YAMAHA WR 250F 2016 Owners Manual

HANDLEBAR
5-37
5. Install:
• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and
the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install:
• Right grip “1”
• Collar “2”
Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the
grip match mark “b” and tube guide slot “c”
form the angle as shown.7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:
• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1b
c
3 64
T R..

HANDLEBAR
5-38
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
10.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install:
• Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Bolt (brake master cylinder holder) “4”
•Clamp “5”
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install:
• Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-12. Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
2
5
1
4
3
4
1LS

HANDLEBAR
5-39
14.Adjust:
• Throttle grip free play
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-13.
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)

FRONT FORK
5-40
EAS2GB7197
FRONT FORK
Removing the front fork legs
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Front wheel Refer to “FRONT WHEEL” on page 5-4.
Front brake caliper Refer to “FRONT BRAKE” on page 5-13.
1 Brake hose holder 2
2 Protector 1
3 Upper bracket pinch bolts 2 Loosen.
4 Damper assembly 1 Loosen.
5 Lower bracket pinch bolts 2 Loosen.
6 Front fork leg 1
7 Reflector/Stay/Nut 1 For Canada
For installation, reverse the removal proce-
dure.

FRONT FORK
5-41
Disassembling the front fork leg
Order Part name Q’ty Remarks
1Adjuster 1
2 Fork spring 1
3 Dust seal 1
4 Stopper ring 1
5 Inner tube 1
6 Outer tube 1
7 Piston metal 1
8Protector guide 1
9 Slide metal 1
10 Washer 1
11 Oil seals 1
12 Base valve 1
13 Damper assembly 1
For assembly, reverse the disassemble pro-
cedure.
LS
13
2 6
9 8
10 11
4
3 1 57
12
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LT
29 Nm (2.9 m•kgf, 21 ftIbf)T.R.
55 Nm (5.5 mkgf, 40 ftIbf)T.R.1.3 Nm (0.13 mkgf, 0.94 ftIbf)T.R.
28 Nm (2.8 mkgf, 20 ftIbf)T.R.
30 Nm (3.0 mkgf, 22 ftIbf)T.R.

FRONT FORK
5-42
EAS2GB7198REMOVING THE FRONT FORK LEGS
1. Use a suitable stand to raise the front wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.
2. Loosen:
• Upper bracket pinch bolts
• Damper assembly
• Lower bracket pinch bolts
EWA
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.
3. Remove:
• Front fork leg (s)
EAS2GB7199DISASSEMBLING THE FRONT FORK LEGS
1. Drain:
• Fork oil
2. Remove:
• Adjuster “1”
(from the inner tube)
TIP
• While compressing the inner tube “2”, set the
cap bolt ring wrench “4” between the inner
tube and locknut “3”.
• Hold the locknut and remove the adjuster.
ECA
NOTICE
Do not scratch the inner tube.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA
NOTICE
Do not scratch the inner tube.
4. Remove:
• Inner tube “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push in slowly “a” the inner tube just before
it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be
pulled out from the outer tube. Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
12
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
1
234
1
2

FRONT FORK
5-43
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• Base valve “1”
(from the damper assembly)
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.
EAS2GB7200CHECKING THE FRONT FORK LEGS
1. Check:
• Inner tube surface “a”
Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace.
• Inner tube bends
Out of specification  Replace.
Use the dial gauge “1”.
TIP
The bending value is shown by one half of the
dial gauge reading.
EWA
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tube
Scratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”
Out of specification  Replace.
4. Check:
• Damper assembly “1”
Bend/damage  Replace.
• O-ring “2”
Wear/damage  Replace.
ECA
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork. Cap bolt wrench
90890-01500
Cap bolt wrench
YM-01500
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
Inner tube bending limit
0.2 mm (0.01 in)
1 23
Fork spring free length
470.0 mm (18.50 in)
Limit
465.0 mm (18.31 in)

FRONT FORK
5-44
5. Check:
• Base valve “1”
Wear/damage  Replace.
Contamination  Clean.
• O-rings “2”
Wear/damage  Replace.
• Base valve bushing “3”
Wear/damage  Replace.
• Spring “4”
Damage/fatigue  Replace the base valve.
• Air bleed screw “5”
Wear/damage  Replace.
6. Check:
• Contacting surface “a”
Wear/damage  Replace.
7. Check:
• Adjuster “1”
• O-rings “2”
Wear/damage  Replace.EAS2GB7201ASSEMBLING THE FRONT FORK LEGSEWA
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
• Inner tube bushing
• Outer tube bushing
• Oil seals
• Copper washers
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill:
• Damper assembly
ECA
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
front fork leg, take care not to allow any
foreign material to enter the front fork.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper
assembly of air.
TIP
Avoid excessive full stroke. A stroke of 200 mm
(7.9 in) or more will cause air to enter. In this
case, repeat the steps 1 to 3.
21
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2
21 543
a
New
Recommended oil
Suspension oil S1
Standard oil amount
210 cm
3 (7.10 US oz, 7.41
Imp.oz)
New
1
2

FRONT FORK
5-45
4. Measure:
• Oil level (left and right) “a”
Out of specification  Regulate.
5. Tighten:
• Locknut “1”
TIP
Fully finger tighten the locknut onto the damper
assembly.6. Loosen:
• Compression damping force adjuster “1”
TIP
• Before loosening the damping force adjuster,
record the setting position.
• Unless the damping force adjuster is fully
loosened, correct damping characteristic can-
not be obtained after installation.
7. Install:
• Base valve “1”
(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
8. Check:
• Damper assembly
Not fully stretched  Repeat the steps 1 to
7. Standard oil level
145–148 mm (5.71–5.83 in)
From top of fully stretched
damper assembly.
1
a1
1
2

FRONT FORK
5-46
9. Tighten:
• Base valve “1”
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to tighten the base valve.
10.After filling, pump the damper assembly “1”
slowly up and down more than 10 times to
distribute the fork oil.
11.While protecting the damper assembly “1”
with a cloth and compressing fully, allow ex-
cessive oil to overflow on the base valve
side.
ECA
NOTICE
Take care not to damage the damper assem-
bly.12.Allow the overflowing oil to escape at the
hole “a” in the damper assembly.
TIP
The overflow measures about 8 cm3 (0.27 US
oz, 0.28 lmp.oz).
13.Check:
• Damper assembly smooth movement
Tightness/binding/rough spots  Repeat
the steps 1 to 12.
14.Install:
• Dust seal “1”
• Oil seal clip “2”
• Oil seals “3”
• Washer “4”
• Outer tube bushing “5”
(to the inner tube “6”)
ECA
NOTICE
Make sure that the numbered side of the oil
seal faces bottom side. Base valve
28 Nm (2.8 m·kgf, 20 ft·lbf)
Cap bolt wrench
90890-01500
Cap bolt wrench
YM-01500
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501
T R..
1 23
1
1
a
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