length YAMAHA WR 250F 2009 User Guide

3-25
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER SPRING PRELOAD
1. Elevate the rear wheel by placing the suitable stand under the en-
gine.
2. Remove: • Rear frame
3. Measure: • Spring fitting length
The I.D. mark "a" is marked at the end
of the spring.
4. Adjust:• Spring preload
Adjustment steps:
a. Loosen the locknut "1".
b. Loosen the adjuster "2" until there is some clearance between the
spring and adjuster.
c. Measure the spring free length
"a".
d. Turn the adjuster "2".
• Be sure to remove all dirt and mud from around the locknut and adjust-
er before adjustment.
• The length of the spring (installed) changes 1.5 mm (0.06 in) per turn
of the adjuster.
Never attempt to turn the adjuster
beyond the maximum or minimum
setting.
e. Tighten the locknut.
5. Install:• Rear frame (upper)
• Rear frame (lower)
ADJUSTING THE REAR SHOCK
ABSORBER REBOUND DAMPING
FORCE
1. Adjust: • Rebound damping forceBy turning the adjuster "1". • STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the bracket.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
ADJUSTING THE REAR SHOCK
ABSORBER LOW COMPRESSION
DAMPING FORCE
1. Adjust:• Low compression damping forceBy turning the adjuster "1".
Standard fitting length:
I.D. MARK/Q'TY Length
Yellow/1 249 mm (9.80 in)
* 245.0 mm
(9.65 in)
** 248.5 mm
(9.78 in)
* For AUS, NZ and ZA
** For EUROPE
Stiffer →Increase the spring pre-
load. (Turn the adjuster "2" in.)
Softer →Decrease the spring pre-
load. (Turn the adjuster "2"
out.)
Extent of adjustment:
Maximum Minimum
Position in
which the
spring is turned
in 13 mm (0.51
in) from its free
length. Position in
which the
spring is turned
in 1.5 mm (0.06
in) from its free
length.
Locknut: 30 Nm (3.0 m•kg, 22
ft•lb)
Rear frame (upper): 38 Nm (3.8 m•kg, 27
ft•lb)
Rear frame (lower): 32 Nm (3.2 m•kg, 23
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" → Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)
Standard position: About 11 clicks out
Stiffer "a" →Increase the low
compression damping force.
(Turn the adjuster "1" in.)
Softer "b" →Decrease the low
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)

4-6
CHASSIS
A. Air spring characteristics in relation to oil level change
B. Load
C. Stroke
1. Max. oil level
2. Standard oil level
3. Min. oil level
ADJUSTING THE SPRING
PRELOAD
The spring preload is adjusted by in-
stalling the adjustment washer "1" be-
tween the fork spring "2" and damper
rod "3".
Do not install three or more adjust-
ment washers for each front fork.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
A. Load
B. Fork stroke
1. Without adjustment washer (standard)
2. 1 adjustment washer
3. 2 adjustment washers
SETTING OF SPRING AFTER
REPLACEMENT
As the front fork setting can be easily
affected by rear suspension, take
care so that the machine front and
rear are balanced (in position, etc.)
when setting the front fork.
1. Use of soft spring • Change the rebound damping.
Turn out one or two clicks.
• Change the compression damp- ing.
Turn in one or two clicks.
Generally a soft spring gives a soft
riding feeling. Rebound damping
tends to become stronger and the
front fork may sink deeply over a se-
ries of gaps.
2. Use of stiff spring• Change the rebound damping.
Turn in one or two clicks.
• Change the compression damp- ing.
Turn out one or two clicks.
Generally a stiff spring gives a stiff
riding feeling. Rebound damping
tends to become weaker, resulting in
lack of a sense of contact with the
road surface or in a vibrating handle-
bar.
FRONT FORK SETTING PARTS
• Adjustment washer "1" • Front fork spring "2"
The I.D. mark (slits) "a" is proved on
the end of the spring.
When using a spring with a spring
rate of 0.469 kg/mm, do not install
two or more adjustment washers
for each front fork.
REAR SUSPENSION SETTING
The rear suspension setting should
be made depending on the rider's
feeling of an actual run and the circuit
conditions.
The rear suspension setting includes
the following two factors:
1. Setting of spring preload
• Change the set length of the spring.
• Change the spring.
2. Setting of damping force • Change the rebound damping.
• Change the compression damp-ing.
Standard washer quanti-
ty:
Zero adjustment wash-
ers
Extent of adjustment: Zero–2 adjustment
washers
TYPE (thick- ness) PART NUMBER
T = 2.3 mm (0.09 in) 5XE-23364-00
TYPESPRI
NG
RATE SPRING
PART
NUMBER (-23141-) I.D.
MARK (slits)
SOFT 0.408 5TJ-00 |
0.418 5TJ-10 ||
0.428 5TJ-20 |||
0.438 5TJ-30 ||||
STD 0.449 5TJ-A0 —
STIFF 0.459 5TJ-50 |-|
0.469 5TJ-60 |-||

4-7
CHASSIS
CHOOSING SET LENGTH
1. Place a stand or block under the engine to put the rear wheel
above the floor, and measure the
length "a" between the rear wheel
axle center and the rear fender
holding bolt.
2. Remove the stand or block from the engine and with a rider astride
the seat, measure the sunken
length "b" between the rear wheel
axle center and the rear fender
holding bolt.
3. Loosen the locknut "1" and make adjustment by turning the spring
adjuster "2" to achieve the stan-
dard figure from the subtraction of
the length "b" from the length "a".
• If the machine is new and after it is broken in, the same set length of
the spring may change because of
the initial fatigue, etc. of the spring.
Therefore, be sure to make reeval-
uation.
• If the standard figure cannot be
achieved by adjusting the spring
adjuster and changing the spring
set length, replace the spring with
an optional one and make re-ad-
justment.
SETTING OF SPRING AFTER
REPLACEMENT
After replacement, be sure to adjust
the spring to the set length [sunken
length 90–100 mm (3.5–3.9 in)] and
set it.
1. Use of soft spring• Set the soft spring for less re-bound damping to compensate
for its less spring load. Run with
the rebound damping adjuster
one or two clicks on the softer
side and readjust it to suit your
preference.
2. Use of stiff spring • Set the soft spring for more re-
bound damping to compensate
for its greater spring load. Run
with the rebound damping adjust-
er one or two clicks on the stiffer
side and readjust it to suit your
preference.
Adjusting the rebound damping will
be followed more or less by a change
in the compression damping. For cor-
rection, turn the low compression
damping adjuster on the softer side.
When using a rear shock absorber
other than currently installed, use
the one whose overall length "a"
does not exceed the standard as it
may result in faulty performance.
Never use one whose overall
length is greater than standard.
REAR SHOCK ABSORBER
SETTING PARTS
• Rear shock spring "1"
• The I.D. mark "a" is marked at the end of the spring.
• Spring specification varies accord- ing to the color and quantity of I.D.
marks.
• Extent of adjustment (spring pre-
load)
For the spring preload adjustment, re-
fer to "ADJUSTING THE REAR
SHOCK ABSORBER SPRING PRE-
LOAD" in the CHAPTER 3.
Standard figure: 90–100 mm (3.5–3.9 in)
Length "a" of standard
shock:
488.5 mm (19.23 in)
TYPE SPRI
NG
RAT E SPRING
PART
NUM- BER
(-22212-) I.D.
MARK/ Q'TY
SOFT 4.3 5UN-00 Brown/1 4.5 5UN-10 Green/1
4.7 5UN-20 Red/1
4.9 5UN-30 Black/1
5.1 5UN-40 Blue/1
STD 5.3 5UN-50 Yellow/1 5.5 5UN-60 Pink/1
STIFF 5.7 5UN-70 White/1
Maximum Minimum
Position in which the
spring is turned in 13 mm (0.51
in) from its free
length. Position in
which the
spring is turned in 1.5 mm (0.06
in) from its free
length.

4-8
CHASSIS
SUSPENSION SETTING (FRONT FORK)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
Symptom Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff over entire
range ○○○ Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).
Spring Replace with soft spring.
Unsmooth move-
ment over entire
range ○○○○ Outer tube
Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Inner tube
Under bracket tighten-
ing torque Retighten to specified torque.
Poor initial move-
ment ○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil seal Apply grease in oil seal wall.
Soft over entire
range, bottoming
out ○○ Compression damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Oil level (oil amount) Increase oil level by about 5–10 mm (0.2–0.4 in).
Spring Replace with stiff spring.
Stiff toward stroke
end ○
Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming out ○
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial move-
ment ○○○○
Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front posture ○○Compression damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping.
Balance with rear end Set sunken length for 95–100 mm (3.7–3.9 in) when one passenger is astride seat (lower rear
posture).
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
"Obtrusive" front,
tending to upper
front posture ○○Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90–95 mm (3.5–3.7 in) when one passenger is astride seat (upper rear
posture).
Spring Replace with soft spring.
Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).

4-9
CHASSIS
SUSPENSION SETTING (REAR SHOCK ABSORBER)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Symptom Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff, tending to sink ○○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spongy and unsta-
ble ○○Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Low compression
damping Turn adjuster clockwise (about 1 click) to increase
damping.
Spring Replace with stiff spring.
Heavy and dragging ○○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring Replace with soft spring.
Poor road gripping ○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low compression
damping Turn adjuster clockwise (about 1 clicks) to in-
crease damping.
High compression
damping Turn adjuster clockwise (about 1/6 turn) to in-
crease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spring Replace with soft spring.
Bottoming out ○○ High compression
damping
Turn adjuster clockwise (about 1/6 turn) to in-
crease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger in astride seat.
Spring Replace with stiff spring.
Bouncing ○○ Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Spring Replace with soft spring.
Stiff travel ○○ High compression
damping
Turn adjuster counterclockwise (about 1/6 turn) to
decrease damping.
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in) when one passenger is astride seat.
Spring Replace with soft spring.

5-16
CAMSHAFTS
REMOVING THE CAMSHAFT
1. Remove:• Timing mark accessing screw "1"
• Crankshaft end accessing screw "2"
2. Align: • T.D.C. mark
With align mark.
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 that 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.
3. Remove:
• Timing chain tensioner cap bolt "1"
• Timing chain tensioner "2"
•Gasket
4. Remove: • Bolt (camshaft cap) "1"
• Camshaft cap "2"
•Clip
Remove the bolts (camshaft cap) in a
crisscross pattern, working from the
outside in.
The bolts (camshaft cap) must be
removed evenly to prevent dam-
age to the cylinder head, cam-
shafts or camshaft caps.
5. Remove:
• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to
prevent it from falling into the crank-
case.
CHECKING THE CAMSHAFT
1. Inspect:• Cam lobePitting/scratches/blue discolora-
tion →Replace.
2. Measure: • Cam lobe length "a" and "b"
Out of specification →Replace.
3. Measure: • Runout (camshaft)Out of specification →Replace.
Cam lobes length:
Intake "a":29.65–29.75 mm
(1.1673–1.1713 in)
: 29.55 mm (1.1634 in)
Intake "b": 22.45–22.55 mm
(0.8839–0.8878 in)
: 22.35 mm (0.8799 in)
Exhaust "a":
30.399–30.499 mm
(1.1968–1.2007 in)
:
30.299 mm (1.1929 in)
Exhaust "b": 22.45–22.55 mm
(0.8839–0.8878 in)
: 22.35 mm (0.8799 in)
Runout (camshaft): Less than 0.03 mm
(0.0012 in)

5-24
VALVES AND VALVE SPRINGS
CHECKING THE VALVE SPRINGS
1. Measure:• Valve spring free length "a"Out of specification →Replace.
2. Measure: • Compressed spring force "a"Out of specification →Replace.
b. Installed length
3. Measure: • Spring tilt "a"Out of specification →Replace. CHECKING THE VALVE LIFTERS
1. Inspect:
• Valve lifterScratches/damage →Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply: • Molybdenum disulfide oilOnto the valve stem and valve
stem seal.
2. Install: •Valve "1"
• Valve spring seat "2"
• Valve stem seal "3"
• Valve spring "4"
• Valve spring retainer "5"To cylinder head.
• Make sure that each valve is in-stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": Orange
Intake (right/left) "b": Green
Exhaust "c": Purple
• Install the valve springs with the larger pitch "d" facing upward.
e. Smaller pitch 3. Install:
• Valve cotter
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil on the valve stem end.
• Apply the engine oil on the valve lift- ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters and pads in their original place.
Free length (valve
spring):
Intake:36.58 mm (1.44 in)
: 36.81 mm
(1.45 in)
Exhaust:
35.58 mm (1.40 in)
: 36.54 mm
(1.44 in)
Compressed spring
force: Intake:103–118 N at 29.13
mm (10.50–12.09 kg at
29.13 mm, 23.15–
26.66 lb at 1.15 in)
Exhaust: 126–144 N at 29.30
mm (12.85–14.68 kg at
29.30 mm, 28.32–
32.37 lb at 1.15 in)
Spring tilt limit: Intake:2.5°/1.6 mm (0.063 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor: YM-4019/90890-04019

5-31
CLUTCH
REMOVING THE CLUTCH BOSS
1. Remove:•Nut "1"
• Lock washer "2"
• Clutch boss "3"
Straighten the lock washer tab and
use the clutch holding tool "4" to hold
the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
CHECKING THE CLUTCH
HOUSING AND BOSS
1. Inspect: • Clutch housing "1"Cracks/wear/damage →Replace.
• Clutch boss "2"
Scoring/wear/damage →Replace.
CHECKING THE PRIMARY DRIVEN
GEAR
1. Check: • Circumferential play
Free play exists →Replace.
• Gear teeth "a" Wear/damage →Replace. CHECKING THE CLUTCH
SPRINGS
1. Measure:
• Clutch spring free length "a"
Out of specification →Replace
springs as a set.
CHECKING THE FRICTION
PLATES
1. Measure: • Friction plate thicknessOut of specification →Replace
friction plate as a set.
Measure at all four points.
CHECKING THE CLUTCH PLATES
1. Measure: • Clutch plate warpageOut of specification →Replace
clutch plate as a set.
Use a surface plate "1" and thick-
ness gauge "2". CHECKING THE PUSH LEVER
SHAFT
1. Inspect:
• Push lever shaft "1"
Wear/damage →Replace.
CHECKING THE PUSH ROD
1. Inspect: • Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
• Ball "5"Wear/damage/bend →Replace.
INSTALLING THE PUSH LEVER
SHAFT
1. Install: • Push lever shaft "1"
• Bolt (push lever shaft) "2"
• Apply the lithium soap base grease on the oil seal lip.
• Apply the engine oil on the push le-
ver shaft.
• Fit the seat plate "3" in the groove "a" of the push lever shaft and tight-
en the bolt (seat plate).
Clutch holding tool:
YM-91042/90890-04086
Clutch spring free
length:37.0 mm (1.46 in)
: 36.0 mm (1.42
in)
Friction plate thickness: 2.9–3.1 mm (0.114–
0.122 in)
: 2.7 mm (0.106
in)
Warp limit: 0.1 mm (0.004 in)
Bolt (push lever shaft):10 Nm (1.0 m•kg, 7.2
ft•lb)

6-18
FRONT FORK
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
The front fork requires careful atten-
tion. So it is recommended that the
front fork be maintained at the deal-
ers.
To prevent an accidental explosion
of air, the following instructions
should be observed:
• The front fork with a built-in pis-ton rod has a very sophisticated
internal construction and is par-
ticularly sensitive to foreign ma-
terial. Use enough care not to
allow any foreign material to
come in when the oil is replaced
or when the front fork is disas-
sembled and reassembled.
• Before removing the cap bolts or front forks, be sure to extract the
air from the air chamber com-
pletely.
REMOVING THE FRONT FORK
CAP BOLT
1. Remove:
• Front fork cap bolt "1"From the outer tube.
Before removing the front fork from
the machine, loosen the front fork cap
bolt.
2. Remove:• Front fork cap bolt "1"
Hold the locknut "2" and remove the
front fork cap bolt.
REMOVING THE INNER TUBE
1. Remove:
• Dust seal "1"
• Stopper ring "2"Using slotted-head screwdriver.
Take care not to scratch the inner
tube.
2. Remove:• Inner tube "1"
Oil seal removal steps:
a. Push in slowly "a" the inner tube just before it bottoms out and then
pull it back quickly "b".
b. Repeat this step until the inner tube can be pulled out from the
outer tube.
REMOVING THE DAMPER ROD
1. Remove:
• Base valve "1"
• Damper rod "2"
Use a damper rod holder "3" to lock
the damper rod.
CHECKING THE DAMPER ROD
1. Inspect:• Damper rod "1"Bend/damage →Replace damper
rod.
The front fork with a built-in piston
rod has a very sophisticated inter-
nal construction and is particularly
sensitive to foreign material.
Use enough care not to allow any
foreign material to come in when
the oil is replaced or when the
front fork is disassembled and re-
assembled.
CHECKING THE BASE VALVE
1. Inspect: • Valve assembly "1"Wear/damage →Replace.
• O-ring "2" Damage → Replace.
CHECKING THE FORK SPRING
1. Measure: • Fork spring free length "a"
Out of specification →Replace.
Damper rod holder:
YM-01494/90890-01494
Fork spring free length:460 mm (18.1 in)
: 455 mm (17.9
in)

6-39
REAR SHOCK ABSORBER
2. Install:• Stopper ring (upper bearing) "1"
After installing the stopper ring, push
back the bearing until it contacts the
stopper ring.
3. Install:• Lower bearing "1"
Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
INSTALLING THE SPRING (REAR
SHOCK ABSORBER)
1. Install:
• Spring "1"
• Upper spring guide "2"
• Lower spring guide "3"
2. Tighten: •Adjuster "1" 3. Adjust:
• Spring length (installed)Refer to "ADJUSTING THE
REAR SHOCK ABSORBER
SPRING PRELOAD" section in
the CHAPTER 3.
4. Tighten:
• Locknut "1"
INSTALLING THE REAR SHOCK
ABSORBER
1. Install: • Dust seal "1"
• O-ring "2"
•Collar "3"
• Apply the molybdenum disulfide grease on the dust seal lips and col-
lars.
• Apply the lithium soap base grease on the O-rings.
2. Install:• Bushing "1"
•Collar "2"
• Dust seal "3"
• Apply the molybdenum disulfide grease on the bearing and dust seal
lips.
• Install the dust seals with their lips
facing outward.
3. Install:• Rear shock absorber
4. Install: • Bolt (rear shock absorber-frame)
"1"
• Washer "2"
• Nut (rear shock absorber-frame) "3"
Apply the molybdenum disulfide
grease on the bolt.
5. Install:• Bolt (rear shock absorber-relay arm)"1"
• Nut (rear shock absorber-relay
arm) "2"
Apply the molybdenum disulfide
grease on the bolt.
6. Install:• Rear frame "1"
• Bolt [rear frame (upper)] "2"
• Bolt [rear frame (lower)] "3"
Installed depth of the
bearing "a":
4 mm (0.16 in)
Nut (rear shock absorb-
er-frame):56 Nm (5.6 m•kg, 40
ft•lb)
Nut (rear shock absorb-
er-relay arm): 53 Nm (5.3 m•kg, 38
ft•lb)
Bolt [rear frame (upper)]: 38 Nm (3.8 m•kg, 27
ft•lb)
Bolt [rear frame (lower)]: 32 Nm (3.2 m•kg, 23
ft•lb)