light YAMAHA WR 250F 2010 User Guide

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 22 2.2 16
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
Headlight body and headlight unit —2 1 0.1 0.7
Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-16
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL
Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m •kg, 47 ft•lb).
△Headlight M6 × 1.0 2 7 0.7 5.1
Taillight — 3 1 0.1 0.7
Taillight lead clamp and rear fender — 3 0.5 0.05 0.36
△ Catch tank (upper) M6 × 1.0 1 16 1.6 11
△ Catch tank (lower) M6 × 1.0 1 7 0.7 5.1
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
Sidestand M10 × 1.25 1 25 2.5 18
Front reflector (For CDN) M6 × 1.0 2 4 0.4 2.9
Rear reflector (For CDN) M5 × 0.8 3 2 0.2 1.4 Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5× 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1Refer to TIP.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Negative lead and cylinder head M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2

2-22
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 under the throttle ca-
ble on the right side of the frame,
and face its ends, as well as the
tie ends, downward.
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.

2-24
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.

2-25
CABLE ROUTING DIAGRAM
1. Clamp
2. Positive battery lead
3. Battery
4. Negative battery lead
5. Taillight coupler
6. CDI unit coupler (6-pin)
7. CDI unit coupler (3-pin)
8. CDI unit coupler (6-pin)

2-26
CABLE ROUTING DIAGRAM
A. Fasten the wire harness, nega-tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side) . Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame.
B. Fasten the wire harness, nega- tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side). Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame. Clamp the wire harness
and negative lead at the mark-
ing.
C. Pass the starter motor lead
through the hole in the relay
holder.
D. Fit the cover securely.
E. Connect the wire harness to the starter relay.
F. Fasten the catch tank breather
hose and catch tank hose to the
rear frame. Clamp them close to
where they are joined to the
frame. Fasten the pipe tightly
enough not to crush it. Locate
the clamp end facing toward the
rear of the frame with the tie end
facing downward.
G. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the upper side of
the frame and cut off the tie end.
H. Connect the negative battery
lead to the battery negative ter-
minal.
I. Connect the negative battery
lead to the wire harness.
J. Fasten the wire harness to the rear frame. Locate the clamp
end facing toward the upper side
of the frame and the tie end to-
ward the inside of the frame.
Clamp the wire harness at the
marking.
K. Pass the wire harness, starter
relay lead, starting circuit cut-off
relay lead and negative battery
lead through the hole in the relay
holder.
L. Fasten the (three) CDI unit leads and taillight lead to the rear
frame. Locate the clamp end
facing toward the lower side of
the frame and cut off the tie end. M. Fasten the taillight lead to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and cut off the tie
end.
N. Do not allow the taillight lead to slacken.
O. Locate the CDI unit lead be- tween the CDI unit and rear
fender.
P. Locate the CDI unit coupler in the clearance between the up-
per side of the CDI unit and low-
er side of the catch tank stay.
Q. Locate the CDI unit lead be- tween the CDI unit and rear
frame.

2-27
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Brake hose
4. Clutch cable
5. Hose guide
6. Main switch coupler
7. Wire harness
8. Headlight coupler
9. Hot starter cable
10. Multi-function display bracket
11. Main switch12. Upper bracket
13. Clutch switch coupler
14. Engine stop switch coupler
15. Multi-function display coupler
16. Start switch coupler
17. Speed sensor coupler
18. Speed sensor lead

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART (ForCanada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER
READINGS600 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
1 Clutch Check operation.
√√√
Adjust or replace cable.
2 * Cooling system Check hoses for cracks of damage.
√√√
Replace if necessary.
Replace with ethylene glycol anti-freeze cool-
ant every 1 year. Every 1 year
3 * Spark arrester Clean. √
4 * Front brake Check operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brake Check operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hoses Check for cracks or damage.
√√
Replace. Every 4 years
7 * Wheels Check runout, spoke tightness and for dam-
age.
√√√
Tighten spokes if necessary.
8*Tires Check tread depth and for damage.
√√√
Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearings Check bearings for smooth operation.
√√√
Replace if necessary.
10 * Swingarm pivot bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease.
11 Drive chain Check chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13 Brake and clutch lever pivot
shafts Apply lithium-soap-bas
ed grease (all-purpose
grease) lightly. √√√
14 Brake pedal pivot shafts Apply lithium-soap-bas
ed grease (all-purpose
grease) lightly. √√√
3

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 mainten ance 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 mainta ining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the ma chine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below.
15 Sidestand pivot Check operation.
√√√
Apply lithium-soap-bas ed 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 ●

3-8
ENGINE
ENGINE
REMOVING THE SEAT, FUEL TANK AND SIDE COVERS
Order Part name Q'ty Remarks Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Open the air filter case cover.
6 Right side cover 1 Refer to removal section.
7 Headlight coupler 1
8 Headlight 1