service YAMAHA WR 250F 2016 Owners Manual

OWNER’S SERVICE MANUALMANUEL D’ATELIER DU PROPRIETAIRE
WR250F
WR250FG
2GB-28199-71PRINTED ON RECYCLED PAPER
2016
WR250F
WR250FG 2016
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
PRINTED IN JAPAN
2015.04—1.1 × 1 !(E, F)
2GB-28199-71_cover.indd 12015/04/22 13:04:37

EAS2GB7002
WR250F
WR250FG
OWNER’S SERVICE MANUAL
©2015 by Yamaha Motor Co., Ltd.
First edition, April 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

EAS2GB7007
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Locking agent (LOCTITE®)
Engine oil Replace the part with a new one.
G
M
BF
B
T R..
LS
M
S
LT
E
New

1
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................ 1-1
DESCRIPTION.................................................................................................. 1-4
IDENTIFICATION............................................................................................. 1-5
VEHICLE IDENTIFICATION NUMBER ...................................................... 1-5
ENGINE SERIAL NUMBER ....................................................................... 1-5
VEHICLE EMISSION CONTROL INFORMATION LABEL......................... 1-5
INCLUDED PARTS.......................................................................................... 1-6
SPARK PLUG WRENCH ........................................................................... 1-6
NIPPLE WRENCH...................................................................................... 1-6
HANDLEBAR PROTECTOR ...................................................................... 1-6
FUEL HOSE JOINT COVER ...................................................................... 1-6
COUPLER FOR CONNECTING OPTIONAL PART................................... 1-6
IMPORTANT INFORMATION.......................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY............................ 1-7
REPLACEMENT PARTS............................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS ..................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS ...................................... 1-8
BEARINGS AND OIL SEALS ..................................................................... 1-8
CIRCLIPS ................................................................................................... 1-8
BASIC SERVICE INFORMATION.................................................................... 1-9
ELECTRICAL SYSTEM.............................................................................. 1-9
SPECIAL TOOLS........................................................................................... 1-13
CONTROL FUNCTIONS................................................................................ 1-19
INDICATOR LIGHTS AND WARNING LIGHTS ....................................... 1-19
ENGINE STOP SWITCH .......................................................................... 1-19
START SWITCH....................................................................................... 1-19
CLUTCH LEVER...................................................................................... 1-19
SHIFT PEDAL .......................................................................................... 1-20
KICKSTARTER LEVER............................................................................ 1-20
THROTTLE GRIP ..................................................................................... 1-20
FRONT BRAKE LEVER ........................................................................... 1-20
REAR BRAKE PEDAL.............................................................................. 1-20
SIDESTAND ............................................................................................. 1-21
STARTER KNOB/IDLE ADJUSTING SCREW ......................................... 1-21
FUEL TANK CAP ..................................................................................... 1-21

BASIC SERVICE INFORMATION
1-9
EAS2GB7026
BASIC SERVICE INFORMATION
EAS2GB7027ELECTRICAL SYSTEM
Electrical parts handling
ECA
NOTICE
Never disconnect a battery lead while the
engine is running; otherwise, the electrical
components could be damaged.
ECA
NOTICE
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gen-
erated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
ECA
NOTICE
Be sure to connect the battery leads to the
correct battery terminals. Reversing the
battery lead connections could damage the
electrical components.
ECA
NOTICE
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery
lead. If the negative battery lead is connect-
ed first and a tool or similar item contacts
the vehicle while the positive battery lead is
being connected, a spark could be generat-
ed, which is extremely dangerous.
ECA
NOTICE
Make sure that the multi-function display
goes off after pushing and holding the en-
gine stop switch before disconnecting or
connecting any electrical components.

BASIC SERVICE INFORMATION
1-10
ECA
NOTICE
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA
NOTICE
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
Push and hold the engine stop switch to turn off
the multi-function display when resetting the
ECU (Electronic Control Unit). Disconnect the
starter motor lead of the starter relay, and then
push the starter switch. Be sure to wait for five
seconds or longer before pushing the start
switch after the multi-function display goes off.Checking the electrical system
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA
NOTICE
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler,
taking care not to loosen or damage the
leads.
ECA
NOTICE
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a water-
proof coupler, use the specified test har-
ness or a suitable commercially available
test harness.
a

BASIC SERVICE INFORMATION
1-11
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler, and then disconnect the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the cou-
pler.
ECA
NOTICE
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the con-
nector.2. Check:
• Lead
• Coupler
• Connector
Moisture  Dry with compressed air.
Rust/stains  Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection  Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
1

BASIC SERVICE INFORMATION
1-12
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector,
make sure that both terminals are connected
securely.
• Make sure all connections are tight.
5. Check:
• No continuity
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

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)

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.