engine YAMAHA WR 250F 2009 Manual Online

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.
5Collar 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

6-6
FRONT BRAKE AND REAR BRAKE
FRONT BRAKE AND REAR BRAKE
REMOVING THE FRONT BRAKEOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Drain the brake fluid. Refer to removal section.
1 Brake hose holder (protector) 2
2 Brake hose holder (brake caliper) 1
3 Union bolt 2
4Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6 Pad pin 1Loosen when disassembling the brake cali-
per.
7 Brake caliper 1
8Brake lever 1
9 Brake master cylinder bracket 1
10 Brake master cylinder 1

6-7
FRONT BRAKE AND REAR BRAKE
REMOVING THE REAR BRAKEOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Rear wheel Refer to "FRONT WHEEL AND REAR
WHEEL" section.
Drain the brake fluid. Refer to removal section.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1Loosen when disassembling the brake cali-
per.
8 Brake caliper 1

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.
1Protector 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

6-25
HANDLEBAR
5. Install:•Right grip "1"
•Collar "2"Apply the adhesive on the tube
guide "3".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark "b" and
tube guide slot "c" form the angle as
shown.
6. Install:• Grip cap cover "1"
• Throttle grip "2"
Apply the lithium soap base grease
on the throttle grip sliding surface.
7. Install:
• Throttle cables "1"To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
8. Install:• Throttle cable cap "1"
• Screw (throttle cable cap) "2"
After tightening the screws, check
that the throttle grip "3" moves
smoothly. If it does not, retighten
the bolts for adjustment.
9. Install:• Grip cap cover "1"
• Cover (throttle cable cap) "2" 10. Install:
• Start switch "1"
• Brake master cylinder "2"
• Brake master cylinder bracket "3"
• Bolt (brake master cylinder brack-et) "4"
•Clamp "5"
• The start switch and brake master cylinder bracket should be installed
according to the dimensions
shown.
• Install the bracket so that the arrow mark "a" faces upward.
• First tighten the bolt on the upper
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
11. Install:• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
•Clamp "6"
Screw (throttle cable
cap): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (clutch lever holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (hot starter lever
holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)

6-26
HANDLEBAR
• The engine stop switch, clutch lever holder and clamp should be in-
stalled according to the dimensions
shown.
• Pass the engine stop switch lead in
the middle of the clutch lever hold-
er.
12. Install:• Clutch cable "1"
• Hot starter cable "2"
Apply the lithium soap base grease
on the clutch cable end and hot start-
er cable end.
13. Adjust:• Clutch lever free play
Refer to "ADJUSTING THE
CLUTCH CABLE FREE PLAY"
section in the CHAPTER 3.
• Hot starter lever free play Refer to "ADJUSTING THE HOT
STARTER LEVER FREE PLAY"
section in the CHAPTER 3.

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

6-31
SWINGARM
SWINGARM
REMOVING THE SWINGARMOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Brake hose holder Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Rear brake caliper Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (connecting rod) 1
5Pivot shaft 1
6 Swingarm 1

6-36
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER
REMOVING THE REAR SHOCK ABSORBEROrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Seat and side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Silencer Refer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING THE COOLANT" sec-
tion in the CHAPTER 3.
Catch tank breather hose Disconnect at the catch tank side.
Catch tank hose Disconnect at the catch tank side.
Air induction hose (air cut-off valve-air filter case) Disconnect at the air filter case side.
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to "CHECKING AND CHARGING THE
BATTERY" section in the CHAPTER 3.
Disconnect the starter relay coupler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 4