YAMAHA WR 250F 2015 Owners Manual

GENERATOR AND STARTER CLUTCH....................................................... 6-62
REMOVING THE GENERATOR .............................................................. 6-64
CHECKING THE STARTER CLUTCH ..................................................... 6-64
INSTALLING THE STARTER CLUTCH ................................................... 6-65
INSTALLING THE GENERATOR............................................................. 6-65
CRANKCASE................................................................................................. 6-68
DISASSEMBLING THE CRANKCASE..................................................... 6-71
REMOVING THE CRANKCASE BEARING ............................................. 6-71
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE,
OIL STRAINER ........................................................................................ 6-71
CHECKING THE CRANKCASE ............................................................... 6-71
INSTALLING THE OIL SEAL................................................................... 6-72
ASSEMBLING THE CRANKCASE........................................................... 6-72
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT............................... 6-73
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 6-74
CHECKING THE CRANKSHAFT ASSEMBLY......................................... 6-74
INSTALLING THE CRANKSHAFT ASSEMBLY....................................... 6-75
INSTALLING THE BALANCER SHAFT ................................................... 6-75
TRANSMISSION............................................................................................. 6-76
REMOVING THE TRANSMISSION ......................................................... 6-77
CHECKING THE SHIFT FORKS.............................................................. 6-77
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 6-78
CHECKING THE TRANSMISSION .......................................................... 6-78
INSTALLING THE TRANSMISSION ........................................................ 6-78

ENGINE REMOVAL
6-1
EAS2GB2227
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS2GB2228
ENGINE REMOVAL
Removing the exhaust pipe
Order Part name Q’ty Remarks
Side cover (right) Refer to “GENERAL CHASSIS” on page 5-1.
Rear shock absorber assembly lower boltRefer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-57.
Connecting arm bolt (frame side)Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-57.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
4 Exhaust pipe 2 1
5 Exhaust pipe 1 1
105 9
26
1
66
3
84 7 (4) (6)
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
9 Nm (0.9 m kgf, 6.5 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
New
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
20 Nm (2.0 m kgf, 14 ft Ibf)T.R.New
1st
2nd 20 Nm (2.0 m kgfkgf
, 14 ft lbf) 13 Nm (1.3 m , 9.4 ft lbf)T.R.
LT
LT
5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R.

ENGINE REMOVAL
6-2
6 Gaskets 3
7 Exhaust pipe 1 protector 1
8 Exhaust pipe 2 protector 1
9 Silencer cap 1
10 Spark arrester 1
For installation, reverse the removal proce-
dure.
Removing the exhaust pipe
Order Part name Q’ty Remarks
105 9
26
1
66
3
84 7 (4) (6)
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
9 Nm (0.9 m kgf, 6.5 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
New
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
20 Nm (2.0 m kgf, 14 ft Ibf)T.R.New
1st
2nd 20 Nm (2.0 m kgfkgf
, 14 ft lbf) 13 Nm (1.3 m , 9.4 ft lbf)T.R.
LT
LT
5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R.

ENGINE REMOVAL
6-3
Removing the electronic parts
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Neutral switch 1
5 AC magneto coupler 1 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 Coolant temperature sensor coupler 1 Disconnect.
For installation, reverse the removal proce-
dure.
T.R.
T.R.
T.R.T.R.
7 3
6
5
142
LT
New
LS

ENGINE REMOVAL
6-4
Removing the engine
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 6-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
Throttle body Refer to “THROTTLE BODY” on page 8-7.
Clutch cable Refer to “CLUTCH” on page 6-40.
Shift pedal Refer to “SHIFT SHAFT” on page 6-52.
Starter motor 1Refer to “ELECTRIC STARTER” on page 6-
35.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
New
New
LS
M
8
8
7
6
13
45
New
1 12
3
2
1110
9
55 Nm (5.5 m kgf, 40 ft Ibf)T.R.

ENGINE REMOVAL
6-5
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
6 Drive chain guide 1
7 Drive sprocket 1
8 Upper engine bracket 2
9 Washer 1 Thickness:2.3 mm (0.09 in)
10 Washer 1 Thickness:1.0 mm (0.04 in)
11 Lower engine bracket 2
12 Pivot shaft 1
13 Engine 1
For installation, reverse the removal proce-
dure.
Removing the engine
Order Part name Q’ty Remarks
New
New
LS
M
8
8
7
6
13
45
New
1 12
3
2
1110
9
55 Nm (5.5 m kgf, 40 ft Ibf)T.R.

ENGINE REMOVAL
6-6
EAS2GB2229REMOVING THE SILENCER
1. Remove:
• Rear shock absorber assembly lower bolt
“1”
• Connecting arm bolt (frame side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS2GB2230REMOVING THE EXHAUST PIPE 2
1. Remove:
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS2GB2231REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:
• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3

ENGINE REMOVAL
6-7
EAS2GB2232REMOVING THE ENGINE
1. Remove:
• Pivot shaft “1”
TIP
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:
• Engine “1”
From the right side.
TIP
• Make sure that the couplers, the hoses, and
the cables are disconnected.
• Lift up the engine, and remove this from its
lower part toward the right of the chassis.
EAS2GB2233
CLEANING THE SPARK ARRESTEREWA
WARNING
• Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
• Do not start the engine when cleaning the
exhaust system.
1. Remove:
• Muffler cap screws “1”
2. Remove:
• Spark arrester bolts “1”
3. Remove:
• Tail pipe “1”
• Tail pipe gasket “2”
• Spark arrester “3”
Pull the spark arrester out of the muffler.
• Spark arrester gasket “4”
4. Clean:
• Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon deposits.
1

ENGINE REMOVAL
6-8
5. Install:
• Spark arrester gasket
• Spark arrester
Insert the spark arrester into the muffler and
align the bolt holes.
• Tail pipe gasket
• Spark arrester bolts
6. Install:
• Muffler cap
TIP
First tighten the two screws “a” located horizon-
tally apart, and then tighten the others.
EAS2GB2234CHECKING THE SILENCER AND EXHAUST
PIPE
1. Check:
•Gasket “1”
Damage  Replace.
EAS2GB2235INSTALLING THE ENGINE
1. Install:
• Engine “1”
Install the engine from the right side.
• Pivot shaft “2”• Engine mounting bolt (lower side) “3”
• Front engine bracket “4”
• Engine bracket bolt (front side) “5”
• Engine mounting bolt (front side) “6”
• Upper engine bracket “7”
• Engine bracket bolt (upper side) “8”
• Engine mounting bolt (upper side) “9”
TIP
Apply molybdenum disulfide grease to the pivot
shaft. Spark arrester bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Muffler cap screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Pivot shaft
85 Nm (8.5 m·kgf, 61 ft·lbf)
New
New
T R..
T R..
1
1
T R..
Engine mounting bolt (lower side)
53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (front side)
34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine mounting bolt (front side)
55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine bracket bolt (upper side)
34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine mounting bolt (upper
side)
45 Nm (4.5 m·kgf, 33 ft·lbf)
T R..
T R..
T R..
T R..
T R..
M
78
9
9 8
7
4 1
2
43
5
56

ENGINE REMOVAL
6-9
EAS2GB2236INSTALLING THE BRAKE PEDAL
1. Install:
• Spring “1”
• Brake pedal “2”
• O-rings “3”
• Bolt (brake pedal) “4”
•Clip “5”
TIP
Apply the lithium-soap-based grease on the
bolt, O-rings and brake pedal bracket.
EAS2GB2237INSTALLING THE DRIVE SPROCKET
1. Install:
• Drive sprocket “1”
• Drive chain “2”
TIP
Install the drive sprocket together with the drive
chain.
2. Install:
• Lock washer “1”
• Nut (drive sprocket) “2”
TIP
Tighten the nut while applying the rear brake.
ECA
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
3. Bend the lock washer tab to lock the nut.
4. Install:
• Drive sprocket guide
• Drive sprocket cover “1”
• Bolt (drive sprocket cover) “2”
EAS2GB2238INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:
•Gasket
• Exhaust pipe 1 “1”
• Nut (exhaust pipe 1) “2”
TIP
First temporarily tighten nuts to 13 Nm (1.3
m·kgf, 9.4 ft·lbf). Then retighten them to 20 Nm
(2.0 m·kgf, 14 ft·lbf). Bolt (brake pedal)
26 Nm (2.6 m·kgf, 19 ft·lbf)
Nut (drive sprocket)
75 Nm (7.5 m·kgf, 54 ft·lbf)
New
T R..
1 2
3
45
LS
New
T R..
Bolt (drive sprocket cover)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Nut (exhaust pipe)
20 Nm (2.0 m·kgf, 14 ft·lbf)
T R..
21
New
T R..