steering YAMAHA WR 250F 2001 User Guide

3 - 45
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
lTighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tighten-
ing):
38 Nm (3.8 m • kg, 27 ft • lb)
lLoosen the steering ring nut one turn.
lRetighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tighten-
ing):
7 Nm (0.7 m • kg, 5.1 ft • lb)
lCheck the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
lInstall the upper bracket 5, steering stem
nut 6, handlebar 7, handlebar holder 8
and headlight 9.
NOTE:
lThe upper handlebar holder should be
installed with the punched mark a for-
ward.
lInsert the end of fuel breather hose 0 into
the hole of the steering stem.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar upper holder:
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (handle crown):
23 Nm (2.3 m • kg, 17 ft • lb)
Headlight:
7 Nm (0.7 m • kg, 5.1 ft • lb)

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CHAS
11. Fasten the decompression cable 1 and
clutch cable 2 with a clamp 3.
1
2
3
12. Insert the end of the fuel breather hose
1 into the hole of the steering stem.
HANDLEBAR

5 - 47
CHAS
EC560000
STEERING
Extent of removal:1 Lower bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Headlight
Handlebar
Cable guide
Front fenderRefer to “HANDLEBAR” section.
1 Trip meter 1
2 Steering stem nut 1
3 Front fork 2 Refer to “FRONT FORK” section.
4 Upper bracket 1
5 Steering ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
6 Lower bracket 1
7Ball race cover
1
2
1
STEERING

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CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
8 Upper bearing 1
9 Lower bearing 1 Refer to “REMOVAL POINTS”.
10Ball race
2Refer to “REMOVAL POINTS”.
2

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CHAS
EC563000
REMOVAL POINTS
Steering ring nut
1. Remove:
lSteering ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering stem so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Lower bearing
1. Remove:
lLower bearing 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering stem
thread.
EC563400
Ball race
1. Remove:
lBall race 1
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
Steering stem
1. Inspect:
lSteering stem 1
Bend/damage ® Replace.
STEERING

5 - 50
CHASSTEERING
EC564101
Bearing and ball race
1. Wash the bearings and ball races with a
solvent.
2. Inspect:
lBearing 1
lBall race
Pitting/damage ® Replace bearings
and ball races as a set.
Install the bearing in the ball races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the ball races, replace
bearings and ball races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Lower bracket
1. Install:
lLower bearing 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
lBall race
lUpper bearing 1
lBall race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and ball race cover lip.
3. Install:
lLower bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing and the portion a of the steering
stem.

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CHAS
4. Install:
lWasher 1
lSteering ring nut 2
Tighten the steering ring nut using the
steering nut wrench 3.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering stem by turning it lock
to lock. If there is any binding, remove
the steering stem assembly and inspect
the steering bearings.
6. Install:
lWasher 1
7. Install:
lFront fork 1
lUpper bracket 2
NOTE:
lTemporarily tighten the pinch bolts (lower
bracket).
lDo not tighten the pinch bolts (upper bracket)
yet.
8. Install:
lWasher 1
lSteering stem nut 2
T R..145 Nm (14.5 m · kg, 105 ft · lb)
STEERING

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CHASSTEERING
9. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the steering
ring nut little by little.
10. Adjust:
lFront fork top end a
* For EUROPE
** For AUS, NZ and ZA
Front fork top end (standard) a:
7 mm (0.28 in)
* 8mm (0.31 in)
** 10.5 mm (0.41 in)
11. Tighten:
lPinch bolt (upper bracket) 1
lPinch bolt (lower bracket) 2
CAUTION:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
12. Install:
lTrip meter 1
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
1

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CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear brake caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Drive chain case 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1