lock YAMAHA WR 250F 2003 Owners Manual

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 7 are
designed as thumb tabs to indicate
the chapter’s number and content.
1General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
7Tuning
Illustrated symbols 8 to D are used
to identify the specifications appear-
ing in the text.
8With engine mounted
9Special tool
0Filling fluid
ALubricant
BTightening
CSpecified value, Service limit
DResistance (Ω
), Voltage (V), Electric
current (A)
Illustrated symbols E to H in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
EApply engine oil
FApply molybdenum disulfide oil
GApply lightweight lithium-soap base
grease
HApply molybdenum disulfide grease
Illustrated symbols I to J in the
exploded diagrams indicate where to
apply a locking agent and where to
install new parts.
IApply locking agent (LOCTITE®)
JUse new one
SYMBOLES
GRAPHIQUES
(Voir l’illustration)
Les symboles graphiques 1 à 7 servent
à repérer les différents chapitres et à
indiquer leur contenu.
1
Renseignements généraux
2
Caractéristiques
3
Controles et réglages courants
4
Moteur
5
Partie cycle
6
Partie électrique
7
Mises au point
Les symboles graphiques 8 à D per-
mettent d’identifier les spécifications
encadrées dans le texte.
8
Avec de montage du moteur
9
Outil spécial
0
Liquide de remplissage
A
Lubrifiant
B
Serrage
C
Valeur spécifiée, limite de service
D
Résistance (Ω
), tension (V), intensité (A)
Les symboles graphiques E à H utilisés
dans les vues en éclaté indiquent les
endroit à lubrifier et le type de lubrifiant.
E
Appliquer de l’huile moteur
F
Appliquer de l’huile au bisulfure de
molybdène
G
Appliquer de la graisse fluide à base de
savon au lithium
H
Appliquer de la graisse au bisulfure de
molybdène
Les symboles graphiques I à J dans
les vues en éclaté indiquent le produit de
blocage à appliquer et les pièces qui
nécessitent un remplacement.
I
Appliquer un agent de blocage
(LOCTITE®)
J
Utiliser une pièce neuve. 12
34
56
78
90
AB
CD
EF
GH
IJ
GEN
INFOSPEC
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CHAS–+ELEC
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New

1 - 7
GEN
INFOIMPORTANT INFORMATION
EC133000GASKETS, OIL SEALS AND O-
RINGS
1. All gaskets, oil seals, and O-
rings should be replaced when
an engine is overhauled. All gas-
ket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and
bearings during reassembly.
Apply grease to the oil seal lips.
EC134000LOCK WASHERS/PLATES AND
COTTER PINS
1. All lock washers/plates
1 and
cotter pins must be replaced
when they are removed. Lock
tab(s) should be bent along the
bolt or nut flat(s) after the bolt or
nut has been properly tightened.
EC135001BEARINGS AND OIL SEALS
1. Install the bearing(s)
1 and oil
seal(s)
2 with their manufac-
turer’s marks or numbers facing
outward. (In other words, the
stamped letters must be on the
side exposed to view.) When
installing oil seal(s), apply a light
coating of lightweight lithium
base grease to the seal lip(s). Oil
the bearings liberally when
installing.
CAUTION:
Do not use compressed air to spin
the bearings dry. This causes
damage to the bearing surfaces.
EC136000CIRCLIPS
1. All circlips should be inspected
carefully before reassembly.
Always replace piston pin clips
after one use. Replace distorted
circlips. When installing a circlip
1, make sure that the sharp-
edged corner
2 is positioned
opposite to the thrust
3 it
receives. See the sectional view.
4Shaft
JOINTS, BAGUES D’ETANCHEITE
ET JOINTS TORIQUES
1. Lorsqu’un moteur est révisé, tous
les joints, bagues d’étanchéité et
joints toriques doivent être changés.
Tous les plans de joint, toutes les
lèvres de bague d’étanchéité et les
joints toriques doivent être nettoyés.
2. Lors du remontage, huiler correcte-
ment toutes les pièces accouplées et
tous les roulements. Graisser les
lèvres de bagues d’étanchéité.
RONDELLES-FREIN, FREINS
D’ECROU ET GOUPILLES
FENDUES
1. Rondelles-frein, freins d’écrou 1 et
goupilles fendues ne doivent jamais
être réutilisés. Les onglets de blo-
cage doivent être dressés contre les
faces de boulon ou d’écrou une fois
que les boulons et écrous ont été
correctement serrés.
ROULEMENTS ET BAGUES
D’ETANCHEITE
1. Monter les roulements 1 et les
bagues d’étanchéité 2 avec leurs
marques ou numéros de fabricant
dirigés vers l’extérieur. (Autrement
dit, les lettres poinçonnées doivent
être sur le côté visible.) Lors de la
mise en place des bagues d’étan-
chéité, appliquer une légère couche
de graisse fluide à base de lithium
sur leurs lèvres. Lors de la mise en
place des roulements, les huiler
généreusement.
ATTENTION:
Ne pas sécher les roulements à l’air
comprimé. Cela endommagerait les
surfaces de roulement.
CIRCLIPS
1. Avant remontage, tous les circlips
doivent être soigneusement vérifiés.
Toujours changer les circlips d’axe
de piston après une utilisation.
Changer tout circlip déformé.
Lorsqu’on monte un circlip 1,
s’assurer que le côté non chanfreiné
2 est positionné du côté opposé à
la poussée 3 qu’il reçoit. Voir la
vue en coupe.
4
Arbre
INFORMATIONS IMPORTANTES

1 - 51
GEN
INFO
EC1B0000
CLEANING AND
STORAGE
EC1B1000CLEANING
Frequent cleaning of your machine
will enhance its appearance, main-
tain good overall performance, and
extend the life of many components.
1. Before washing the machine,
block off the end of the exhaust
pipe to prevent water from enter-
ing. A plastic bag secured with a
rubber band may be used for this
purpose.
2. If the engine is excessively
greasy, apply some degreaser to
it with a paint brush. Do not
apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off
with a garden hose; use only
enough pressure to do the job.
CAUTION:
Excessive hose pressure may
cause water seepage and contami-
nation of wheel bearings, front
forks, brakes and transmission
seals. Many expensive repair bills
have resulted from improper high
pressure detergent applications
such as those available in coin-
operated car washers.
4. After the majority of the dirt has
been hosed off, wash all sur-
faces with warm water and a
mild detergent. Use an old tooth-
brush to clean hard-to-reach
places.
5. Rinse the machine off immedi-
ately with clean water, and dry
all surfaces with a soft towel or
cloth.
6. Immediately after washing,
remove excess water from the
chain with a paper towel and
lubricate the chain to prevent
rust.
7. Clean the seat with a vinyl uphol-
stery cleaner to keep the cover
pliable and glossy.
8. Automotive wax may be applied
to all painted or chromed sur-
faces. Avoid combination
cleaner-waxes, as they may con-
tain abrasives.
9. After completing the above, start
the engine and allow it to idle for
several minutes.
NETTOYAGE ET
RANGEMENT
NETTOYAGE
Un nettoyage fréquent de la machine
améliorera son aspect, maintiendra ses
bonnes performances et augmentera la
durée de service de bon nombre de ses
composants.
1. Avant de laver la moto, boucher la
sortie du pot d’échappement pour
éviter toute pénétration d’eau. Un
sachet en plastique retenu par un
élastique fera l’affaire.
2. Si le moteur est fortement encrassé,
appliquer un peu de dégraissant au
pinceau. Eviter tout contact avec la
chaîne, ses pignons et les axes de
roue.
3. Rincer la boue et le dégraissant au
tuyau d’arrosage, en utilisant juste
la pression suffisante.
ATTENTION:
Une pression excessive risque de pro-
voquer des infiltrations d’eau dans les
roulements des roues, la fourche
avant, des freins et les joints de la
transmission. Noter que bien des notes
de réparation onéreuses ont résulté de
l’emploi abusif des vaporisateurs de
détergent à haute pression, tels que
ceux qui équipent les laveries automa-
tiques de voitures.
4. Après avoir chassé la majeure partie
de la boue, laver toutes les surfaces
avec de l’eau chaude et un détergent
neutre. Utiliser une vieille brosse à
dents pour atteindre les endroits dif-
ficiles d’accès.
5. Rincer immédiatement l’engin avec
de l’eau propre et sécher toutes les
surfaces avec un chiffon doux.
6. Immédiatement après le lavage, éli-
miner l’excès d’eau de la chaîne
avec des mouchoirs en papier et
lubrifier la chaîne pour éviter
qu’elle ne rouille.
7. Nettoyer la selle avec un produit
pour meubles rembourrés pour que
sa housse reste souple et brillante.
8. Un encaustique pour automobile
peut être appliqué sur toutes les sur-
faces peintes et chromées. Eviter les
liquides de nettoyage à encaustique,
car ils contiennent de l’abrasif.
9. Les opérations ci-dessus terminées,
lancer le moteur et le laisser tourner
pendant quelques minutes.
CLEANING AND STORAGE
NETTOYAGE ET RANGEMENT

1 - 53
GEN
INFO
EC1B2001STORAGE
If your machine is to be stored for 60
days or more, some preventive mea-
sures must be taken to avoid deterio-
ration. After cleaning the machine
thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines,
and the carburetor float bowl.
2. Remove the spark plug, pour a
tablespoon of SAE 10W-30
motor oil in the spark plug hole,
and reinstall the plug. With the
engine stop switch pushed in,
kick the engine over several
times to coat the cylinder walls
with oil.
3. Remove the drive chain, clean it
thoroughly with solvent, and
lubricate it. Reinstall the chain or
store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the
wheels off the ground.
6. Tie a plastic bag over the
exhaust pipe outlet to prevent
moisture from entering.
7. If the machine is to be stored in a
humid or salt-air environment,
coat all exposed metal surfaces
with a film of light oil. Do not
apply oil to rubber parts or the
seat cover.
NOTE:Make any necessary repairs before
the machine is stored.RANGEMENT
Si l’on remise la machine pour 60 jours
ou plus, il faut prendre des mesures de
conservation pour éviter sa détérioration.
Après un nettoyage soigné, préparer la
machine de la manière suivante:
1. Vider le réservoir, les conduites
d’essence et la cuve du carburateur.
2. Déposer la bougie, verser une
cuillère à soupe d’huile moteur SAE
10W-30 dans le trou de bougie, et la
remettre en place. Coupe-circuit à la
position arrêt, donner plusieurs
coups de kick pour enduire le cylin-
dre d’huile.
3. Déposer la chaîne, la nettoyer soi-
gneusement au dissolvant et lubri-
fier. Remonter la chaîne ou la
ranger dans un sachet plastique
fermé fixé au cadre.
4. Lubrifier tous les câbles de com-
mande.
5. Mettre le cadre sur plots pour soule-
ver les roues du sol.
6. Fixer un sachet plastique sur la sor-
tie du pot d’échappement pour évi-
ter l’introduction d’humidité.
7. Si la machine est placée dans une
atmosphère humide ou marine,
enduire toutes les surfaces métalli-
ques nues d’une fine couche
d’huile. Ne pas appliquer d’huile
sur les parties en caoutchouc ou sur
la selle.
N.B.:
Avant de ranger la machine, effectuer
toutes les réparations nécessaires.
CLEANING AND STORAGE
NETTOYAGE ET RANGEMENT

MAINTENANCE SPECIFICATIONS
2 - 6
SPEC
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 37.81 mm (1.49 in) 35.9 mm
(1.41 in)
EX 37.54 mm (1.48 in) 35.7 mm
(1.41 in)
Set length (valve closed) IN 29.13 mm (1.15 in) ----
EX 29.30 mm (1.15 in) ----
Compressed force (installed) IN 99 ~ 114 N at 29.13 mm
(9.9 ~ 11.4 kg at 29.13 mm,
22.27 ~ 25.57 lb at 1.15 in)----
EX 126 ~ 144 N at 29.30 mm
(12.6 ~ 14.4 kg at 29.30 mm,
28.44 ~ 32.41 lb at 1.15 in)----
Tilt limit IN ----
2.5°/ 1.7 mm
(2.5°/0.067 in)
EX ----2.5°/1.6 mm
(2.5°/0.063 in)
Direction of winding (top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”76.955 ~ 76.970 mm
(3.0297 ~ 3.0303 in)----
Measuring point “H”8 mm (0.31 in) ----
Piston off-set 0.5 mm (0.020 in)/IN-side ----Item Standard Limit
*
H
D

MAINTENANCE SPECIFICATIONS
2 - 14
SPEC
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 upper 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
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
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting nut M5 × 0.8 1 2 0.2 1.4
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
Rear brake disc M6 × 1.0 6 14 1.4 10
Brake pedal M8 × 1.25 1 26 2.6 19
Rear brake master cylinder M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90

MAINTENANCE SPECIFICATIONS
2 - 15
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—72 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 6 50 5.0 36
Rear brake disc cover M6 × 1.0 2 7 0.7 5.1
Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:
Engine and engine bracket (front) M10 × 1.25 1 69 6.9 50
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine bracket and frame M8 × 1.25 6 34 3.4 24
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Lower engine guard M6 × 1.0 3 10 1.0 7.2
Left engine guard M8 × 1.25 2 23 2.3 17
Right engine guard M8 × 1.25 2 23 2.3 17
Regulator bracket and frame M6 × 1.0 2 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 80 8.0 58
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 19 1.9 13
Lower drive chain tensioner M8 × 1.25 1 20 2.0 14
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank M6 × 1.0 2 10 1.0 7.2
Fuel cock M6 × 1.0 2 7 0.7 5.1
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Hooking screw (fitting band) and fuel tank M6 × 1.0 1 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 4 0.4 2.9
Air scoop and radiator guard (lower) M6 × 1.0 2 4 0.4 2.9
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 10 1.0 7.2
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
Trip meter M6 × 1.0 2 7 0.7 5.1
Meter cable holder and front fork protector M5 × 0.8 2 4 0.4 2.9
Headlight stay (lower) and lower bracket M8 × 1.25 2 7 0.7 5.1

SPEC
2 - 99
CABLE ROUTING DIAGRAM
ÊFasten the diode and rectifier/regulator lead, with the diode at
its white tape and the rectifier/regulator lead at its protecting
tube.
ËFasten the wire harness, starter motor lead and negative bat-
tery lead so that the plastic locking tie ends do not contact the
ignition coil lead.
ÌFasten the wire harness, rectifier/regulator lead, coolant reser-
voir hose, hot starter cable, negative battery lead and starter
motor lead.
ÍFasten the wire harness, negative battery lead, starter motor
lead, rectifier/regulator lead and coolant reservoir hose at the
white tape for the negative battery lead.
ÎFasten the wire harness at its white tape.ÏFasten the wire harness, throttle position sensor lead (in the
wire harness), starter motor lead and negative battery lead.
ÐMake sure that the throttle position sensor coupler does not go
outside the chassis.
ÑFasten the throttle position sensor lead.
ÒPass the carburetor breather hoses, carburetor overflow hose
and coolant reservoir breather hose between the connecting
rod and cross tube (frame).
ÓFasten the neutral switch lead and oil hose together with the
plastic locking ties and cut off the tie ends.
ÔPass the cylinder head breather hose through the hose guide.
ÕFasten the neutral switch lead.

SPEC
2 - 101
CABLE ROUTING DIAGRAM
ÖFasten the neutral switch lead and AC magneto lead.
×Pass the cylinder head breather hose on the inside of the radi-
ator hose 1 and on the outside of the radiator pipe (radiator
hose 4). Make sure that the cylinder head breather hose does
not go forward of the chassis.
ØPass the starter motor lead in front of the radiator hose 4.
ÙPass the clutch cable through the cable guide.
ÚPass the wire harness on the outside of the neutral switch lead
and AC magneto lead.
ÛFit the brake hose into the guides on the protector.
ÜPass the wire harness, clutch cable and light switch lead
through the cable guide.ÝFasten the AC magneto lead, neutral switch lead and light
switch lead to the cable guide at their protecting tube with a
plastic locking tie and cut off the tie end.
ÞPass the carburetor breather hoses, carburetor overflow hose
and coolant reservoir breather hose so that the hoses do not
contact the rear shock absorber.

SPEC
2 - 105
ÌFasten the coolant reservoir breather hose and carburetor
breather hoses together.
ÍFasten the CDI unit lead.
ÎInsert the CDI unit band over the CDI unit stay as far as possi-
ble.
ÏFasten the rectifier/regulator lead to the rectifier/regulator
bracket with a plastic locking tie and cut off the tie end.
CABLE ROUTING DIAGRAM