engine oil YAMAHA WR 250F 2016 User Guide

ENGINE SPECIFICATIONS
2-2
EAS2GB7062
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 250 cm
3
Cylinder arrangement Single cylinder
Bore  stroke 77.0  53.6 mm (3.0  2.1 in)
Compression ratio 13.5:1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
Fuel reserve amount 1.6 L (0.42 US gal, 0.35 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 1.10 L (1.16 US qt, 0.97 Imp.qt)
Without oil filter element replacement 0.83 L (0.88 US qt, 0.73 Imp.qt)
With oil filter element replacement 0.85 L (0.90 US qt, 0.75 Imp.qt)
Oil filter
Oil filter type Paper
Bypass valve opening pressure 40.0–80.0 kPa (0.40–0.80 kgf/cm
2,
5.8–11.6 psi)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator (including all routes) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Radiator capacity 0.56 L (0.60 US qt, 0.50 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kg/cm
2,
15.6–19.9 psi)
Radiator core
Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/LMAR8G
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)

ENGINE SPECIFICATIONS
2-4
Valve spring
Free length (intake) 36.69 mm (1.44 in)
Limit 35.69 mm (1.41 in)
Free length (exhaust) 34.86 mm (1.37 in)
Limit 33.86 mm (1.33 in)
Installed length (intake) 31.40 mm (1.24 in)
Installed length (exhaust) 28.50 mm (1.12 in)
Spring rate K1 (intake) 29.65 N/mm (3.02 kgf/mm, 169.30 lbf/in)
Spring rate K2 (intake) 39.31 N/mm (4.01 kgf/mm, 224.46 lbf/in)
Spring rate K1 (exhaust) 23.11 N/mm (2.36 kgf/mm, 131.96 lbf/in)
Spring rate K2 (exhaust) 30.88 N/mm (3.15 kgf/mm, 176.32 lbf/in)
Installed compression spring force (intake) 146.00–168.00 N (14.89–17.13 kgf,
32.82–37.77 lbf)
Installed compression spring force (exhaust) 137.00–157.00 N (13.97–16.01 kgf,
30.80–35.29 lbf)
Spring tilt (intake) 2.5 °/1.6 mm (2.5 °/0.06 in)
Spring tilt (exhaust) 2.5 °/1.5 mm (2.5 °/0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 77.000–77.010 mm (3.0315–3.0319 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Limit 0.15 mm (0.006 in)
Diameter 76.955–76.970 mm (3.0297–3.0303 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Offset 0.00 mm (0.0000 in)
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B  T) 0.90  2.70 mm (0.04  0.11 in)
End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in)
Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B  T) 1.50  2.25 mm (0.06  0.89 in)
End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)
Crankshaft
Crank assembly width 55.95–56.00 mm (2.203–2.205 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.150–0.450 mm (0.0059–0.0177 in)

ENGINE SPECIFICATIONS
2-5
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.85 mm (0.112 in)
Plate quantity 9 pcs
Clutch plate thickness 1.10–1.30 mm (0.043–0.051 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 47.80 mm (1.88 in)
Limit 46.80 mm (1.84 in)
Spring quantity 5 pcs
Push rod bending limit 0.10 mm (0.004 in)
Transmission
Transmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 3.353 (57/17)
Final drive Chain
Secondary reduction ratio 3.846 (50/13)
Operation Left foot operation
Gear ratio
1st 2.385 (31/13)
2nd 1.813 (29/16)
3rd 1.444 (26/18)
4th 1.143 (24/21)
5th 0.957 (22/23)
6th 0.815 (22/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 4.85 mm (0.1909 in)
Decompression device
Device type Auto decomp
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity 30NA-FZ31/1
Resistance 12 

ENGINE SPECIFICATIONS
2-6
Throttle body
Type/quantity 30RA-A95R/1
ID mark 2GB1 00
Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm
2, 47.0 psi)
Throttle position sensor
Resistance 6.30 k
Output voltage (at idle) 0.5 V
Fuel injection sensor
Crankshaft position sensor resistance 228–342  (Gy–B)
Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01
kgf/cm
2, 3.61–3.67 V at 14.7 psi)
Intake air temperature sensor resistance 290–390  at 80 °C (290–390  176 °F)
Coolant temperature sensor resistance 2.51–2.78 k at 20 °C (2.51–2.78 k at 68 °F)
210–221  at 100 °C (210–221  at 212 °F)
Idling condition
Engine idling speed 1900–2100 r/min
CO% 3.0–4.0 % (USA) (CAN)
Intake vacuum 25.3–29.3 kPa (190–220 mmHg, 7.5–8.7 inHg)
(USA) (CAN)
Water temperature 70.0–90.0 °C (158.00–194.00 °F)
Oil temperature 70.0–80.0 °C (158.00–176.00 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

ELECTRICAL SPECIFICATIONS
2-10
EAS2GB7064
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unit
Model/manufacturer 2GB0/YAMAHA (USA) (CAN)
2GB1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
Spark plug cap
Resistance 10.00 k
AC magneto
Standard output 14.0 V, 160 W at 5000 r/min
Stator coil resistance 0.528–0.792  (W–W)
Rectifier/regulator
Regulator type Semi conductor-short circuit
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 23.0 A
Battery
Model YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate charging current 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage  quantity
Headlight 12 V, 35 W/35 W  1
Tail/brake light LED
Meter lighting EL (Electroluminescent)
Indicator light
Fuel level warning light 12 V, 1.7 W  1
Engine trouble warning light 12 V, 1.7 W  1
Electric starting system
System type Constant mesh
Starter motor
Power output 0.35 kW
Armature coil resistance 0.0189–0.0231 
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)

TIGHTENING TORQUES
2-13
EAS2GB7066ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt
M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug
M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug
M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder head bolts
M9 4 33 Nm (3.3 m·kgf, 24 ft·lbf)
Cylinder head nuts
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)
Balancer nut M10 1 38 Nm (3.8 m·kgf, 27 ft·lbf)
Timing chain guide stopper plate
(exhaust side)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw
M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan bolt
M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump housing cover bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt
M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw
M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp bolt
M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp bolt
M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
E
LT
M
LT
E
LT
LT

TIGHTENING TORQUES
2-14
Air filter guide holder screw
M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw
M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw
M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut
M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch cable locknut (engine side)
M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut
M8 2 See TIP.
Exhaust pipe protector screw
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt
M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt
M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Spark arrester bolt
M5 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Muffler cap bolt
M5 6 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil nozzle bolt
M5 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Engine oil drain bolt
M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt
M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw
M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw
M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screwM6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft)M8 4 22 Nm (2.2 m·kgf, 16 ft·lbf)
Oil passage squeeze nozzle
M8 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Clutch cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt
M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt
M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kick starter lever bolt
M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
Kick starter lever boss screw
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Primary drive gear nut
M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Clutch spring bolt
M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
LT
LT
LT
LT
LT
LT
LT
E

LUBRICATION POINTS AND LUBRICANT TYPES
2-20
EAS2GB7068
LUBRICATION POINTS AND LUBRICANT TYPES
EAS2GB7069ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
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)
Balancer nut threads (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
LS
E
LS
E
M
M
M
E
M
M
M
E
E
E
M
E
E
E
E
LS
E
M
E
E
M
E
E
E
E
E
E
E
M
E
E
E
E

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................. 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE.......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-13
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM..................................................... 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL..................................................... 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-18
ADJUSTING THE VALVE CLEARANCE ................................................. 3-19
CLEANING THE SPARK ARRESTER ..................................................... 3-23
CHASSIS........................................................................................................ 3-24
BLEEDING THE BRAKE SYSTEM .......................................................... 3-24
CHECKING THE BRAKE HOSE .............................................................. 3-25
ADJUSTING THE FRONT BRAKE .......................................................... 3-25
ADJUSTING THE REAR BRAKE ............................................................. 3-26
CHECKING THE FRONT BRAKE PADS ................................................. 3-26
CHECKING THE REAR BRAKE PADS ................................................... 3-28
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-29
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-29
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-30
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-31
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-31
AIR BLEEDING FROM FRONT FORK .................................................... 3-31
ADJUSTING THE FRONT FORK LEGS .................................................. 3-32
CHECKING THE SWINGARM OPERATION ........................................... 3-33
CHECKING THE REAR SUSPENSION ................................................... 3-33

PERIODIC MAINTENANCE
3-1
EAS2GB7074
PERIODIC MAINTENANCE
EAS2GB7075INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2GB7076PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000
km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER READ-
INGS
600 mi
(1000
km) or 1
month1800 mi
(3000
km) or 3
months3000 mi
(5000
km) or 6
months
1*Fuel line• Check fuel hoses for cracks or dam-
age.
• Replace if necessary.
2Spark plug• Check condition.
• Adjust gap and clean.
3*Valve clear-
ance• Check and adjust valve clearance
when engine is cold.
4*Air filter ele-
ment• Clean with solvent and apply foam air-
filter oil or equivalent oil.
• Replace if necessary.
5*Breather
system• Check ventilation hose for cracks or
damage and drain any deposits.
• Replace. Every 2 years
6*Fuel injec-
tion• Adjust engine idling speed.
7Exhaust sys-
tem• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
8Engine oil• Change (warm engine before drain-
ing).
9Engine oil fil-
ter element•Replace.
10Engine oil
strainer• Clean.