oil YAMAHA WR 250F 2004 Betriebsanleitungen (in German)

1 - 45
GEN
INFO
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Rear Installation of rear
shock absorberRear shock absorber to frame
Rear Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp
NOTE:Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” sec-
tion in the CHAPTER 2.
TORQUE-CHECK POINTS

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

GENERAL SPECIFICATIONS
2 - 1
SPEC
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR250FS (USA)
WR250F (EUROPE)
WR250F(S) (CDN, AUS, NZ, ZA)
Model code number: 5UM5 (USA)
5UM6 (EUROPE)
5UM7 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,165 mm (85.2 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 998 mm (39.3 in)
Wheelbase 1,475 mm (58.1 in)
Minimum ground clearance 382 mm (15.0 in)
Dry weight:
Without oil and fuel 105.5 kg (232.6 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
3 (8.76 Imp oz, 8.42 US oz)
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 12.5 : 1
Starting system Kick and electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE 20W-40 type
SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE 10W-30 type
SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
(Except for USA and CDN)
API “SG” or higher grade
-20
-4-10
140
3010
5020
6830
8640 50
104
122˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40
2

GENERAL SPECIFICATIONS
2 - 2
SPEC
Oil capacity:
Engine oil
Periodic oil change 1.2 L (1.06 Imp qt, 1.27 US qt)
With oil filter replacement 1.3 L (1.14 Imp qt, 1.37 US qt)
Total amount 1.4 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
(Except for ZA)
Premium gasoline (For ZA)
Tank capacity 10 L (2.2 Imp gal, 2.64 US gal)
Reserve 1.2 L (0.26 Imp gal, 0.32 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 52/13 (4.000)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 31/13 (2.385)
2nd 28/16 (1.750)
3rd 28/21 (1.333)
4th 25/24 (1.042)
5th 22/27 (0.815)
Chassis:
Frame type Semi double cradle
Caster angle 27.1°
Trail 117.4 mm (4.62 in)
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)
130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
1
2
3
4
5
6
7

GENERAL SPECIFICATIONS
2 - 3
SPEC
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
Generator system AC magneto
Battery type YTX5L-BS
Battery voltage/capacity 12 V/4 AH
Specific gravity 1.320
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Taillight 12 V 21/5 W × 1

MAINTENANCE SPECIFICATIONS
2 - 7
SPEC
Piston pin bore inside diameter 16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)16.043 mm
(0.6316 in)
Piston pin outside diameter 15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ----
End gap (installed) 0.15 ~ 0.25 mm
(0.006 ~ 0.010 in)0.50 mm
(0.020 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ----
End gap (installed) 0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)0.80 mm
(0.031 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ----
End gap (installed) 0.10 ~ 0.40 mm
(0.004 ~ 0.016 in)----
Crankshaft:
Crank width “A”55.95 ~ 56.00 mm
(2.203 ~ 2.205 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F”0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in) Item Standard Limit
T
B
B
T
B
T

MAINTENANCE SPECIFICATIONS
2 - 9
SPEC
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 220 mm (8.7 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

MAINTENANCE SPECIFICATIONS
2 - 10
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil hose clamp—220.21.4
Oil strainer and frame M14 × 1.5 1 70 7.0 50
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

MAINTENANCE SPECIFICATIONS
2 - 11
SPEC
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Spark arrester (for USA) M6 × 1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6 × 1.0 1 10 1.0 7.2
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 3 10 1.0 7.2
Idle gear plate M6 × 1.0 2 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 8 0.8 5.8
Clutch boss M16 × 1.0 1 60 6.0 43
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Shift pedal M6 × 1.0 1 12 1.2 8.7 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

MAINTENANCE SPECIFICATIONS
2 - 12
SPEC
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in)←←
Fork spring free length 460 mm (18.1 in)←←
Spring rate, STD K = 4.31 N/mm
(0.44 kg/mm,
24.6 lb/in)K = 4.12 N/mm
(0.42 kg/mm,
23.5 lb/in)K = 4.22 N/mm
(0.43 kg/mm,
24.1 lb/in)
Optional spring/spacer Yes←←
Oil capacity578 cm
3
(20.3 lmp oz,
19.5 US oz) 573 cm3
(20.2 lmp oz,
19.4 US oz) ←
Oil level 125 mm (4.92 in) 130 mm (5.12 in)←

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 150 mm
(3.15 ~ 5.91 in)←←
Oil grade Suspension oil
“01”←←
Inner tube outer diameter 46 mm (1.81 in)←←
Front fork top end 5 mm (0.20 in)←10 mm (0.39 in)
Rear suspension: USA, CDN, AUS,
NZ, ZAEUROPE
Shock absorber travel 132 mm (5.20 in)←----
Spring free length
260 mm (10.24 in)←----
Fitting length 245 mm (9.65 in)
246.5 mm (9.70 in)----
240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)←----
Spring rate, STD K = 50.0 N/mm
(5.10 kg/mm,
285.6 lb/in)K = 46.0 N/mm
(4.70 kg/mm,
263.2 lb/in)----
Optional spring Yes←----
Enclosed gas pressure
1,000 kPa (10 kg/cm2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm
(0.04 in)