Yamaha WR 250f Assembly Manual
WR250FR
5UM-28107-10
ASSEMBLY MANUAL
LIT-11666-16-48
WR250FR
ASSEMBLY MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, December 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11666-16-48
EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct reassembly of this Yamaha
machine prior to delivery to the customer. Since some external parts of the machine have been
removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is
required. It should be noted that the assembled machine should be thoroughly cleaned, inspected,
and adjusted prior to delivery to the customer.
EAA00005
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its model. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to the machine and/or rider.
w
Failure to follow WARNING instructions could result in se
vere injury or death to
the machine operator, a bystander, or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
CAUTION:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
!!
Particularly important information is distinguished in this manual by the following notations.
EAA00001
EAA00008
SYMBOLS USED IN
ASSEMBLY MANUAL
In order to simplify descriptions in this
assembly manuals, the following symbols
are used:
(1) Coat with lithium-soap-based-grease.
(2) Tighten to 10 Nm.
(10 Nm = 1.0 mdkg = 7.2 ftdlb)
(3) Towards the front of the machine.
(4) Clearance required.
(5) Install so that the arrow mark faces
upward.
(6) Apply a motor oil.
(7) Made of rubber or plastics.
(8)
A: Ref No. (indicating the order of
operations.)
B: Part name
C: Quantity of parts per machine.
D: Place where parts are held.
V: Stored in vinyl bag.
C: Stored in carton box.
S: Fixed inside the steel frame,
and/or contained in the styrofoam tray (upper or lower).
*: Temporarily installed or secured.
E: Size or material of parts.
d/D: Diameter of part.
l: Length of part.
ex, D = 5 (0.2) = 5 mm (0.2 in)
(1) (2)
(3) (4)
(5) (6)
(7)
(8)
(1) (2)
(3)
(4)
EAA00040
PREPARATION
To assemble the machine correctly, supplies (e.g. oils, greases, and shop rags)
and sufficient working space are required.
Workshop
The workshop where the machine is assembled, should be clean, specious, and have a
level floor.
Self-protection
Protect your eyes with suitable safety
glasses or goggles when using compressed air, when grinding or when doing
any operation which may cause particles
to fly off.
Protect hands and feet by wearing safety
gloves and shoes.
EAA00050
SYMBOLS USED ON
CRATE CARTON
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(2) Indicates correct upright position of
the transport package.
(3) Transport package must be kept away
from rain.
(4) Insertion of the forklift arm from this
side will cause damage.
(5) Do not step anywhere on the transport
package.
(6) Up to 6 of the transport packages can
be piled up.
(7)
(7)
(7) Yellow label
Lift arm insertion position
If the forklift arms cannot be inserted
under the transport package in alignment with the two yellow labels, adjust
the arms so that they are positioned
evenly in relation to these marks while
taking care not to damage the package
contents.
(5)
(6)
EAA00060
UNPACKING
1. Remove the frame cover (1).
NOTE:
To remove the frame cover, cut the vinyl
bands around the cover using a cutter or
scissors.
2. Remove the carton boxes (2), front tire
(3).
3. Remove the packing frame bolt (4),
and handlebar holder bolts (5).
4. Remove the packing frames (in order
of sideways (6), upward (7), and
front/back (8)).
NOTE:
Hold the frame while removing the frame
bolts.
5. Remove the bolts (9). (front axle fixed
plate (10)).
NOTE:
Before starting the assembly, check for
damaged or missing parts. Check the
parts contained in the carton boxes and
on the machine for damage, scratches
and other defects.
-1-
EAA00070
PARTS LOCATION
1. Front wheel
2. Front fender
3. Carton Box 1
4. Carton Box 2
-2-
Packing frame
1. Front wheel
2. Front fender
EAA00080
Carton Box 1
3. Handlebar
4. Headlight
5. Plastic bag
6. Handlebar upper holder
7. Flange bolt [d=8 (0.31), l=35 (1.38)]
8. Master cylinder bracket
9. Flange bolt [d=6 (0.24), l=22 (0.87)]
10.Panhead screw (light switch) [d=4
(0.16), l=14 (0.55)]
11.Bracket (light switch)
12.Collar (front wheel axle)
13.Trip meter gear unit
14.Flange bolt (headlight) [d=6 (0.24),
l=10 (0.39)]
15.Panhead screw with plain washer
(headlight) [d=6 (0.24), l=12 (0.47)]
Carton Box 2
16.Air scoop (left)
17.Owner’s service manual
18.Plastic bag
19.Brake hose cover
20.Fuel tank breather hose
21.Spark plug wrench
22.Nipple wrench
23.Boot (adjust nut)
24.Handlebar clamp
25.Boot (clutch lever)
26.Hexagon bolt with plain washer (front fender)
[d=6 (0.24), l=20 (0.79)]
27.Collar (front fender) [d=6 (0.24)]
28.Flange bolt (brake hose cover)
[d=6 (0.24), l=12 (0.47)]
29.Plain washer (brake hose cover)
[d=8 (0.31)]
30.Flange bolt (brake hose cover)
[d=8 (0.31), l=20 (0.79)]
31.Brake hose holder
32.Hexagon socket bolt (brake hose holder)
[d=6 (0.24), l=14 (0.55)]
33.Hexagon bolt with plain washer (air scoop)
[d=6 (0.24), l=16 (0.63)]
34.Panhead screw with plain washer (air scoop)
[d=6 (0.24), l=11 (0.43)]
35.Cable clamp (handlebar)
36.Boot [hot starter (choke) lever]
37.Bracket (trip meter cable)
38.Button head bolt (trip meter cable)
[d=5 (0.20), l=8 (0.31)]
39.Steering shaft cap
-3-
EAA00100
SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers.
Always follow the order as shown.
-4-
1 Handlebar 1 C
2 Handlebar upper holder 2 V
3 Flange bolt 4 V d=8 (0.31), l=35 (1.38)
-5-
EAA00200*
1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: First tighten the bolts on the
front side of the handlebar
holder, and then tighten the
bolts on the rear side to specification.
NOTE:
The upper handlebar holder
should be installed with the
punched mark (a) forward.
Bolt:
28 Nm (2.8 mdkg, 20 ftdlb)
EAA00018
2. THROTTLE GRIP
A: Slip the throttle grip over the
right handlebar completely
and then slide it back about 2
mm (0.08 in).
B: Tighten the screws to specifi-
cation.
Screw:
4 Nm (0.4 mdkg, 2.9 ftdlb)
C: Check the throttle grip for
smooth action.
W
D The throttle cables should
not be twisted, and make
sure that the throttle grip
rotates on the handlebar
freely, without binding.
D Proper cable routing is
essential to assure safe
machine operation.
Refer to "CABLE ROUTING".
C: Connect the couplers.
CAUTION:
Proper cable and lead routing
is essential to assure safe
machine operation. Refer to
"CABLE ROUTING".
EAA000205*
3. FRONT WHEEL
A: Clean the brake disc.
B: Clean the front wheel axle.
C: Clean the collars.
NOTE:
Install the collars with its position
(a) facing the wheel.
D:
W
Take care not to get grease on
the brake disc or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign material on the braking surface can
cause impaired braking action.
E: Make sure the two projections
in the wheel hub are meshed
with the two slots in the trip
meter gear unit.
F: Lift the front wheel and install
the front wheel axle.
NOTE:
Do not depress the brake lever
when the caliper is off the brake
disc.
G: Before tightening the front
wheel axle, make sure the
projection (torque stopper) on
the front fork end is placed in
the slot in the trip meter gear
unit as shown.
H: Tighten the front axle bolts
temporarily before tightening
the axle.
1 Throttle grip 1 *
2 Panhead screw 2 * d=5 (0.2), l=20 (0.79)
3 Grip cap cover 1 *
1 Front wheel 1 S
2 Front wheel axle 1 *
3 Collar (front wheel axle) 1 V d=20 (0.79)
4 Trip meter gear unit 1 V
5 Axle nut 1 * d=16 (0.63)
6 Flange bolt 4 * d=8 (0.31), l=40 (1.57)
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