ignition YAMAHA WR 250F 2008 Owners Manual

CONTENTS
CHAPTER 1GENERAL
INFORMATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION .................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
MULTI-FUNCTION
DISPLAY .......................... 1-9
STARTING AND
BREAK-IN ...................... 1-14
TORQUE-CHECK
POINTS........................... 1-16
CLEANING AND
STORAGE ...................... 1-17
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-11
LUBRICATION
DIAGRAMS .................... 2-18
CABLE ROUTING
DIAGRAM ....................... 2-21
CHAPTER 3 REGULAR
INSPECTION AND ADJUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-17
ELECTRICAL ................. 3-27
CHAPTER 4 TUNING
ENGINE ............................ 4-1
CHASSIS .......................... 4-5
CHAPTER 5ENGINE
RADIATOR ....................... 5-1
CARBURETOR................. 5-4
AIR INDICTOIN
SYSTEM ......................... 5-12
CAMSHAFTS.................. 5-14
CYLINDER HEAD........... 5-19
VALVES AND VALVE
SPRINGS ........................ 5-21
CYLINDER AND
PISTON ........................... 5-25
CLUTCH ......................... 5-29
OIL FILTER ELEMENT
AND WATER PUMP ....... 5-34
BALANCER .................... 5-38
OIL PUMP ....................... 5-40
KICK SHAFT AND
SHIFT SHAFT ................. 5-43
AC MAGNETO AND
STARTER CLUTCH ....... 5-48
ENGINE REMOVAL ....... 5-53 CRANKCASE AND
CRANKSHAFT ...............5-57
TRANSMISSION, SHIFT
CAM AND SHIFT FORK .5-63
CHAPTER 6
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................6-1
FRONT BRAKE AND
REAR BRAKE ..................6-6
FRONT FORK .................6-16
HANDLEBAR..................6-23
STEERING ......................6-27
SWINGARM ....................6-31
REAR SHOCK
ABSORBER ....................6-36
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-1
IGNITION SYSTEM...........7-3
ELECTRIC STARTING
SYSTEM............................7-5
CHARGING SYSTEM .....7-13
THROTTLE POSITION
SENSOR SYSTEM .........7-15
LIGHTING SYSTEM .......7-18
SIGNALING SYSTEM.....7-20

1-5
SPECIAL TOOLS
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.
Damper rod holder
YM-01494, 90890-01494 Use this tool to remove and install
the damper rod.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Sheave holder
YS-1880-A, 90890-01701 This tool is used for when loosening
or tightening the flywheel magneto
securing nut.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Timing light
YM-33277-A, 90890-03141 This tool is necessary for checking
ignition timing.
Tool name/Part number How to use Illustration

1-6
SPECIAL TOOLS
Valve spring compressor
YM-4019, 90890-04019 This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
YM-91042, 90890-04086 This tool is used to hold the clutch
when removing or installing the
clutch boss securing nut.
Valve guide remover
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4111, 90890-04111
YM-4116, 90890-04116 This tool is needed to remove and
install the valve guide.
Valve guide installer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4112, 90890-04112
YM-4117, 90890-04117 This tool is needed to install the
valve guide.
Valve guide reamer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4113, 90890-04113
YM-4118, 90890-04118 This tool is needed to rebore the
new valve guide.
Rotor puller
YM-04141, 90890-04141 This tool is used to remove the fly-
wheel magneto.
Dynamic spark tester
YM-34487
Ignition checker
90890-06754 This instrument is necessary for
checking the ignition system compo-
nents.
Tool name/Part number
How to useIllustration

2-3
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINEBrake:
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 310 mm (12.2 in)
Electrical: Ignition system CDI
Generator system AC magneto
Battery type YTZ7S (F)
Battery voltage/capacity 12V/6 AH
Specific gravity 1.310
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity: Headlight 12 V 35/36.5 W × 1
Taillight 12 V 1.6/0.3 W × 1
ItemStandardLimit
Cylinder head: Warp limit ----0.05 mm (0.002
in)
Cylinder: Bore size 77.00–77.01 mm (3.0315–3.0319 in) ----
Out of round limit ----0.05 mm (0.002
in)
Camshaft: Drive method Chain drive (Left)----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)

2-10
MAINTENANCE SPECIFICATIONS
ELECTRICALDrive chain:
Type/manufacturer DID520VM/DAIDO----
Number of links 113 links + joint----
Chain slack 48–58 mm (1.9–2.3 in)----
Chain length (15 links) ----239.3 mm
(9.42 in)
Front disc brake: Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in)250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in)1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in)----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2----
Brake fluid type DOT #4----
Rear disc brake: Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in)245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ----0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in)1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in)----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1----
Brake fluid type DOT #4----
Brake lever and brake pedal: Brake lever position 95 mm (3.74 in)----
Brake pedal height (vertical height above footrest
top) 10 mm (0.39 in)
----
Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in)----
Throttle grip free play 3–5 mm (0.12–0.20 in)----
Item
StandardLimit
Item StandardLimit
Ignition system: Advancer type Electrical----
CDI: USA, CDN, ZA,
AUS, NZ EUROPE
Pickup coil resistance (color) 248–372 Ωat 20 °C
(68 °F) (White–Red) ←
----
CDI unit-model/manufacturer 5UM-F0/YAMAHA 5UM-L0/YAMAHA ----
Ignition coil: Model/manufacturer 5UL-10/DENSO----
Minimum spark gap 6 mm (0.24 in)----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
Charging system: System type AC magneto----
Model (stator)/manufacturer 5UM 30/YAMAHA----

2-23
CABLE ROUTING DIAGRAM
1. Throttle cable (pull)
2. Throttle cable (return)
3. Catch tank hose
4. Ignition coil
5. Clamp
6. Air induction hose (air cut-off valve - rear of cylinder head)
7. Catch tank breather hose
A. Cross the pull and push throttle cables. B. Fasten the catch tank hose and
air induction hose (air cut-off
valve-rear of cylinder head) onto
the frame. Locat e the clamp end
facing toward the lower side of
the frame and cut off the tie end.
C. Fasten the catch tank breather hose and carburetor breather
hoses together. D. Pass the carburetor breather
hose (of the throttle cable cover)
through the hose holder.

3-5
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCEItem RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-9 – 10
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.
P.1-14
Engine oil Check that the oil level is correct. Check the crankcase and oil line
for leakage. P.3-12 – 14
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-10
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.
P.3-10 – 11
Brakes Check the play of front brake and ef fect of front and rear brake. P.3-17 – 20
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly. P.3-20 – 21
Wheels Check for excessive wear and ti
re pressure. Check for loose
spokes and have no excessive play. P.3-24
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play.
P.3-24 – 25
Front forks and rear shock
absorber Check that they operate smoothly and there is no oil leakage.
P.3-21 – 24
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 pipe Check that the exhaust pipe is tightly mount ed and has no cracks. P.3-8 – 9
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-20
Lubrication Check for smooth operation. Lubricate if necessary. P.3-26
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are con-
nected tightly. P.1-3
Settings Is the machine set suitably for the
condition of the racing course
and weather or by taking into account the results of test runs be-
fore racing? Are inspection and maintenance completely done? P.4-1 – 9

3-14
ENGINE
ADJUSTING THE PILOT SCREW
1. Adjust:• Pilot screw "1"
Adjustment steps:
To optimize the fuel flow at a smaller
throttle opening, each machine's pilot
screw has been individually set at the
factory. Before adjusting the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
a. Turn in the pilot screw until it is
lightly seated.
b. Turn out the pilot screw by the factory-set number of turns.
ADJUSTING THE ENGINE IDLING
SPEED
1. Start the engine and thoroughly warm it up.
2. Adjust: • Engine idling speed
Adjustment steps:
a. Turn the throttle stop screw "1"
until the specified engine idling
speed.
Using a digital engine tachometer for
idle speed adjustment, detect the en-
gine idling speed by bringing the
sensing element "c" of the engine ta-
chometer close to the ignition coil "2".
ADJUSTING THE VALVE
CLEARANCE
• The valve clearance should be ad0justed when the engine is cool
to the touch.
• The piston must be at Top Dead Center (T.D.C.) on compression
stroke to check or adjust the valve
clearance.
1. Remove:
•Seat
•Fuel tankRefer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section.
2. Drain:
• CoolantRefer to "CHANGING THE
COOLANT" section.
3. Remove: • Right radiatorRefer to "RADIATOR" section in
the CHAPTER 5.
• Carburetor Refer to "CARBU RETOR" section
in the CHAPTER 5.
• Spark plug
• Upper engine bracket
• Cylinder head cover Refer to "CAMSHAFTS" section
in the CHAPTER 5. 4. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw "2"
• O-ring
5. Check: • Valve clearanceOut of specification →Adjust.
Checking steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
In order to be sure t hat the piston is at
Top Dead Center, the punch mark "c"
on the exhaust camshaft and the
punch mark "d" on the intake cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion.
Pilot screw (example):
1-1/2 turns out
(For EUROPE)
To increase idle speed →Turn the
throttle stop screw "1" in "a".
To decrease idle speed →Turn the
throttle stop screw "1" out "b".
Engine idling speed:1,750–1,950 r/min
Valve clearance (cold):
Intake valve:0.10–0.15 mm
(0.0039–0.0059 in)
Exhaust valve: 0.17–0.22 mm
(0.0067–0.0087 in)

3-27
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:• Spark plug
2. Inspect:
• Electrode "1"Wear/damage →Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color →Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure: • Plug gap "a"Use a wire gauge or thickness
gauge.
Out of specification →Regap.
4. Clean the plug with a spark plug cleaner if necessary.
5. Tighten: • Spark plug
• Before installing a spark plug, clean the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:• Timing mark accessing screw "1"
2. Attach: • Timing light
• Inductive tachometerTo the ignition coil lead (orange
lead"1").
3. Adjust: • Engine idling speedRefer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check: • Ignition timingVisually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range →Check ro-
tor and pickup assembly.
5. Install: • Timing mark accessing screw
CHECKING AND CHARGING THE
BATTERY
Batteries generate explosive hy-
drogen gas and contain electrolyte
which is made of poisonous and
highly caustic sulfuric acid. There-
fore, always follow these preven-
tive measures:
• Wear protective eye gear when handling or working near batter-
ies. • Charge batteries
in a well-venti-
lated area.
• Keep batteries away from fire, sparks or open flames (e.g.,
welding equipment, lighted ciga-
rettes).
• DO NOT SMOKE when charging
or handling batteries.
• KEEP BATTERIES AND ELEC- TROLYTE OUT OF REACH OF
CHILDREN.
• Avoid bodily contact with elec- trolyte as it can cause severe
burns or permanent eye injury.
FIRST AID IN CASE OF BODILY
CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15
minutes and get immediate med-
ical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magne-
sia, beaten egg or vegetable oil.
Get immediate medical attention.
Charging time, charging amperage
and charging voltage for an MF
battery are different from those of
conventional batteries. The MF
battery should be charged as ex-
plained in the charging method il-
lustrations. If the battery is
overcharged, the electrolyte level
will drop considerably. Therefore,
take special care when charging
the battery.
Since MF batteries are sealed, it is
not possible to check the charge state
of the battery by measuring the spe-
cific gravity of the electrolyte. There-
fore, the charge of the battery has to
be checked by measuring the voltage
at the battery terminals.
1. Remove:• Seat
2. Disconnect:
• Battery leads(from the battery terminals)
First, disconnect the negative bat-
tery lead "1", and then the positive
battery lead "2".
Spark plug gap: 0.7–0.8 mm (0.028–
0.031 in)
Spark plug: 13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:
YM-33277-A/90890-
03141

5-53
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ENGINEOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the frame. Refer to "HANDLING NOTE".
Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Seat and fuel tank Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Carburetor Refer to "CARBURETOR" section.
Exhaust pipe and silencer Refer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section.
Clutch cable Disconnect at the engine side.
Radiator Refer to "RADIATOR" section.
Shift pedal Refer to "AC MAGNETO AND STARTER
CLUTCH" section.
Cylinder head breather hose Refer to "CAMSHAFTS" section.
Oil hose and oil tank breather ho seRefer to "OIL PUMP" section.
Ignition coil