brake light YAMAHA WR 250F 2008 User Guide

3-26
CHASSIS
LUBRICATION
To ensure smooth operation of all
components, lubricate your machine
during setup, after break-in, and after
every race.
1. All control cable
2. Clutch lever pivot
3. Shift pedal pivot
4. Footrest pivot
5. Throttle-to-handlebar contact
6. Drive chain
7. Tube guide cable winding por-tion
8. Throttle cable end
9. Clutch cable end
10. Hot starter cable end
A. Use Yamaha cable lube or equivalent on these areas. B. Use SAE 10W-30 motor oil or
suitable chain lubricants.
C. Lubricate the following areas
with high quality, lightweight lith-
ium-soap base grease.
Wipe off any excess grease, and
avoid getting grease on the brake
discs.

6-13
FRONT BRAKE AND REAR BRAKE
2. Install:• Brake lever "1"
• Bolt (brake lever) "2"
• Nut (brake lever) "3"
Apply the silicone grease on the
brake lever sliding surface, bolt and
contacting surface of the brake mas-
ter cylinder piston.
INSTALLING THE REAR BRAKE
MASTER CYLINDER
1. Install:• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake master cylinder.
2. Install:• Brake master cylinder "1"
• Bolt (brake master cylinder) "2"
3. Install: • Spring "1"
• Brake pedal "2"
• O-ring "3"
• Bolt (brake pedal) "4"
• Clip "5"
Apply the lithium soap base grease
on the bolt, O-ring and brake pedal
bracket.
4. Install:
•Pin "1"
• Washer "2"
• Cotter pin "3"
After installing, check the brake pedal
height. Refer to "ADJUSTING THE
REAR BRAKE" section in the CHAP-
TER 3.
INSTALLING THE FRONT BRAKE
HOSE
1. Install:• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:
• Brake hose holder "1"
• Bolt (brake hose holder) "2"
Bolt (brake lever):
6 Nm (0.6 m•kg, 4.3
ft•lb)
Nut (brake lever): 6 Nm (0.6 m•kg, 4.3
ft•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Bolt (brake master cylin-
der):10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (brake pedal): 26 Nm (2.6 m•kg, 19
ft•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Bolt (brake hose holder): 10 Nm (1.0 m•kg, 7.2
ft•lb)

6-14
FRONT BRAKE AND REAR BRAKE
3. Install:• Brake hose holder "1"
• Nut (brake hose holder) "2"
Align the top "a" of the brake hose
holder with the paint "b" of the brake
hose.
4. Pass the brake hose through the front brake hose guides "1".
5. Install: • Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that it
contacts the brake master cylinder
projection "a" and that its bent
portion "b" faces downward.
INSTALLING THE REAR BRAKE
HOSE
1. Install:• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:
• Brake hose holder "1"
• Screw (brake hose holder) "2"
After installing the brake hose
holders, make sure the brake hose
does not contact the spring (rear
shock absorber). If it does, correct
its twist.
FILLING THE BRAKE FLUID
1. Fill:• Brake fluidUntil the fluid level reaches
"LOWER" level line "a".
• Use only the designated quality brake fluid:
otherwise, the rubber seals may
deteriorate, causi ng leakage and
poor brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a
harmful chemical reaction and
lead to poor performance.
• Be careful that water does not enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the flu-
id and may result in vapor lock.
Brake fluid may erode painted sur-
faces or plastic parts. Always
clean up spilled fluid immediately.
A. Front
B. Rear
2. Air bleed: • Brake system
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion in the CHAPTER 3.
Nut (brake hose holder):
7 Nm (0.7 m•kg, 5.1 ft
•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Union bolt:30 Nm (3.0 m•kg, 22
ft•lb)
Screw (brake hose hold-
er): 2 Nm (0.2 m•kg, 1.4
ft•lb)
Recommended brake flu-
id: DOT #4

6-16
FRONT FORK
FRONT FORK
REMOVING THE FRONT FORKOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
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 Pinch bolt (upper bracket) 2 Only loosening.
3 Cap bolt 1 Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 2 Only loosening.
5 Front fork 1

6-23
HANDLEBAR
HANDLEBAR
REMOVING THE HANDLEBAROrder Part name Q'ty Remarks Headlight
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5 Engine stop switch 1 Disconnect the engine stop switch lead.
6 Brake master cylinder 1 Refer to removal section.
7 Start switch 1 Disconnect the start switch lead.
8 Throttle cable cap 1
9 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Right grip 1 Refer to removal section.
12 Tube guide 1
13 Left grip 1 Refer to removal section.
14 Handlebar upper holder 2
15 Handlebar 1
16 Handlebar lower holder 2

6-27
STEERING
STEERING
REMOVING THE STEERINGOrder Part name Q'ty Remarks TIGHTENING STEPS:
• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)
• Loosen it one turn.
• Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb)
Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Headlight
Handlebar Refer to "HANDLEBAR" section.
Front brake hose guide
Front fender
1 Multi-function display 1
2 Multi-function display bracket 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering stem nut 1
5 Front fork 2 Refer to "FRONT FORK" section.
6 Upper bracket 1
7 Steering ring nut 1 Refer to removal section.
8 Lower bracket 1