oil YAMAHA WR 250F 2017 Manual PDF

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 10 cm3 (0.34 US
oz, 0.35 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
New
New
New

FRONT FORK
5-47
TIP
• Apply the lithium-soap-based grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat “a”
with fork oil applied to protect the oil seal lip.
15.Install:
• Inner tube bushing “1”
TIP
Install the inner tube bushing onto the slot on
inner tube.
16.Install:
• Outer tube “1”
(to the inner tube “2”)17.Install:
• Inner tube bushing “1”
• Washer “2”
(to the outer tube)
TIP
Press the inner tube bushing into the outer tube
with fork seal driver “3”.
18.Install:
• Oil seals “1”
TIP
Using a fork seal driver “2”, press the oil seal in
until the stopper ring groove fully appears.
LS
New
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948
New

FRONT FORK
5-48
19.Install:
• Oil seal clip “1”
TIP
Fit the oil seal clip correctly in the groove in the
outer tube.
20.Install:
• Dust seal “1”
TIP
Apply lithium-soap-based grease on the inner
tube.
21.Check:
• Inner tube smooth movement
Tightness/binding/rough spots  Repeat
the steps 14 to 20.22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
23.Install:
• Collar “1”
• Fork spring “2”
(to the damper assembly “3”)
TIP
Install the collar with its larger dia. end “a” fac-
ing the fork spring.
24.Install:
• Damper assembly “1”
(to the inner tube “2”)
New
Distance “a”
16 mm (0.63 in) or more
Between the damper assembly
“1” bottom and locknut “2” bot-
tom.
1 2a
12
3
a

FRONT FORK
5-50
29.Install:
• Adjuster “1”
(to the inner tube)
30.Fill:
• Front fork leg
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, do not allow any foreign ma-
terial to enter the front fork.
31.Install:
• Damper assembly “1”
(to the outer tube)
TIP
Temporarily tighten the damper assembly.32.Install:
• Protector guide “1”
EAS2GBB202INSTALLING THE FRONT FORK LEGS
1. Install:
• Front fork “1”
TIP
• Temporarily tighten the pinch bolts (lower
bracket).
• Do not tighten the pinch bolts (upper bracket)
yet.
2. Tighten:
• Damper assembly “1” Adjuster
55 Nm (5.5 m·kgf, 40 ft·lbf)
LOCTITE®
Recommended oil
Yamaha Suspension Oil S1
Standard oil amount
340 cm
3 (11.50 US oz, 11.99
lmp.oz)
Extent of adjustment
300–365 cm
3 (10.14–12.34 US
oz, 10.58–12.87 lmp.oz)
T R..
1LT
Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
T R..

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
Order Part name Q’ty Remarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
5
6
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf) kgf, 58 ft
M
M
M
M
M MM

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:
• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GBB212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace.
• Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts
Bends/damage/wear  Replace.
EAS2GBB213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check:
• Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check:
• Oil seals
Damage/pitting  Replace.
EAS2GBB214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install:
• Bearing “1”
• Washer “2”
• Oil seals “3”
(to relay arm “4”)
3. Install:
• Bearing “1”
• Oil seals “2”
(to connecting arm “3”)
1
Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0 mm (0 in)
Installed depth “a”
0 mm (0 in)
New
3 3
43
2 2
22
a
1
11
New

SWINGARM
5-65
EAS2GBB216
SWINGARM
Removing the swingarm
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 5-23.
Rear brake caliper Refer to “REAR BRAKE” on page 5-23.
Bolt (brake pedal)
Drive chain
1Collars 2
2Oil seals 2
3Thrust bearing 2
4Bushing 2
5Oil seals 2
6Bearing 4
For installation, reverse the removal proce-
dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf) kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf) kgf, 2.9 ft

SWINGARM
5-66
EAS2GBB217REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GBB218REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GBB219CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..

SWINGARM
5-67
EAS2GBB220INSTALLING THE SWINGARM
1. Lubricate:
• Bearing
•Collars
• Spacers
• Oil seal
• Pivot shaft
2. Install:
• Bearing “1”
• Oil seals “2”
(to the swingarm)
TIP
First install the outer and then the inner bear-
ings to a specified depth from inside.
3. Install:
• Swingarm
TIP
Install the pivot shaft from the right.
4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 5-9.
5. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-31.Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0–0.5 mm (0–0.02 in)
Installed depth “b”
6.5 mm (0.26 in)
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Drive chain slack (on a suitable
stand)
50.0–60.0 mm (1.97–2.36 in)
New
New
2 22
1 1
aaa
b ba
NewNewNew
T R..

CLUTCH......................................................................................................... 6-42
REMOVING THE CLUTCH ...................................................................... 6-45
CHECKING THE FRICTION PLATES...................................................... 6-45
CHECKING THE CLUTCH PLATES ........................................................ 6-45
CHECKING THE CLUTCH SPRINGS...................................................... 6-45
CHECKING THE CLUTCH HOUSING ..................................................... 6-46
CHECKING THE CLUTCH BOSS ............................................................ 6-46
CHECKING THE PRESSURE PLATE ..................................................... 6-46
CHECKING THE PUSH LEVER SHAFT .................................................. 6-46
CHECKING THE CLUTCH PUSH RODS ................................................ 6-46
CHECKING THE PRIMARY DRIVE GEAR .............................................. 6-46
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 6-47
INSTALLING THE OIL SEAL................................................................... 6-47
INSTALLING THE RIGHT CRANKCASE COVER ................................... 6-47
INSTALLING THE CLUTCH ..................................................................... 6-47
INSTALLING THE KICKSTARTER LEVER ............................................. 6-50
KICKSTATER................................................................................................. 6-51
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 6-52
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-52
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 6-52
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 6-52
INSTALLING THE KICK IDLE GEAR ....................................................... 6-53
SHIFT SHAFT................................................................................................. 6-54
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-56
REMOVING THE SEGMENT ................................................................... 6-56
CHECKING THE SHIFT SHAFT .............................................................. 6-56
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-56
CHECKING THE STOPPER LEVER ....................................................... 6-56
INSTALLING THE STOPPER LEVER ..................................................... 6-56
INSTALLING THE SEGMENT.................................................................. 6-57
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 6-57
INSTALLING THE SHIFT SHAFT ............................................................ 6-58
INSTALLING THE SHIFT PEDAL ............................................................ 6-58
OIL PUMP AND BALANCER GEAR............................................................. 6-59
REMOVING THE BALANCER ................................................................. 6-62
CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR,
AND BALANCER WEIGHT GEAR .......................................................... 6-62
CHECKING THE BALANCER .................................................................. 6-62
CHECKING THE OIL PUMP .................................................................... 6-62
ASSEMBLING THE OIL PUMP ................................................................ 6-63
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 6-63