Yamaha WR250F(R) User manual

WR250FR
5UM-28107-10
ASSEMBLY MANUAL
LIT-11666-16-48

WR250FR
ASSEMBLY MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, December 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11666-16-48
EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct reassembly of this Yamaha
machine prior to delivery to the customer. 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.
EAA00005
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its model. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the machine and/or rider.
wFailure to follow WARNING instructions could result in severe injury or death to
the machine operator, a bystander, or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
CAUTION:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
!!
Particularly important information is distinguished in this manual by the following notations.
EAA00001

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.
(5) Install so that the arrow mark faces
upward.
(6) Apply a motor oil.
(7) Made of rubber or plastics.
(8)
A: Ref No. (indicating the order of
operations.)
B: Part name
C: Quantity of parts per machine.
D: Place where parts are held.
V: Stored in vinyl bag.
C: Stored in carton box.
S: Fixed inside the steel frame,
and/or contained in the styro-
foam tray (upper or lower).
*: Temporarily installed or secured.
E: Size or material of parts.
d/D: Diameter of part.
l: Length of part.
ex, D = 5 (0.2) = 5 mm (0.2 in)
(1) (2)
(3) (4)
(5) (6)
(7)
(8)

(1) (2)
(3) (4)
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
any operation which may cause particles
to fly off.
Protect hands and feet by wearing safety
gloves and shoes.
EAA00050
SYMBOLS USED ON
CRATE CARTON
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(2) Indicates correct upright position of
the transport package.
(3) Transport package must be kept away
from rain.
(4) Insertion of the forklift arm from this
side will cause damage.
(5) Do not step anywhere on the transport
package.
(6) Up to 6 of the transport packages can
be piled up.
(7) (7)
(7) Yellow label
Lift arm insertion position
If the forklift arms cannot be inserted
under the transport package in align-
ment with the two yellow labels, adjust
the arms so that they are positioned
evenly in relation to these marks while
taking care not to damage the package
contents.
(5) (6)

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).
4. Remove the packing frames (in order
of sideways (6), upward (7), and
front/back (8)).
NOTE:
Hold the frame while removing the frame
bolts.
5. Remove the bolts (9). (front axle fixed
plate (10)).
NOTE:
Before starting the assembly, check for
damaged or missing parts. Check the
parts contained in the carton boxes and
on the machine for damage, scratches
and other defects.
-
1
-

EAA00070
PARTS LOCATION
1. Front wheel
2. Front fender
3. Carton Box 1
4. Carton Box 2
-
2
-

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)
12.Collar (front wheel axle)
13.Trip meter gear unit
14.Flange bolt (headlight) [d=6 (0.24),
l=10 (0.39)]
15.Panhead screw with plain washer
(headlight) [d=6 (0.24), l=12 (0.47)]
Carton Box 2
16.Air scoop (left)
17.Owner’s service manual
18.Plastic bag
19.Brake hose cover
20.Fuel tank breather hose
21.Spark plug wrench
22.Nipple wrench
23.Boot (adjust nut)
24.Handlebar clamp
25.Boot (clutch lever)
26.Hexagon bolt with plain washer (front fender)
[d=6 (0.24), l=20 (0.79)]
27.Collar (front fender) [d=6 (0.24)]
28.Flange bolt (brake hose cover)
[d=6 (0.24), l=12 (0.47)]
29.Plain washer (brake hose cover)
[d=8 (0.31)]
30.Flange bolt (brake hose cover)
[d=8 (0.31), l=20 (0.79)]
31.Brake hose holder
32.Hexagon socket bolt (brake hose holder)
[d=6 (0.24), l=14 (0.55)]
33.Hexagon bolt with plain washer (air scoop)
[d=6 (0.24), l=16 (0.63)]
34.Panhead screw with plain washer (air scoop)
[d=6 (0.24), l=11 (0.43)]
35.Cable clamp (handlebar)
36.Boot [hot starter (choke) lever]
37.Bracket (trip meter cable)
38.Button head bolt (trip meter cable)
[d=5 (0.20), l=8 (0.31)]
39.Steering shaft cap
-
3
-

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

1 Handlebar 1 C
2 Handlebar upper holder 2 V
3 Flange bolt 4 V d=8 (0.31), l=35 (1.38)
-
5
-
EAA00200*
1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: First tighten the bolts on the
front side of the handlebar
holder, and then tighten the
bolts on the rear side to speci-
fication.
NOTE:
The upper handlebar holder
should be installed with the
punched mark (a) forward.
Bolt:
28 Nm (2.8 mdkg, 20 ftdlb)
EAA00018
2. THROTTLE GRIP
A: Slip the throttle grip over the
right handlebar completely
and then slide it back about 2
mm (0.08 in).
B: Tighten the screws to specifi-
cation.
Screw:
4 Nm (0.4 mdkg, 2.9 ftdlb)
C: Check the throttle grip for
smooth action.
W
DThe throttle cables should
not be twisted, and make
sure that the throttle grip
rotates on the handlebar
freely, without binding.
DProper cable routing is
essential to assure safe
machine operation.
Refer to "CABLE ROUTING".
C: Connect the couplers.
CAUTION:
Proper cable and lead routing
is essential to assure safe
machine operation. Refer to
"CABLE ROUTING".
EAA000205*
3. FRONT WHEEL
A: Clean the brake disc.
B: Clean the front wheel axle.
C: Clean the collars.
NOTE:
Install the collars with its position
(a) facing the wheel.
D:
W
Take care not to get grease on
the brake disc or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign materi-
al on the braking surface can
cause impaired braking action.
E: Make sure the two projections
in the wheel hub are meshed
with the two slots in the trip
meter gear unit.
F: Lift the front wheel and install
the front wheel axle.
NOTE:
Do not depress the brake lever
when the caliper is off the brake
disc.
G: Before tightening the front
wheel axle, make sure the
projection (torque stopper) on
the front fork end is placed in
the slot in the trip meter gear
unit as shown.
H: Tighten the front axle bolts
temporarily before tightening
the axle.
1 Throttle grip 1 *
2 Panhead screw 2 *d=5 (0.2), l=20 (0.79)
3 Grip cap cover 1 *
1 Front wheel 1 S
2 Front wheel axle 1 *
3 Collar (front wheel axle) 1 V d=20 (0.79)
4 Trip meter gear unit 1 V
5 Axle nut 1 *d=16 (0.63)
6 Flange bolt 4 *d=8 (0.31), l=40 (1.57)

-
6
-
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)
EAA90001*
4. TRIP METER CABLE
A: Connect the trip meter cable to
trip meter gear unit.
B: Tighten the bolts to specifica-
tion.
Bolts:
4 Nm (0.4 mdkg, 2.9 ftdlb)
W
Proper cable routing is essen-
tial to assure safe machine
operation.
Refer to "CABLE ROUTING".
1 Trip meter cable 1 *
2 Bracket (trip meter cable) 1 V
3Button head bolt
(trip meter cable) 2 V d=5 (0.20), l=8 (0.31)
1 Front wheel 1 S
2 Front wheel axle 1 *
3 Collar (front wheel axle) 1 V d=20 (0.79)
4 Trip meter gear unit 1 V
5 Axle nut 1 *d=16 (0.63)
6 Flange bolt 4 *d=8 (0.31), l=40 (1.57)

-
7
-
EAA00031
6. BRAKE HOSE COVER
A: Tighten the bolts to specifica-
tion.
Bolt (M8):
16 Nm (1.6 mdkg, 11 ftdlb)
Bolt (M6):
7 Nm (0.7 mdkg, 5.1 ftdlb)
1 Brake hose cover 1 V
2 Collar 1 V d=8 (0.31)
3 Collar 1 V d=6 (0.24)
4Flange bolt
(brake hose cover) 1 V d=8 (0.31), l=20 (0.79)
5 Plain Washer 1 V d=8 (0.31)
6Flange bolt
(brake hose cover) 1 V d=6 (0.24), l=12 (0.47)
EAA00030
5. FRONT BRAKE HOSE
HOLDER
A: Remove the front fork cover
bolts to slide the front fork
cover upwards.
B:
NOTE:
DAlign the top (d) of the brake
hose neck with the brake hose
holder bottom (c).
DPass the brake hose in front
of the axle boss (a), then fit it
into the brake hose groove (b).
DMake sure that brake hose
does not contact the front axle
nut.
C: Tighten the brake hose hold-
er bolts to specification.
Bolt:
10 Nm (1.0 mdkg, 7.2 ftdlb)
D: Slide the front fork cover to its
original position.
E: Tighten the front fork cover
bolts to specification.
Bolt:
10 Nm (1.0 mdkg, 7.2 ftdlb)
1 Brake hose holder 2 V
2Hexagon socket bolt
(brake hose holder) 2 V d=6 (0.24), l=14 (0.55)

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.
W
Proper cable routing is essen-
tial to assure safe machine
operation.
Refer to "CABLE ROUTING".
EAA00033
8. FRONT BRAKE MAS-
TER CYLINDER
A: Lubricate the pivoting part of
the brake lever.
Recommended lubricants:
Lithium-soap-based grease
B: Tighten the bolts to specifica-
tion.
NOTE:
DMake sure that the "UP" mark
on the bracket is pointed
upwards.
DFirst tighten the bolt on the
upper side of the master cylin-
der bracket, and then tighten
the bolt on the lower side.
Bolt:
9 Nm (0.9 mdkg, 6.5 ftdlb)
C: Check the brake lever for
smooth action.
W
Proper hose routing is essen-
tial to assure safe machine
operation. Refer to "CABLE
ROUTING".
1 Front fender 1 S
2Hexagon bolt with plain
washer (front fender) 4 V d=6 (0.24), l=20 (0.79)
3 Collar (front fender) 4 V d=6 (0.24)
1Front brake master
cylinder 1*
2 Master cylinder bracket 1 V
3 Flange bolt 2 V d=6 (0.24), l=22 (0.87)
EAA00049*
9. CLUTCH CABLE
A: Install the boot and lever
cover to the clutch cable.
B: Lubricate the pivoting part of
the clutch lever.
Recommended lubricants:
Lithium-soap-based grease
C: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjusting nut on
the lever holder until tight.
Next, align the slit in the
adjusting nut and cable socket
with the slit in the lever holder.
b. Insert the cable end into the
lever hole. Next, while pulling
the outer cable in the direction
opposite to the lever, seat the
outer cable into the cable
socket.
c. Install the boot and lever
cover to the clutch lever.
NOTE:
Check the clutch lever for smooth
action. Refer to "ADJUSTMENTS
AND PREDELIVERY SERVICE".
W
Proper cable routing is essen-
tial to assure safe machine
operation.
Refer to "CABLE ROUTING".
1 Clutch cable 1 *
2 Boot (adjust nut) 1 V
3 Lever cover (clutch lever) 1 V
-
8
-

-
9
-
EAA00198*
10. HOT STARTER (CHOKE)
CABLE
A: Install the boot to the hot
starter (choke) lever cable.
B: Lubricate the pivoting part of
the hot starter (choke) lever.
Recommended lubricants:
Lithium-soap-based grease
C: Insert the cable end into the
lever hole, then squeeze the
lever.
While pulling the outer cable
in the direction opposite to the
lever, release the lever quickly.
While releasing the lever, seat
the outer cable into the lever
holder.
D: Install the boot to the hot
starter (choke) lever.
NOTE:
Check the hot starter (choke)
lever for smooth action. Refer to
"ADJUSTMENTS AND PREDE-
LIVERY SERVICE".
W
Proper cable routing is essen-
tial to assure safe machine
operation.
Refer to "CABLE ROUTING".
1Boot [hot starter (choke)
lever] 1V
2 Hot starter (choke) lever 1 *
EAA00037
11. LIGHT SWITCH
A:
W
Proper hose routing is essen-
tial to assure safe machine
operation.
Refer to "CABLE ROUTING".
B: Tighten the screws to specifi-
cation.
Screws:
2 Nm (0.2 mdkg, 1.4 ftdlb)
EAA00212*
12. HEADLIGHT
A: Connect the headlight coupler
to the headlight.
NOTE:
Refer to “CABLE ROUTING”.
B: Tighten the bolts to specifica-
tion.
Bolt:
10 Nm (1.0 mdkg, 7.2 ftdlb)
C: Tighten the screw to specifi-
cation.
Screw:
7 Nm (0.7 mdkg, 5.1 ftdlb)
1 Light switch 1 *
2 Bracket (light switch) 1 V
3
Panhead screw (light switch)
2 V d=4 (0.16), l=14 (0.55)
1 Headlight 1 C
2 Flange bolt (headlight) 2 V d=6 (0.24), l=10 (0.39)
3Panhead screw with plain
washer (headlight) 1 V d=6 (0.24), l=12 (0.47)

-
10
-
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”.
EAA00209*
14. CABLE CLAMP
A: Clamp the hot starter (choke)
cable and clutch cable.
NOTE:
Refer to "CABLE ROUTING".
1 Cable clamp 1 V
EAA00071*
15. FUEL TANK BREATHER
HOSE
A: Install the steering shaft cap
to the fuel tank breather hose.
B: Connect one end of the
breather hose to the fuel tank
filler cap, and insert the other
end into the hole of the steer-
ing shaft.
NOTE:
Refer to "CABLE ROUTING".
CAUTION:
Install the hose joint with its
arrow mark facing the TANK
side.
1 Steering shaft cap 1 V
2 Fuel tank breather hose 1 V
1 Handlebar clamp 4 V

-
11
-
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) 1 C
2Panhead screw with plain
washer (air scoop) 3V
3Hexagon bolt with plain
washer (air scoop) 1V
EAA00189*
17. BATTERY
A: Remove the bolts (seat).
B: First, connect the positive
lead to the positive terminal.
C: Second, connect the negative
lead to the negative terminal.
NOTE:
Refer to "CABLE ROUTING".
D: Install the bolts (seat) to speci-
fication.
Bolt:
23 Nm (2.3 mdkg, 17 ftdlb)
1Hexagon bolt with plain 2*
washer
2 Seat 1 *
3 Positive lead 1 *
4 Negative lead 1 *

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.
(B)Pass the wire harness, clutch cable and light switch lead
through the cable guide.
(C)Fit the brake hose into the guides on the protector.
-
12
-
EAA00900
CABLE ROUTING

(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.
-
13
-

(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
-