clutch YAMAHA WR 250F 2005 Manuale de Empleo (in Spanish)

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 M51 × 1.5 2 30 3.0 22
Front fork and base valve M27 × 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 protector and brake hose holder M6 × 1.0 2 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 and front brake hose
guide bracketM5 × 0.8 1 4 0.4 2.9
Front brake hose guide and lower bracket M6 × 1.0 1 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting nut M6 × 1.0 1 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
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
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
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

SPEC
2 - 97
CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Clamp
4Diode
5Wire harness
6Hot starter cable
7Throttle position sensor lead
8Neutral switch lead
9Oil hose
0Hose guideAAC magneto lead
BCylinder head breather hose
CStarter motor lead
DClutch cable
ERadiator hose 1
FCable guide
GRadiator pipe (radiator hose 4)
HNegative battery lead
IBrake hose
JCarburetor breather hoseKCarburetor overflow hose
LCoolant reservoir breather hose
ÈInsert the fuel tank breather hose into
the hole in the steering stem cap.
ÉPass the oil tank breather hose on the
outside of the AC magneto lead, neu-
tral switch lead, wire harness, starter
motor lead, negative battery lead and
cylinder head breather hose.
B
BA
B-B
A
Ö3 ×BØC
Ô0
Õ3 G
D
EH
ÙF ÙF
I0ÛF
Ü30
1
È
3
Ê
4
3
Ë
3
Ì5
63
Í
3
Î3
Ï
Ð
Ò Ú3
Ñ
7
9 3
Ó 0
ÔÝ JJ
KL
8 A2
É
9
8

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 guides.
ÚPass the wire harness on the outside of the neutral switch lead
and AC magneto lead.
ÛPass the wire harness and clutch cable through the cable
guide.ÜFasten the AC magneto lead and neutral switch lead to the
cable guide at their protecting tube.
ÝPass the carburetor breather hoses, carburetor overflow hose
and coolant reservoir breather hose so that the hoses do not
contact the rear shock absorber.
B
BA
B-B
A
Ö3 ×BØC
Ô0
Õ3 G
D
EH
ÙF ÙF
I0ÛF
Ü30
1
È
3
Ê
4
3
Ë
3
Ì5
63
Í
3
Î3
Ï
Ð
Ò Ú3
Ñ
7
9 3
Ó 0
ÔÝ JJ
KL
8 A2
É
9
8

SPEC
2 - 111
CABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Brake hose
4Hot starter cable
5Clutch cable
6Hose guide
7Clutch switch lead
8Engine stop switch lead
9Trip meter cable
0Main switch lead
ATrip meter
BMain switch
CStart switch leadÈFasten the start switch lead.
ÉFasten the engine stop switch lead and clutch switch lead.
ÊPass the brake hose through the hose guides.
ËPass the start switch lead in front of the main switch lead.
ÌPass the hot starter cable and clutch cable between the upper
bracket and coupler bracket.
ÍPass the throttle cables between the upper bracket and trip
meter.
C
A
B
C-C
4
5
2
8
7
1
4
5
Ì
Í
B
B
A
1
C2
3
22
4
5
6
7
8
6 90 A BÈ
É
Ê
Ê Ë
C
40˚±10˚

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks
ENGINE OIL
Replace
Inspect
VALVES
Check the valve clearances The engine must be cold.
Check the valve seats and
valve stems for wear. Inspect
Replace
VALVE SPRINGS
InspectCheck the free length and
the tilt.
Replace
VALVE LIFTERS
InspectCheck for scratches and
wear.
Replace
CAMSHAFTSInspect the camshaft
surface.
Inspect the decompression
system. Inspect
Replace
TIMING CHAIN SPROCKETS, TIMING
CHAIN
InspectCheck for wear on the teeth
and for damage.
Replace
PISTON
InspectInspect crack
Inspect carbon deposits and
eliminate them. Clean
Replace
PISTON RING
InspectCheck ring end gap
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEADInspect carbon deposits and
eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect and adjust Inspect housing, friction
plate, clutch plate and spring
Replace
TRANSMISSION
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
*marked: For USAFRONT FORKS
Inspect and adjust
Replace oilSuspension oil “S1”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
Inspect and adjust
Lube
(After
rain
ride)Molybdenum disulfide
grease
Retighten
DRIVE CHAIN GUIDE AND ROLLERS
Inspect
DRIVE CHAIN STOPPER
Inspect
SWINGARMMolybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD Molybdenum disulfide
grease
Inspect, lube and retighten
SIDESTAND
LubricateLithium base grease
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out, tire
wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE Yamaha cable lube or SAE
10W-30 motor oil
Inspect dirt and wear on the
throttle cable on the
carburetor side. Check routing and connection
Lubricate
Inspect and clean (throttle cable)
HOT STARTER, CLUTCH LEVER
Inspect free play
BATTERY
Check terminal for looseness and
corrosionItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks

3 - 16
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 the cooling system for leakage.P.3-21 ~ 29
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-35
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-39 ~ 47
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-29 ~ 31
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-31 ~ 33
Brakes Check the play of front brake and effect of front and rear brake. P.3-65 ~ 77
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-79 ~ 83
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-99 ~ 101
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-101 ~ 103
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-85 ~ 97
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.4-7 ~ 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-77
Lubrication Check for smooth operation. Lubricate if necessary. P.3-105
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-45
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are
connected tightly.P.1-9
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 ~ 42

3 - 29
INSP
ADJ
3. Inspect:
Pressure
Impossible to maintain the
specified pressure for 10 sec-
onds
→ Replace.
COOLING SYSTEM INSPECTION
1. Inspect:
Coolant level
2. Attach:
Radiator cap tester
1 and
adapter
2
3. Apply the specified pressure.
NOTE:Do not apply pressure more than
specified pressure.
Radiator should be filled fully.
Radiator cap tester:
YU-24460-01/
90890-01325
Radiator cap tester
adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa
(1.8 kg/cm
2, 25.6 psi)
4. Inspect:
Pressure
Impossible to maintain the
specified pressure for 10 sec-
onds
→ Repair.
Radiator
1
Radiator hose joint
2
Coolant leakage
→ Repair or
replace.
Radiator hose
3
Swelling
→ Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play
a
Out of specification
→ Adjust.
Clutch lever free play a:
8 ~ 13 mm
(0.31 ~ 0.51 in)
3. Contrôler:
Pression
Impossible de maintenir la pres-
sion spécifiée pendant 10 secon-
des → Remplacer.
CONTROLE DU CIRCUIT DE
REFROIDISSEMENT
1. Contrôler:
Niveau du liquide de refroidisse-
ment
2. Fixer:
Testeur de bouchon de radiateur
1 et adaptateur 2
3. Appliquer la pression spécifiée.
N.B.:
Ne pas appliquer de pression supé-
rieure à la pression spécifiée.
Le radiateur doit être entièrement rem-
pli.
4. Contrôler:
Pression
Impossible de maintenir la pres-
sion spécifiée pendant 10 secon-
des → Réparer.
Radiateur 1
Raccords du tuyau de radiateur
2
Fuite de liquide de refroidisse-
ment → Réparer ou remplacer.
Tuyau du radiateur 3
Gonflement → Remplacer.
Testeur de bouchon de
radiateur:
YU-24460-01/
90890-01325
Adaptateur du testeur de
bouchon de radiateur:
YU-33984/90890-01352
Pression standard:
180 kPa
(1,8 kg/cm
2, 25,6 psi)
REGLAGE DE L’EMBRAYAGE
1. Contrôler:
Jeu du levier d’embrayage a
Hors spécifications → Ajuster.
Jeu du levier d’embrayage
a:
8 à 13 mm (0,31 à 0,51 in)
ENGINE
MOTEUR

3 - 31
INSP
ADJ
2. Adjust:
Clutch lever free play
NOTE:Make minute adjustment on the
lever side using the adjuster
2.
After adjustment, check proper
operation of clutch lever. Clutch lever free play adjust-
ment steps:
Loosen the locknuts
1.
Adjust the free play by changing
their tightening position.
Tighten the locknuts.
T R..
Locknut:
7 Nm
(0.7 m  kg, 5.1 ft  lb)
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play
a
Out of specification
→ Adjust.
Throttle grip free play a:
3 ~ 5 mm
(0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjust-
ment steps:
Slide the adjuster cover.
Loosen the locknut
1.
Turn the adjuster
2 until the
specified free play is obtained.
Tighten the locknut.
NOTE:Before adjusting the throttle cable
free play, the engine idle speed
should be adjusted.
WARNING
After adjusting the throttle
cable free play, start the engine
and turn the handlebar to right
and left and make sure that the
engine idling does not run
faster.
21
2. Régler:
Jeu du levier d’embrayage
N.B.:
Pour un réglage ponctuel, utiliser le
dispositif de réglage 2 du côté du
levier.
Après le réglage, contrôler le fonction-
nement du levier d’embrayage. Etapes du réglage du jeu du levier
d’embrayage:
Desserrer les contre-écrous 1.
Régler le jeu en changeant leur
position de serrage.
Serrer les contre-écrous.
T R..
Contre-écrou:
7 Nm
(0,7 m  kg, 5,1 ft  lb)
REGLAGE DU CABLE DES GAZ
1. Contrôler:
Jeu de la poignée des gaz a
Hors spécifications → Ajuster.
Jeu de la poignée des gaz a:
3 à 5 mm (0,12 à 0,20 in)
2. Régler:
Jeu de la poignée des gaz
Etapes du réglage du jeu de la poi-
gnée des gaz:
Glisser le cache du dispositif de
réglage.
Desserrer le contre-écrou 1.
Faire tourner le dispositif de
réglage 2 jusqu’à obtention du jeu
spécifié.
Serrer le contre-écrou.
N.B.:
Avant de régler le jeu du câble des
gaz, régler le régime de ralenti du
moteur.
AVERTISSEMENT
Après avoir réglé le jeu du câble
des gaz, démarrer le moteur et
faire tourner le guidon vers la
droite et la gauche pour contrôler
que le régime de ralenti n’aug-
mente pas.
ENGINE
MOTEUR

3 - 39
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for
several minutes, and then turn
off the engine and wait for five
minutes.
2. Place the machine on a level
place and hold it up on upright
position by placing the suitable
stand under the engine.
3. Remove:
Oil tank cap
1
1
4. Inspect:
Oil level
Oil level should be between
maximum
a and minimum b
marks.
Oil level is low → Add oil to
proper level.
NOTE:When inspecting the oil level, do not
screw the oil tank cap into the oil
tank. Insert the gauge lightly.
(For USA and CDN)
CAUTION:
Do not add any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
Do not allow foreign material to
enter the crankcase.
Recommended oil:
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)
a
b
CONTROLE DU NIVEAU D’HUILE
MOTEUR
1. Mettre le moteur en marche, le faire
chauffer pendant quelques minutes
puis le couper et attendre cinq
minutes.
2. Placer la moto sur un sol plan et la
maintenir à la verticale en plaçant
un support adéquat sous le moteur.
3. Déposer:
Bouchon du réservoir d’huile 1
4. Contrôler:
Niveau d’huile
Le niveau d’huile doit se situer
entre les repères de niveau maxi-
mum a et minimum b.
Le niveau d’huile est bas → Faire
l’appoint au niveau correct.
N.B.:
Pour contrôler le niveau d’huile, ne pas
visser le bouchon du réservoir d’huile
dans le réservoir. Insérer légèrement la
jauge.
(USA et CDN)
ATTENTION:
Ne pas ajouter d’additifs chimiques.
L’huile moteur lubrifie également
l’embrayage et les additifs pour-
raient provoquer un patinage de
l’embrayage.
Veiller à empêcher toute pénétra-
tion de corps étrangers dans le car-
ter moteur.
Huile recommandée:
A 5 °C (40 °F) ou plus È
Yamalube 4 (20W-40) ou
huile moteur SG de type
SAE 20W-40 (non modi-
fiée pour la friction)
A 15 °C (60 °F) ou plus
É Yamalube 4 (10W-30)
ou huile moteur SG de
type SAE 10W-30 (non
modifiée pour la friction)
et/ou
Yamalube 4-R (15W-50)
(non modifiée pour la
friction)
ENGINE
MOTEUR