brake light YAMAHA WR 250F 2001 Owners Manual

GEN
INFO

1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Decompression lever
3
Trip meter
4
Light switch
5
Front brake lever
6
Throttle grip
7
Radiator cap
8
Fuel tank cap
9
Oil tank cap
0
Engine stop switch
A
Taillight
B
Kickstarter crank
C
Fuel tank
D
Headlight
E
Radiator
F
Coolant drain bolt
G
Rear brake pedal
H
Valve joint
I
Fuel cock
J
Cold starter knob
K
Hot starter knob (red)
L
Drive chain
M
Air filter
N
Shift pedal
O
Front fork
NOTE:

l
The machine you have purchased may differ
slightly from those shown in the following.
l
Designs and specifications are subject to
change without notice.
1

SPEC

2 - 3
GENERAL SPECIFICATIONS
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)
90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)
120/90-18 65R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kg/cm
2

, 15 psi)
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
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Headlight type: Quartz bulb (halogen)
Bulb wattage
´
quantity:
Headlight 12 V 60/55 W
´
1
Taillight 12 V 21/5 W
´
1

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 7 Nm (0.7 m • kg, 5.1 ft • lb).Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 ´ 1.25 4 23 2.3 17
Lower bracket and outer tube M8 ´ 1.25 4 20 2.0 14
Upper bracket and steering stem M24 ´ 1.0 1 145 14.5 105
Handlebar holder and upper bracket M8 ´ 1.25 4 28 2.8 20
Steering stem and steering ring nut M28 ´ 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M48 ´ 1.0 2 30 3.0 22
Front fork and base valve M30 ´ 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 ´ 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 ´ 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 ´ 1.0 6 10 1.0 7.2
Meter cable holder and front fork protector M5 ´ 0.8 2 4 0.4 2.9
Front fork and brake hose guide M5 ´ 0.8 2 4 0.4 2.9
Front fork and brake hose holder M6 ´ 1.0 2 10 1.0 7.2
Front fork and brake hose cover (M8) M8 ´ 1.25 1 16 1.6 11
(M6) M6 ´ 1.0 1 7 0.7 5.1
Throttle grip cap M5 ´ 0.8 2 4 0.4 2.9
Front brake master cylinder M6 ´ 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 ´ 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 ´ 1.0 1 6 0.6 4.3
Brake lever position locknut M6 ´ 1.0 1 5 0.5 3.6
Front brake hose guide M5 ´ 0.8 2 4 0.4 2.9
Clutch lever holder M5 ´ 0.8 2 4 0.4 2.9
Clutch lever mounting bolt M6 ´ 1.0 1 2 0.2 1.4
Decompression lever holder M5 ´ 0.8 2 4 0.4 2.9
Light switch M4 ´ 0.7 2 2 0.2 1.4
Front brake master cylinder cap M4 ´ 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 ´ 1.25 2 30 3.0 22
Front brake caliper M8 ´ 1.25 2 23 2.3 17
Pad pin plug M10 ´ 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 ´ 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 ´ 1.5 1 105 10.5 75
Front wheel axle holder M8 ´ 1.25 4 23 2.3 17
Front brake disc M6 ´ 1.0 6 12 1.2 8.7

2 - 19
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Hose guide
2
Brake hose
3
Voltage regulator
4
Light switch lead
5
Fuel tank breather hose
6
Clamp
7
Oil tank breather hose
8
Engine stop switch lead
9
Sub-wire harness
0
Taillight lead
A
Throttle position sensor lead
B
Neutral switch lead
C
Oil hose
D
Cylinder head breather hose
E
CDI magneto lead
F
Clutch cable
G
Cable guide
H
Carburetor breather hose
I
Carburetor overflow hose
J
Coolant reservoir breather hose
K
Decompression cable
L
CDI unit lead
M
Ignition coil lead
N
Voltage regulator lead

Pass the fuel tank breather hose
behind handlebar, then insert it
into the steering stem hole.
õ
Pass the decompression cable,
engine stop switch lead and light
switch lead under where the oil
hose is attached.
‚
Pass the voltage regulator lead,
engine stop switch lead and light
switch lead over the radiator
hose.
ë
Fasten the engine stop switch
lead and ignition coil lead of the
sub-wire harness.
ä
Fasten the sub-wire harness
and engine stop switch lead.
ì
Pass the cylinder head breather
hose along the right side of the
oil tank breather hose.
í
Fasten the sub-wire harness
and engine stop switch lead in
front of the upper engine brack-
ets.
î
Fasten the sub-wire harness.
é
Pass the sub-wire harness
between the upper engine
brackets.
ï
Fasten the sub-wire harness.
ð
Fasten the throttle position sen-
sor lead.

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 - 46
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Decompression cable endUse Yamaha cable lube or equivalent on these
areas.
õUse SAE 10W-30 motor oil or suitable chain
lubricants.
‚Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lCopper washer 1
lUnion bolt 2
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake caliper.
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
lBrake hose holder 1
lBrake caliper 2
lBolt (brake caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
4. Tighten:
lPad pin 4
5. Install:
lPad pin plug 5
Rear brake caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pads with their projections
a into the brake caliper recesses b.
lTemporarily tighten the pad pin at this point.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

5 - 28
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (upper bracket) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (lower bracket) 2 Only loosening.
6 Front fork 1
1