ABS YAMAHA WR 250F 2009 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 ...................... 2-12
LUBRICATION
DIAGRAMS .................... 2-18
CABLE ROUTING
DIAGRAM ....................... 2-20
CHAPTER 3 REGULAR
INSPECTION AND ADJUSTMENTS
PERIODIC MAINTENANCE
CHART FOR THE EMISSION
CONTROL SYSTEM
(For Canada) .................... 3-1
GENERAL MAINTENANCE
AND LUBRICATION CHART
(For Canada) .................... 3-2
MAINTENANCE
INTERVALS FOR
COMPETITION USE ......... 3-3
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-7
ENGINE ............................ 3-8
CHASSIS ........................ 3-19
ELECTRICAL ................. 3-29
CHAPTER 4 TUNING
ENGINE
(Except for Canada) ........ 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

1-9
MULTI-FUNCTION DISPLAY
COLD STARTER KNOB
When cold, the engine requires a
richer air-fuel mixture for starting. A
separate starter circuit, which is con-
trolled by the cold starter knob "1",
supplies this mixture. Pull the cold
starter knob out to open the circuit for
starting. When the engine has
warmed up, push it in to close the cir-
cuit.
HOT STARTER LEVER
The hot starter lever "1" is used when
starting a warm engine. Use the hot
starter lever when starting the engine
again immediately after it was
stopped (the engine is still warm).
Pulling the hot starter lever injects
secondary air to thin the air-fuel mix-
ture temporarily, allowing the engine
to be started more easily.
SIDESTAND
This sidestand "1" is used to support
only the machine when standing or
transporting it.
• Never apply additional force to the sidestand.
• Hold up the sidestand before starting out.
MULTI-FUNCTION DISPLAY
Be sure to stop the machine before
making any setting changes to the
multi-function display.
The multi-function display is
equipped with the following:
BASIC MODE:
• Speedometer
•Clock
• Two tripmeters (which shows the distance that has been traveled
since it was last set to zero)
RACE MODE:
• Timer (which shows the time that has been accumulated since the
start of timer measurement)
• Tripmeter (which shows the accu-
mulated travel distance in timer
measurement)
• Change tripmeter digits (capable of
change to any given ones)
DESCRIPTION
Operation buttons:
1. Select button "SLCT 1"
2. Select button "SLCT 2"
3. Reset button "RST"
Screen display:
4. Tripmeter indicator
5. Tripmeter indicator
6. Timer indicator
7. Clock/Timer
8. Speedometer
9. Odometer/Tripmeter
The operation buttons can be pushed
in the following two manners:
Short push: Push the button. ( )
Long push: Push the button for 2 sec-
onds or more. ( )
BASIC MODE
Changing speedometer display
(for U.K.)
1. Push the "SLCT2" button for 2 seconds or more to change the
speedometer units. The speed-
ometer display will change in the
following order:
MPH →km/h →MPH.
Setting the time
1. Push the "SLCT1" button for 2 seconds or more to enter the time
setting mode.
2. Push the "RST" button to change the display for time indication.
The display will change in the fol-
lowing order:
Hour →Minute →Second →Hour.
The digits capable of setting go on
flashing.
3. Push the "SLCT1" button (plus) or
"SLCT2" button (minus) and
change the time. A long push on
the button will fast-forward the
time.
4. To end the setting, push the "RST" button for 2 seconds or
more.
• In a 30-second absence of button operation, the setting will come to
an end with the indicated time.
• To reset the seconds, push the
"SLCT1" button or "SLCT2" button.

1-16
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame constructionFrame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp

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)

2-9
MAINTENANCE SPECIFICATIONS
CHASSISItem Standard Limit
Steering system: Steering bearing type Taper roller bearing----
Front suspension: Front fork travel 300 mm (11.8 in)----
Fork spring free length 460 mm (18.1 in)455 mm (17.9
in)
Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in)----
Optional spring/spacer Yes----
Oil capacity 648 cm
3 (22.8 lmp oz, 21.9 US oz)----
Oil level 132 mm (5.20 in)----
(From top of outer tube with inner
tube and damper rod fully compressed without
spring.) 95–150 mm (3.74–5.91 in)
----
Oil grade Suspension oil "S1"----
Inner tube outer diameter 48 mm (1.89 in)----
Front fork top end 5 mm (0.20 in)----
Rear suspension: USA, CDN AUS, NZ, ZA EUROPE
Shock absorber travel 130 mm (5.12
in) ←←
----
Spring free length 260 mm (10.24
in) ←←
----
Fitting length 249 mm (9.80
in) 245.0 mm (9.65
in) 248.5 mm (9.78
in)----
Preload length
1.5–13 mm
(0.06–0.51 in) ←←
----
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in) ←←
----
Optional spring Yes←← ----
Enclosed gas pressure 1,000 kPa (10
kg/cm
2, 142
psi) ←←
----
Swingarm: Swingarm free play limitEnd ---- 1.0 mm (0.04
in)
Wheel: USA, CDN, ZA AUS, NZ, EUROPE
Front wheel type Spoke wheel←----
Rear wheel type Spoke wheel←----
Front rim size/material 21 × 1.60/Aluminum←----
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum ----
Rim runout limit: Radial --------2.0 mm (0.08
in)
Lateral --------2.0 mm (0.08
in)

2-15
TIGHTENING TORQUES
△Rear wheel sprocket M8 × 1.25 6 50 5.0 36
△ Rear brake disc cover M6 × 1.0 2 10 1.0 7.2
△ Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
△ Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△ Upper engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Lower engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
△ Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
△ Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△ Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△ Connecting rod and frame M14 × 1.5 1 80 8.0 58
△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△ Rear frame (upper) M8 × 1.25 1 38 3.8 27
△ Rear frame (lower) M8 × 1.25 2 32 3.2 23
△ Swingarm and brake hose holder M5 × 0.8 4 3 0.3 2.2
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△ Fuel tank M6 × 1.0 2 9 0.9 6.5
△ Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
△ Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
△ Air scoop and radiator guard (lower) M6 × 1.0 2 6 0.6 4.3
△ Front fender M6 × 1.0 4 7 0.7 5.1
△ Rear fender (front) M6 × 1.0 2 7 0.7 5.1
△ Rear fender (rear) M6 × 1.0 2 11 1.1 8.0
△ Side cover M6 × 1.0 2 7 0.7 5.1
△ Seat M8 × 1.25 2 23 2.3 17
Multi-function display bracket and upper bracket M6 × 1.0 2 7 0.7 5.1
Multi-function display M5 × 0.8 2 4 0.4 2.9
Plate 1 and front fork protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and front fork protector — 2 0.5 0.05 0.36
Speed sensor lead holder and lower bracket M6 × 1.0 1 13 1.3 9.4
Speed sensor lead holder and clamp M6 × 1.0 1 7 0.7 5.1 Part to be tightened Thread size Q'ty
Tightening torque
Nm m•kg ft•lb

2-21
CABLE ROUTING DIAGRAM
A. Insert the end of the fuel tank breather hose into the hole in
the steering stem.
B. Fasten the throttle cable, hot
starter cable and rectifier/regula-
tor lead onto the frame. Locate
the clamp end facing the lower
side of the hot starter cable and
cut off the tie end.
C. Fasten the diode (at the mark-
ing), throttle cable and hot start-
er cable onto the frame. Locate
the clamp end facing toward the
lower right of the frame and with
the tie end facing downward.
D. Fasten the wire harness, throttle
position sensor lead, starter mo-
tor lead and negative battery
lead onto the frame. Pass the
clamp through the hole in the
stay (air cut-off valve). Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
E. Pass the carburetor breather
hoses, carburetor overflow hose
and catch tank breather hose
between the connecting rod and
cross tube (frame).
F. Fasten the neutral switch lead and oil hose together with the
plastic locking ties and cut off
the tie ends.
G. Fasten the neutral switch lead
and AC magneto lead onto the
frame. Locate the clamp end
facing toward the outside of the
frame and tie end facing toward
the rear of the frame.
H. Pass the clutch cable through the cable guide.
I. Fasten the starter motor lead, AC magneto lead and neutral
switch lead onto the frame. Lo-
cate the clamp end facing to-
ward the rear of the frame and
cut off the tie end.
J. Fasten the clutch cable, starter motor lead, negative battery
lead, AC magneto lead and neu-
tral switch lead onto the frame.
Locate the clamp end facing to-
ward the rear of the frame and
cut off the tie end.
K. Pass the neutral switch lead and AC magneto lead on the inside
of the wire harness.
L. Fasten the clutch cable, AC magneto lead and neutral switch
lead onto the frame. Locate the
clamp end near the clutch cable
and cut off the tie end. M. Pass the clutch cable and wire
harness through the cable
guide.
N. Locate the couplers in the frame
recess.
O. Pass the carburetor breather hoses, carburetor overflow hose
and catch tank breather hose so
that the hoses do not contact the
rear shock absorber.
P. Secure the coupler by pushing it into the hole in the headlight
unit.
Q. Fasten the throttle position sen- sor lead and the hot starter ca-
ble.
R. Locate the clamp between the hot starter cable protector and
rubber cap.

2-23
CABLE ROUTING DIAGRAM
1. Brake master cylinder
2. Brake hose holder
3. Brake hoseA. Install the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the brake caliper.
B. Pass the brake hose into the
brake hose holders. C. If the brake hose contacts the
spring (rear shock absorber),
correct its twist.
D. Install the brake hose so that its pipe portion directs as shown
and lightly touches the projec-
tion on the brake master cylin-
der.

3-3
MAINTENANCE INTERVALS FOR COMPETITION USE
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
MAINTENANCE INTERVALS FOR COMPETITION USE
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
15 Sidestand pivot Check operation.
√√√
Apply lithium-soap-based grease (all-purpose
grease) lightly.
16 * Front fork Check operation and for oil leakage.
√√
Replace if necessary.
17 * Shock absorber assembly Check operation and for oil leakage.
√√
Replace if necessary.
18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. √√
19 * Control cables Apply Yamaha chain and cable lube or engine
oil 10W-30 thoroughly. √√√
20 * Throttle grip housing and cable Check operation and free play.
√√√
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
21 * Chassis fasteners Check all chassis fitting and fasteners.
√√√
Correct if necessary.
22 Battery Check terminal for looseness and corrosion. √√
No.
ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER
READINGS
600 mi (1,000
km) or 1
month 1,800 mi
(3,000
km) or 3
months 3,000 mi
(5,000
km) or 6
months
Item After
break-
in Every
race
Every
third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks
ENGINE OIL Replace ●●
VALVES Check the valve clearances ●● The engine must be cold.
Inspect ●Check the valve seats and valve
stems for wear.
Replace ●
VALVE SPRINGS Inspect ●Check the free length and the tilt.
Replace ●

3-6
MAINTENANCE INTERVALS FOR COMPETITION USE
FRONT FORKSInspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
REAR SHOCK ABSORBER Inspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
SIDESTAND Lubricate ●Lithium base grease
STEERING HEAD Inspect free play and retighten ●●
Clean and lube ●Lithium base grease
Replace bearing ●
TIRE, WHEELS Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness ●●
Retighten sprocket bolt ●●
Inspect bearings ●
Replace bearings ●
Lubricate ●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection ●●
Lubricate ●● Yamaha cable lube or SAE 10W-30
motor oil
HOT STARTER, CLUTCH LEVER Inspect free play ●
BATTERY
Check terminal for looseness
and corrosion ●
Item
After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks