Torque Specifications/ Definition Of Units

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.

  • Page 46: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 9 Oil hose G Cable guide 2 Oil tank breather hose 0 Hose guide H Negative battery lead 3 Clamp A AC magneto lead I Light switch lead 4 Diode B Cylinder head breather hose J Brake hose...
  • Page 47 SPEC CABLE ROUTING DIAGRAM È Insert the fuel tank breather hose into the hole in Ë Fasten the wire harness, starter motor lead and the steering stem cap. negative battery lead so that the plastic locking tie É Pass the oil tank breather hose on the outside of ends do not contact the ignition coil lead.

  • Page 48: Chassis

    SPEC CABLE ROUTING DIAGRAM Î Fasten the wire harness at its white tape. Ó Fasten the neutral switch lead and oil hose Ï Fasten the wire harness, throttle position sensor together with the plastic locking ties and cut off the lead (in the wire harness), starter motor lead and tie ends.
  • Page 49 SPEC CABLE ROUTING DIAGRAM × Pass the cylinder head breather hose on the Ü Pass the wire harness, clutch cable and light inside of the radiator hose 1 and on the outside of switch lead through the cable guide. Ý Fasten the AC magneto lead, neutral switch lead the radiator pipe (radiator hose 4).
  • Page 50 SPEC CABLE ROUTING DIAGRAM 1 Hot starter cable 0 Clamp É Pass the throttle cables and 2 Cable guide A CDI unit lead hot starter cable between the 3 Throttle cable (return) B CDI unit radiator and frame, then under 4 Throttle cable (pull) C CDI unit band the radiator mounting boss.
  • Page 51 SPEC CABLE ROUTING DIAGRAM Ì Fasten the coolant reservoir breather hose and carburetor breather hoses together. Í Fasten the CDI unit lead. Î Insert the CDI unit band over the CDI unit stay as far as possible. Ï Fasten the rectifier/regulator lead to the rectifier/ regulator bracket with a plastic locking tie and cut off the tie end.
  • Page 52 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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