seats YAMAHA WR 250F 2015 Owners Manual

LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GB2070
LUBRICATION POINTS AND LUBRICANT TYPES
EAS2GB2071ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Balancer shaft journal (left)
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft
Shift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
LS
E
LS
M
M
M
E
M
M
M
E
E
E
M
E
E
E
LS
E
M
E
E
M
E
E
E
E
E
E
E
M
E
E
E
E
E
E

PERIODIC MAINTENANCE
3-4
EAS2GB2080MAINTENANCE INTERVALS FOR COMPETITION USE
TIP
• 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 re-
quired 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.
• Periodic inspection is essential in making full use of the machine performance. The service life of
the parts varies substantially 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.
ITEMAfter
break-
inEvery
raceEvery
third
(or
500
km)Every
fifth
(or
1,000
km)As re-
quiredRemarks
ENGINE OIL
Replace
VALVES
Check the valve
clearancesThe engine must be cold.
InspectCheck the valve seats and
valve stems for wear.
Replace
VALVE SPRINGS
InspectCheck the free length and the
tilt.
Replace
VALVE LIFTERS
InspectCheck for scratches and wear.
Replace
CAMSHAFTS Inspect the camshaft surface.
InspectInspect the decompression
system.
Replace
CAMSHAFT
SPROCKETS
InspectCheck for wear on the teeth
and for damage.
Replace
PISTON Inspect crack.
InspectInspect carbon deposits and
eliminate them.
Clean
ReplaceIt is recommended that the pis-
ton pin and ring are also re-
placed at the same time.
PISTON RING
InspectCheck ring end gap.
Replace

6
ENGINE
ENGINE REMOVAL......................................................................................... 6-1
REMOVING THE SILENCER ..................................................................... 6-6
REMOVING THE EXHAUST PIPE 2.......................................................... 6-6
REMOVING THE DRIVE SPROCKET ....................................................... 6-6
REMOVING THE ENGINE ......................................................................... 6-7
CLEANING THE SPARK ARRESTER ....................................................... 6-7
CHECKING THE SILENCER AND EXHAUST PIPE.................................. 6-8
INSTALLING THE ENGINE........................................................................ 6-8
INSTALLING THE BRAKE PEDAL ............................................................ 6-9
INSTALLING THE DRIVE SPROCKET...................................................... 6-9
INSTALLING THE EXHAUST PIPE AND MUFFLER................................. 6-9
CAMSHAFT.................................................................................................... 6-11
REMOVING THE CAMSHAFT ................................................................. 6-13
CHECKING THE CAMSHAFT.................................................................. 6-14
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .......... 6-15
CHECKING THE TIMING CHAIN TENSIONERS .................................... 6-15
CHECKING THE DECOMPRESSION SYSTEM...................................... 6-16
INSTALLING THE CAMSHAFTS ............................................................. 6-16
CYLINDER HEAD........................................................................................... 6-18
REMOVING THE CYLINDER HEAD........................................................ 6-20
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE) ...................... 6-20
CHECKING THE CYLINDER HEAD ........................................................ 6-20
INSTALLING THE CYLINDER HEAD ...................................................... 6-21
VALVES AND VALVE SPRINGS................................................................... 6-22
REMOVING THE VALVES ....................................................................... 6-23
CHECKING THE VALVES AND VALVE GUIDES ................................... 6-24
CHECKING THE VALVE SEATS ............................................................. 6-26
CHECKING THE VALVE SPRINGS......................................................... 6-27
CHECKING THE VALVE LIFTERS .......................................................... 6-28
INSTALLING THE VALVES ..................................................................... 6-28
CYLINDER AND PISTON............................................................................... 6-30
REMOVING THE PISTON ....................................................................... 6-31
CHECKING THE CYLINDER AND PISTON ............................................ 6-31
CHECKING THE PISTON RINGS............................................................ 6-32
CHECKING THE PISTON PIN ................................................................. 6-33
INSTALLING THE PISTON AND CYLINDER .......................................... 6-33
ELECTRIC STARTER.................................................................................... 6-35
CHECKING THE STARTER MOTOR ...................................................... 6-37
ASSEMBLING THE STARTER MOTOR .................................................. 6-38

CYLINDER HEAD
6-20
EAS2GB2247REMOVING THE CYLINDER HEAD
1. Remove:
• Intake camshaft
• Exhaust camshaft
Refer to “REMOVING THE CAMSHAFT” on
page 6-13.
2. Remove:
• Cylinder head nuts
• Cylinder head bolts
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
fully loosening all the bolts, remove them.
EAS2GB2248CHECKING THE TIMING CHAIN GUIDE (IN-
TAKE SIDE)
1. Check:
• Timing chain guide (intake side)
Damage/wear  Replace.
EAS2GB2249CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
TIP
Use a rounded scraper, not a sharp instrument,
in order not to damage or scratch the spark
plug bore threads.2. Check:
• Cylinder head
Damage/scratches  Replace.
TIP
When replacing the cylinder head, replace also
the valve.
Refer to “CHECKING THE VALVE SEATS” on
page 6-26.
• Cylinder head coolant passages
Mineral deposits/rust  Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification  Resurface the cylin-
der head.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on a
surface plate, and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, turn the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
61
2
35
4 x2 x4FWD
Warpage limit
0.05 mm (0.0020 in)

VALVES AND VALVE SPRINGS
6-23
EAS2GB2252REMOVING THE VALVES
TIP
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves are properly
sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2”
TIP
• Place a cloth in the timing chain space to pre-
vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters
and adjusting pads so that they can be rein-
stalled in their original places.
2. Check:
• Valve sealing
Leakage at the valve seat  Check the
valve face, the valve seat, and the valve seat
width.
Refer to “CHECKING THE VALVE SEATS”
on page 6-26.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves are properly sealed.
TIP
Check that there are no kerosene leaks from
the valve seat “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• Valve cotter “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor adapter
“3”. Valve lapper
90890-04101
Valve lapping tool
YM-A8998
1
2
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108
a1
a

VALVES AND VALVE SPRINGS
6-26
EAS2GB2254CHECKING THE VALVE SEATS
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear  Replace the cylinder head.
3. Measure:
• Valve seat width C “a”
Out of specification  Replace the cylinder
head.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width “c”.
TIP
Where the valve seat and the valve face are in
contact with each other, the blueing will have
been removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
ECA
NOTICE
This model uses titanium intake and ex-
haust valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used
for lapping with new ones.
TIP
• When replacing the cylinder head, replace
also the valves with new ones without them.
• When replacing the valves or the valve
guides, use new valves to lap the valve seats,
and then replace them with new valves.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECA
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and the
valve seat are evenly polished, then clean
off all of the lapping compound. Valve seat width C (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
c