Yamaha WR250R User manual

SERVICE MANUAL
WR250RX(C)
2008
32C-28197-10
WR250XX(C)
LIT-11616-21-66

EAS20050
WR250RX(C)/WR250XX(C)
SERVICE MANUAL
©2008 by Yamaha Motor Corporation, U.S.A.
First edition, December 2007
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.
P/N LIT-11616-21-66

NOTICE
1-1
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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
●
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
● Designs and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

HOW TO USE THIS MANUAL
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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
●
The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
●
Sub-section titles appear in smaller print than the section title “2”.
●
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
●
Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-
bly step “4”.
● Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
●
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
●
Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
3
4
5
6
7
1
2

SYMBOLS
1-3
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SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
G
M
E
BLS
M
910
11 12
13 14
15 16
17 18
LT New
BF
S
T
R
.
.
123
456
78
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10. Gear oil
11. Molybdenum-disulfide oil
12. Brake fluid
13. Wheel-bearing grease
14. Lithium-soap-based grease
15. Molybdenum-disulfide grease
16. Silicone grease
17. Apply locking agent (LOCTITE®)
18. Replace the part

GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND
ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
COOLING SYSTEM
6
FUEL SYSTEM
7
ELECTRICAL SYSTEM
8
TROUBLESHOOTING
9
EAS20110
TABLE OF CONTENTS

1
2
3
4
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER....................................................1-1
MODEL LABEL ........................................................................................1-1
FEATURES ....................................................................................................1-2
OUTLINE OF THE FI SYSTEM................................................................1-2
FI SYSTEM ..............................................................................................1-3
MULTI-FUNCTION DISPLAY...................................................................1-4
IMPORTANT INFORMATION ........................................................................1-8
PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-8
REPLACEMENT PARTS .........................................................................1-8
GASKETS, OIL SEALS AND O-RINGS ...................................................1-8
LOCK WASHERS/PLATES AND COTTER PINS....................................1-8
BEARINGS AND OIL SEALS...................................................................1-8
CIRCLIPS.................................................................................................1-9
CHECKING THE CONNECTIONS.................................................................1-10
SPECIAL TOOLS...........................................................................................1-11

IDENTIFICATION
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IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1”is stamped
into the right side of the steering head pipe.
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MODEL LABEL
The model label “1”is affixed to the frame. This
information will be needed to order spare parts.
1
1