brake YAMAHA WR 250F 2008 Owner's Manual

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.

5-29
CLUTCH
CLUTCH
REMOVING THE CLUTCHOrder Part name Q'ty Remarks Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8Ball 1
9 Push rod 2 1
10 Friction plate 9
11 Clutch plate 8
12 Cushion spring 1
13 Seat plate 1

5-34
OIL FILTER ELEMENT AND WATER PUMP
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE OIL FILTER ELEMENT AND WATER PUMPOrder Part name Q'ty Remarks Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING
THE COOLANT" sec-
tion in the CHAPTER 3.
Radiator hose 3 Disconnect at water pump side.
Exhaust pipe Refer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
Brake pedal Refer to "ENGINE REMOVAL" section.
Engine guard
1 Oil filter element cover 1
2 Oil filter element 1
3 Water pump housing 1
4 Oil delivery pipe 1
5 Bolt (oil hose) 1
6 Kickstarter crank 1
7 Right crankcase cover 1
8 Impeller 1 Refer to removal section.

5-54
ENGINE REMOVAL
Disconnect the AC magneto lead.
Negative battery lead Disconnect at the engine side.
1 Engine guard 1
2 Neutral switch 1
3 Drive chain sprocket cover 1
4 Nut (drive sprocket) 1 Refer to removal section.
5 Lock washer 1 Refer to removal section.
6 Drive sprocket 1 Refer to removal section.
7Clip 1
8 Bolt (brake pedal) 1
9 Brake pedal 1
10 Upper engine bracket 2
11 Lower engine bracket 2
12 Engine mounting bolt 3
13 Pivot shaft 1 Refer to removal section.
14 Engine 1 Refer to removal section.
Order
Part name Q'tyRemarks

5-55
ENGINE REMOVAL
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE DRIVE
SPROCKET
1. Remove:• Nut (drive sprocket) "1"
• Lock washer "2"
• Straighten the lock washer tab.
• Loosen the nut while applying the rear brake.
2. Remove:• Drive sprocket "1"
• Drive chain "2"
Remove the drive sprocket together
with the drive chain.
REMOVING THE ENGINE
1. Remove:• Pivot shaft "1"
If the pivot shaft is pulled all the way
out, the swingarm will come loose. If
possible, insert a sh aft of similar di-
ameter into the other side of the swin-
garm to support it.
2. Remove:
• Engine "1"From right side.
Make sure that the couplers, hoses
and cables are disconnected.
INSTALLING THE ENGINE
1. Install:
• Engine "1"Install the engine from right side.
• Pivot shaft "2"
• Engine mounting bolt (lower) "3"
• Lower engine bracket "4"
• Bolt (lower engine bracket) "5"
• Patch "6"
• Engine mounting bolt (front) "7"
• Upper engine bracket "8"
• Bolt (upper engine bracket) "9"
• Engine mounting bolt (upper) "10"
• Lower engine guard "11"
• Bolt (lower engine guard) "12"
• Apply the molybdenum disulfide grease on the pivot shaft.
• Install the patch with the claw "a"
facing outside the chassis.
INSTALLING THE BRAKE PEDAL
1. 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-rings and brake pedal
bracket.
INSTALLING THE DRIVE
SPROCKET
1. Install:• Drive sprocket "1"
• Drive chain "2"
Install the drive sprocket together
with the drive chain.
Pivot shaft:
85 Nm (8.5 m•kg, 61
ft•lb)
Engine mounting bolt
(lower): 53Nm (5.3 m•kg, 38
ft•lb)
Bolt (lower engine brack-
et): 34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(front): 53 Nm (5.3 m•kg, 38
ft•lb)
Bolt (upper engine brack-
et): 34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(upper): 55 Nm (5.5 m•kg, 40
ft•lb)
Bolt (lower engine
guard): 7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (brake pedal): 26 Nm (2.6 m•kg, 19
ft•lb)

5-56
ENGINE REMOVAL
2. Install:• Lock washer "1"
• Nut (drive sprocket) "2"
Tighten the nut while applying the
rear brake.
3. Bend the lock washer tab to lock the nut.
4. Install: • Drive chain sprocket guide "1"
• Drive chain sp rocket cover "2"
• Screw (drive chain sprocket cov- er) "3"
INSTALLING THE NEUTRAL
SWITCH
1. Install: • Spring "1"
•Pin "2"
• O-ring "3"
• Neutral switch "4"
• Screw (neutral switch) "5"
Apply the lithium soap base grease
on the O-ring.
Nut (drive sprocket): 75 Nm (7.5 m•kg, 54
ft•lb)
Screw (drive chain
sprocket cover): 8 Nm (0.8 m•kg, 5.8
ft•lb)
Screw (neutral switch): 4 Nm (0.4 m•kg, 2.9
ft•lb)

6-1
FRONT WHEEL AND REAR WHEEL
CHASSIS
FRONT WHEEL AND REAR WHEEL
REMOVING THE FRONT WHEELOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Oil seal 1
8 Bearing 2 Refer to removal section.
9 Brake disc 1
21 Nm (2.1 m kg, 15 ft lb)
21 Nm (2.1 m kg, 15 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)
90 Nm (9.0 m kg, 65 ft lb)

6-2
FRONT WHEEL AND REAR WHEEL
REMOVING THE REAR WHEELOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to removal section.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to removal section.
10 Brake disc 1
125 Nm (12.5 m kg, 90 ft lb)
14 Nm (1.4 m kg, 10 ft lb)
19 Nm (1.9 m kg, 13 ft lb)
19 Nm (1.9 m kg, 13 ft lb)
50 Nm (5.0 m kg, 36 ft lb)
6

6-3
FRONT WHEEL AND REAR WHEEL
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE REAR WHEEL
1. Remove:• Wheel "1"
Push the wheel forward and remove
the drive chain "2".
REMOVING THE WHEEL BEARING
1. Remove:• Bearing "1"
Remove the bearing using a general
bearing puller "2".
CHECKING THE WHEEL
1. Measure:• Wheel runout
Out of limit → Repair/replace.
2. Inspect: • BearingRotate inner race with a finger.
Rough spot/seizure → Replace.
Replace the bearings, oil seal and
wheel collar as a set.
CHECKING THE WHEEL AXLE
1. Measure:
• Wheel axle bendsOut of specification → Replace.
Use the dial gauge "1".
The bending value is shown by one
half of the dial gauge reading.
Do not attempt to straighten a bent
axle.
CHECKING THE BRAKE DISC
1. Measure: • Brake disc deflection (only rear
brake disc)
Use the dial gauge "1".
Out of specification → Inspect
wheel runout.
If wheel runout is in good condi-
tion, replace the brake disc.
2. Measure: • Brake disc thickness "a"
Out of limit → Replace. INSTALLING THE FRONT WHEEL
1. Install:
• Bearing (left) "1"
• Spacer "2"
• Bearing (right) "3"
• Oil seal "4"
• Apply the lithium soap base grease on the bearing and oil seal lip when
installing.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Left side of bearing shall be in- stalled first.
• Install the oil seal with its manufac-
ture's marks or numbers facing out-
ward.
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
Wheel runout limit: Radial "1": 2.0 mm
(0.08 in)
Lateral "2": 2.0 mm
(0.08 in)
Wheel axle bending limit:
0.5 mm (0.020 in)
Brake disc deflection lim-
it: Rear:
: 0.15 mm
(0.006 in)
Brake disc thickness: Front:3.0 mm (0.12 in)
: 2.5 mm (0.10
in)
Rear:
4.0 mm (0.16 in)
: 3.5 mm (0.14
in)

6-4
FRONT WHEEL AND REAR WHEEL
2. Install:• Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:•Collar "1"
Apply the lithium soap base grease
on the oil seal lip.
4. Install:• Speed sensor "1"
• Apply the lithium soap base grease on the oil seal lip of the speed sen-
sor.
• Make sure the two projections "a" in the wheel hub are meshed with the
two slots "b" in the speed sensor.
5. Install:• Wheel
• Install the brake disc "1" between
the brake pads "2" correctly.
• Make sure that the projections "a" in the speed sensor fits over the stop-
per "b" on the front fork inner tube.
6. Install:• Wheel axle "1"
Apply the lithium soap base grease
on the wheel axle.
7. Install:• Nut (wheel axle) "1"
8. Tighten: • Bolt (axle holder) "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok-
ing the front fork several times with
the front brake applied.
INSTALLING THE REAR WHEEL
1. Install:• Bearing (right) "1"
• Circlip "2"
• Spacer "3"
• Bearing (left) "4"
• Oil seal "5"
• Apply the lithium soap base grease on the bearing and oil seal lip when
installing.
• Install the bearing with seal facing outward.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Right side of bearing shall be in- stalled first.
• Install the oil seal with its manufac-
ture's marks or numbers facing out-
ward.
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7
ft•lb)
Nut (wheel axle):
90 Nm (9.0 m•kg, 65
ft•lb)
Bolt (axle holder): 21 Nm (2.1 m•kg, 15
ft•lb)