brake YAMAHA WR 250F 2001 User Guide

2 - 20
SPEC

CABLE ROUTING DIAGRAM
ñ
Pass the carburetor breather
hose and overflow hose
between the connecting rod
and cross tube (frame).
÷
Pass the cylinder head
breather hose through the hose
guide.
ö
Pass the clutch cable through
the cable guide.
¯
Fasten the neutral switch lead
and CDI magneto lead.
¸
Pass the clutch cable along the
inner side of the cylinder head
breather hose.
Î
Pass the cylinder head
breather hose along the inner
side of the radiator hose.
å
Pass the clutch cable in front of
the radiator mounting boss.
ê
Fit the brake hose into the
guides on the protector.
æ
Fasten the ground lead
together with the ignition coil
lead.
è
Do not allow the engine stop
switch leads and light switch
lead to slacken between the
two clamps.
×
Pass the decompression cable
along the right side of the cylin-
der head breather hose.
ã
Pass the clutch cable through
the cable guides.
ô
Pass the carburetor breather
hoses and overflow hose so
that all there hoses do not con-
tact the rear shock absorber.
ç
Position each lead at the lower
left of the main tube (frame).

2 - 23
SPECCABLE ROUTING DIAGRAM
1Brake hose
2Brake hose holder
3Brake master cylinderInstall the brake hose to the brake caliper with the
paint on the pipe facing the brake caliper and with
the pipe contacting the brake caliper projection.
õPass the brake hose into the brake hose holders.
‚If the brake hose contacts the spring (rear shock
absorber), correct its twist.
ëInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projection
on the brake master cylinder.
A
A 2
3
1
12
3 ë
‚
õ

2 - 24
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Light switch
3Light switch lead
4Clamp
5Decompression cable
6Clutch cable
7Hose guide
8Trip meter
9Brake hose
0Engine stop switch leadFasten the engine stop switch lead to the handlebar with the plastic
band.
õPass the decompression cable between the brake hose and clutch
cable.
‚Pass the throttle cables between the upper bracket and trip meter.
ëPass the light switch leads behind the engine stop switch lead, then
pass the headlight lead (of the light switch leads) in front of the head
pipe.
äInstall the trip meter cable so that its bent portion faces the chassis
rear.
ìInstall the brake hose so that it contacts the master cylinder projec-
tion and that its bent portion faces downward.

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
c
Inspect wear
ROTOR NUT
Retighten
c

c

EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace
c

c

c

c
* Whichever comes first
*SPARK ARRESTER
Clean
(Every six
months)
c
CRANK
Inspect and clean
c

c

CARBURETOR
Inspect, adjust and clean
c

c
When using a high-pres-
sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace
c

c

c

DRIVE CHAIN
Lubricate, slack, alignment
Replace
c

c

c
Use chain lube
Chain slack: 40 ~ 50 mm
(1.6 ~ 2.0 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
c

c

c

c

c
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
c

c
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
c

c

c
Use foam air-filter oil
FRAME
Clean and inspect
c

c

FUEL TANK, COCK
Clean and inspect
c

c

BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
c

c

c

c

c

c

c

c

c

c

c

c
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
c

c

c

c

c
Suspension oil “01” ItemAfter
break-inEvery
race
Every
third race
or
500 km
(300 mi)Every
fifth race
or
1,000 km
(600 mi)
As re-
quiredRemarks


3

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check that the coolant level is correct in the coolant reservoir.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-26 ~ 32
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-33 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 45
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 22

3 - 26
INSP
ADJ
CHASSIS/BRAKE SYSTEM AIR BLEEDING
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING
WARNING
Bleed the brake system if:
lThe system has been disassembled.
lA brake hose has been loosened or
removed.
lThe brake fluid is very low.
lThe brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not prop-
erly bleed.
1. Remove:
lReservoir cap
lDiaphragm
lProtector (rear brake)
2. Bleed:
lBrake fluid
Front
õRear
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 2 tightly
to the caliper bleed screw 1.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever or pedal
several times.
f. Pull the lever in or push down on the
pedal. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever
or pedal limit has been reached; then
release the lever or pedal.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
i. Repeat steps (e) to (h) until of the air
bubbles have been removed from the
system.

õ

3 - 27
INSP
ADJ
FRONT BRAKE ADJUSTMENT
3. Install:
lProtector (rear brake)
lDiaphragm
lReservoir cap
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the
reservoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
EC362040
FRONT BRAKE ADJUSTMENT
1. Check:
lBrake lever position a
Brake lever position a:
Standard position Extent of adjustment
95 mm
(3.74 in)76 ~ 97 mm
(2.99 ~ 3.82 in)
2. Adjust:
lBrake lever position
Brake lever position adjustment steps:
lLoosen the locknut 1.
lTurn the adjusting bolt 2 until the lever
position a is within specified position.
lTighten the locknut.
T R..
Locknut:
5 Nm (0.5 m • kg, 3.6 ft • lb)
CAUTION:
Be sure to tighten the locknut, as it will
cause poor brake performance.
2
1

3 - 28
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
lBrake pedal height a
Out of specification ® Adjust.
Brake pedal height a:
5 mm (0.20 in)
2. Adjust:
lBrake pedal height
Pedal height adjustment steps:
lLoosen the locknut 1.
lTurn the adjusting nut 2 until the pedal
height a is within specified height.
lTighten the locknut.
WARNING
lAdjust the pedal height between the
maximum and the minimum õ as
shown. (In this adjustment the bolt 3
end b should protrude out of the lower
adjusting nut 4 but not be less than
2 mm (0.08 in) c away from the brake
pedal 5).
lAfter the pedal height adjustment, make
sure that the rear brake does not drag.

õ
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
lBrake pad thickness a
Out of specification ® Replace as a
set.
2. Replace:
lBrake pad
Brake pad thickness:
4.4 mm (0.17 in)
: 1.0 mm (0.04 in)
Brake pad replacement steps:
lRemove the pad pin plug 1.

3 - 29
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
lLoosen the pad pin 2.
lRemove the brake hose holder 3 and
brake caliper 4 from the front fork.
lRemove the pad pin and brake pads 5.
lConnect the transparent hose 6 to the
bleed screw 7 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake pads 8 and pad pin.
NOTE:
lInstall the brake pads with their projec-
tions a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this
point.
lInstall the brake hose holder 9 and brake
caliper 0 and tighten the pad pin A.
NOTE:
Fit the brake hose holder cut c over the
projection d on the front fork and clamp the
brake hose.
T R..
Bolt (brake caliper):
23 Nm (2.3 m • kg, 17 ft • lb)
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)

3 - 30
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
3. Inspect:
lBrake fluid level
Refer to “BRAKE FLUID LEVEL
INSPECTION” section.
lInstall the pad pin plug B.
T R..
Pad pin plug:
3 Nm (0.3 m • kg, 2.2 ft • lb)
4. Check:
lBrake lever operation
A softy or spongy feeling ® Bleed
brake system.
Refer to “BRAKE SYSTEM AIR
BLEEDING” section.
REAR BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
lBrake pad thickness a
Out of specification ® Replace as a
set.
2. Replace:
lBrake pad
Brake pad thickness:
6.4 mm (0.25 in)
: 1.0 mm (0.04 in)
Brake pad replacement steps:
lRemove the protector 1 and pad pin plug
2.
lLoosen the pad pin 3.
lRemove the rear wheel 4 and brake cali-
per 5.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.