Yamaha WR250XZ(C) Service Manual

SERVICE MANUAL WR250RX(C) 2008 32C-28197-10 WR250XX(C) LIT-11616-21-66

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stampedinto the right side

CHASSIS 3-28 cle before this adjustment.Refer to “REAR SHOCK ABSORBER ASSEM- BLY” on page 4-53.▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring

CHASSIS 3-29▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or“b”.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21650 CHECKIN

CHASSIS 3-30WARNING EWA14080 ● Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from s

CHASSIS 3-31 EAS21670 CHECKING THE WHEELS The following procedure applies to both of thewheels.1. Check: ● WheelDamage/out-of-round → Replace.WARNI

CHASSIS 3-32 EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metalmoving parts of the pedal. EAS21720 LUBRICATING THE SIDEST

ELECTRICAL SYSTEM 3-33 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” onpage 8-59. EAS21770 C

ELECTRICAL SYSTEM 3-34▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲abab

ELECTRICAL SYSTEM 3-35

ELECTRICAL SYSTEM 3-36

123456789 CHASSIS GENERAL CHASSIS ...4-1FRONT WHEEL ...

FEATURES 1-2 EAS20170 FEATURES EAS32D1017 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion cha

FRONT FORK ...4-39 REMOVING THE FRONT FORK LEGS...

GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the cowlingOrder Job/Parts to remove Q’ty Remarks 1 Seat 12 Left side cover 13 Right side cover

FRONT WHEEL 4-2 EAS21870 FRONT WHEEL Removing the front wheel and brake discsOrder Job/Parts to remove Q’ty Remarks Use a suitable stand to raise the

FRONT WHEEL 4-3 Disassembling the front wheelOrder Job/Parts to remove Q’ty Remarks 1 Oil seal 22 Bearing 23 Spacer 1For assembly, reverse the disass

FRONT WHEEL 4-4 EAS21890 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that ther

FRONT WHEEL 4-5 EAS21910 DISASSEMBLING THE FRONT WHEEL 1. Remove: ● Oil seals ● Wheel bearings▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside o

FRONT WHEEL 4-61

REAR WHEEL 4-7 EAS22020 REAR WHEEL Removing the rear wheelOrder Job/Parts to remove Q’ty Remarks Use a suitable stand to raise the front wheel off th

REAR WHEEL 4-8 Disassembling the rear wheelOrder Job/Parts to remove Q’ty Remarks 1 Oil seal (left/right) 1/12 Bearing (left/right) 1/13 Spacer 1For

REAR WHEEL 4-9 EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that there

FEATURES 1-3 EAS32D1018 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator is installed inthe fue

REAR WHEEL 4-10 b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.c. Install the new rear wheel s

FRONT BRAKE 4-11 EAS22210 FRONT BRAKE Removing the front brake padsOrder Job/Parts to remove Q’ty Remarks 1 Pin plug 1 WR250X only2 Front brake calip

FRONT BRAKE 4-12 Removing the front brake master cylinderOrder Job/Parts to remove Q’ty Remarks Brake fluidDrain.Refer to“BLEEDING THE HYDRAULIC BRAKE

FRONT BRAKE 4-13 Disassembling the front brake master cylinderOrder Job/Parts to remove Q’ty Remarks 1 Master cylinder kit 1For assembly, reverse the

FRONT BRAKE 4-14 Removing the front brake calipersOrder Job/Parts to remove Q’ty Remarks Brake fluidDrain.Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM

FRONT BRAKE 4-15 Disassembling the front brake calipersOrder Job/Parts to remove Q’ty Remarks 1 Brake caliper piston 22 Brake caliper dust seal 23 Br

FRONT BRAKE 4-16 EAS22220 INTRODUCTIONWARNING EWA14100 Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive

FRONT BRAKE 4-17 d. Measure the brake disc deflection.e. If out of specification, repeat the adjustmentsteps until the brake disc deflection is withi

FRONT BRAKE 4-18 4. Check: ● Brake fluid levelBelow the minimum level mark “a” → Add therecommended brake fluid to the proper level.Refer to “CHECK

FRONT BRAKE 4-19 ● Brake caliper cylinders “2”Scratches/wear → Replace the brake caliperassembly. ● Brake caliper body “3”Cracks/damage → Replace

FEATURES 1-4 EAS32D1004 MULTI-FUNCTION DISPLAYWARNING EWA32D1008 Be sure to stop the vehicle before makingany setting changes to the multi-function

FRONT BRAKE 4-20 brake performance. ● Refill with the same type of brake fluid thatis already in the system. Mixing brake flu-ids may result in a har

FRONT BRAKE 4-21 EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDERWARNING EWA13520 ● Before installation, all internal brake com-ponents should be

FRONT BRAKE 4-22 brake performance. ● Refill with the same type of brake fluid thatis already in the system. Mixing brake flu-ids may result in a har

REAR BRAKE 4-23 EAS22550 REAR BRAKE Removing the rear brake padsOrder Job/Parts to remove Q’ty Remarks Rear wheel Refer to“REAR WHEEL” on page 4-7.1

REAR BRAKE 4-24 Removing the rear brake master cylinderOrder Job/Parts to remove Q’ty Remarks Brake fluidDrain.Refer to “BLEEDING THE HYDRAULIC BRAKE

REAR BRAKE 4-25 Disassembling the rear brake master cylinderOrder Job/Parts to remove Q’ty Remarks 1 Master cylinder kit 1For assembly, reverse the d

REAR BRAKE 4-26 Removing the rear brake calipersOrder Job/Parts to remove Q’ty Remarks Brake fluidDrain.Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM”

REAR BRAKE 4-27 Disassembling the rear brake calipersOrder Job/Parts to remove Q’ty Remarks 1 Brake caliper piston 12 Brake caliper dust seal 13 Brak

REAR BRAKE 4-28 EAS22560 INTRODUCTIONWARNING EWA14100 Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive

REAR BRAKE 4-29 and a brake pad spring as a set.▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to thebleed screw “2”. P

FEATURES 1-5NOTE: Indicator “” comes on when tripmeter A is se-lected, and indicator “” comes on when tripmeter B is selected.If the fuel level warni

REAR BRAKE 4-30WARNING EWA13550 ● Cover the brake caliper piston with a rag.Be careful not to get injured when the pis-ton is expelled from the brak

REAR BRAKE 4-31 BLE ROUTING” on page 2-30.CAUTION: ECA14170 When installing the brake hose onto thebrake caliper “1”, make sure the brake pipe“a” to

REAR BRAKE 4-32 Obstruction → Blow out with compressed air.2. Check: ● Brake master cylinder kitDamage/wear → Replace.3. Check: ● Master cylinder

REAR BRAKE 4-33 brake performance. ● Refill with the same type of brake fluid thatis already in the system. Mixing brake flu-ids may result in a harm

HANDLEBAR 4-34 EAS22840 HANDLEBAR Removing the handlebarOrder Job/Parts to remove Q’ty Remarks 1 Rear view mirror (left/right) 1/12 Front brake light

HANDLEBAR 4-35 For installation, reverse the removal proce-dure. Removing the handlebarOrder Job/Parts to remove Q’ty Remarks112345678910111213141517

HANDLEBAR 4-36 EAS22860 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that there

HANDLEBAR 4-37▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly coat the handlebar left end with a rub-ber adhesive. ● Install the handlebar grip on the h

HANDLEBAR 4-38 9. Adjust: ● Clutch cable free playRefer to “ADJUSTING THE CLUTCH CA-BLE FREE PLAY” on page 1-14.10.Adjust: ● Throttle cable free play

FRONT FORK 4-39 EAS22950 FRONT FORK Removing the front fork legsOrder Job/Parts to remove Q’ty Remarks Front wheel Refer to“FRONT WHEEL” on page 4-2.

FEATURES 1-6 1. Push the “RESET” button to start the stop-watch.2. Push the “SELECT 1” button and “SELECT2” button together to stop the stopwatch.3.

FRONT FORK 4-40 Disassembling the front fork legsOrder Job/Parts to remove Q’ty Remarks 1 Front fork cap bolt 12 O-ring 13 Rod 14 Spring seat 15 Fork

FRONT FORK 4-41 For assembly, reverse the disassembly pro-cedure. Disassembling the front fork legsOrder Job/Parts to remove Q’ty Remarks123456789101

FRONT FORK 4-42 EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs.1. Stand the vehicle on a level s

FRONT FORK 4-43 6. Remove: ● Inner tube “1”▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally.b. Securely clamp the brake calip

FRONT FORK 4-44WARNING EWA13660 ● Make sure the oil levels in both front forklegs are equal. ● Uneven oil levels can result in poor han- dling and a

FRONT FORK 4-45CAUTION: ECA32D1008 Face stamp "a" of the oil seal toward the front caliper mount during assembling.NOTE: ● Before installi

FRONT FORK 4-46 10.Install: ● Stopper ring “1”(in the slot of outer tube)11.Install: ● Dust seal “1”(Slightly apply grease to the inner tube.)12.Chec

FRONT FORK 4-47 ate the oil, then measure the fork oil level.CAUTION: ECA32D1010 Add the suspension oil to the top level of in-ner tube and deaerate

FRONT FORK 4-48 top face becomes 3 mm, and tighten it tempo- rarily.2. Tighten: ● Lower bracket pinch bolt “1”3. Tighten: ● Cap bolt “2”4. Tighten: ●

STEERING HEAD 4-49 EAS23090 STEERING HEAD Removing the headlight unit, meter assembly and front fenderOrder Job/Parts to remove Q’ty Remarks Fuel tan

FEATURES 1-7 system. Refer to “FUEL INJECTION SYSTEM”on page 8-29.CAUTION: ECA32D1007 If the display indicates an error code, the ve-hicle should be

STEERING HEAD 4-50 Order Job/Parts to remove Q’ty Remarks Headlight unit/Meter assemblies/Front fender Refer to“STEERING HEAD” on page 4-49.1 Bracket

STEERING HEAD 4-51 EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that

STEERING HEAD 4-52 Refer to “CHECKING AND ADJUSTINGTHE STEERING HEAD” on page 1-27.3. Install: ● Upper bracket ● Steering stem nutNOTE: Temporarily t

REAR SHOCK ABSORBER ASSEMBLY 4-53 EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assemblyOrder Job/Parts to remove Q’ty Remar

REAR SHOCK ABSORBER ASSEMBLY 4-54 EAS23180 HANDLING THE REAR SHOCK ABSORBERWARNING EWA13740 This rear shock absorber contains highlycompressed nitro

REAR SHOCK ABSORBER ASSEMBLY 4-55 Damage/wear → Replace.2. Check: ● Bearings ● Oil sealsDamage/pitting → Replace.3. Check: ● CollarDamage/scratch

SWINGARM 4-56 EAS23330 SWINGARM Removing the swingarmOrder Job/Parts to remove Q’ty Remarks Rear wheel Refer to“REAR WHEEL” on page 4-7.1 Bolt (Swing

SWINGARM 4-57 EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that there is

SWINGARM 4-58 3. Install: ● Rear shock absorber assemblyRefer to “REAR SHOCK ABSORBER AS-SEMBLY” on page 4-53.4. Install: ● Swing arm assembly5. Inst

CHAIN DRIVE 4-59 EAS23400 CHAIN DRIVE Removing the drive chainOrder Job/Parts to remove Q’ty Remarks Swingarm Refer to“SWINGARM” on page 4-56.1 Drive

IMPORTANT INFORMATION 1-8 EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove a

CHAIN DRIVE 4-60 EAS23420 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface.WARNING EWA13120 Securely support the vehicle so that the

CHAIN DRIVE 4-61 c. Remove the drive chain from the keroseneand completely dry it.CAUTION: ECA14290 ● This motorcycle has a drive chain withsmall ru

CHAIN DRIVE 4-62NOTE: ● While applying the rear brake, tighten the drivesprocket nut. ● Stake the nut “1”.5. Adjust: ● Drive chain slackRefer to “ADJ

123456789 ENGINE ENGINE REMOVAL ...5-1 INSTALLING THE ENGINE ...

SHIFT SHAFT ...5-43 CHECKING THE SHIFT SHAFT ...

ENGINE REMOVAL 5-1 EAS23710 ENGINE REMOVAL Removing the exhaust pipeOrder Job/Parts to remove Q’ty Remarks Seat side cover (left/right) Refer to“GENE

ENGINE REMOVAL 5-2 Removing the shift pedal, leads and hosesOrder Job/Parts to remove Q’ty Remarks CoolantDrain.Refer to“CHANGING THE COOLANT” on pag

ENGINE REMOVAL 5-3 For installation, reverse the removal proce-dure. Removing the shift pedal, leads and hosesOrder Job/Parts to remove Q’ty Remarks9

ENGINE REMOVAL 5-4 Order Job/Parts to remove Q’ty RemarksNOTE: Use a suitable stand to supported the engine side. Engine oilDrain.Refer to“CHANGING T

ENGINE REMOVAL 5-5 EAS23720 INSTALLING THE ENGINE 1. Install: ● Engine assembly “1” ● Pivot shaft “2” ● Down tube “3” ● Down tube bolt (rear lower si

IMPORTANT INFORMATION 1-9CAUTION: ECA13300 Do not spin the bearing with compressed airbecause this will damage the bearing surfac- es. EAS20240 CIRC

CAMSHAFT 5-6 EAS23730 CAMSHAFT Removing the cylinder head coverOrder Job/Parts to remove Q’ty Remarks Side cover (left/right)Refer to “GENERAL CHASSI

CAMSHAFT 5-7 REMOVING THE CAMSHAFTOrder Job/Parts to remove Q’ty Remarks 1 Timing mark accessing screw 12 Crankshaft end cover 13 Timing chain tensio

CAMSHAFT 5-8 EAS23800 REMOVING THE CAMSHAFT 1. Remove: ● Crankshaft end cover ● Timing mark accessing screw2. Align: ● TDC on the generator rotor(mar

CAMSHAFT 5-9 3. Measure: ● Camshaft runoutOut of specification → Replace.4. Measure: ● Camshaft-journal-to-camshaft-cap clearanceOut of specificati

CAMSHAFT 5-10▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: ● Camshaft journal diameter “a” Out of specification → Replace the camshaft.Within specif

CAMSHAFT 5-11▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS32D1001 CHECKING THE DECOMPRESSION SYSTEM 1. Check: ● Decompression system▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

CAMSHAFT 5-12▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: ● Dowel pin ● Camshaft cap ● Camshaft cap boltsNOTE: ● Lubricate the camshaft cap bolt thre

CAMSHAFT 5-13 d. Unlock the camshaft chain tensioner by turn-ing the crankshaft counterclockwise, and ten-sion the timing chain.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CYLINDER HEAD 5-14 EAS24100 CYLINDER HEAD Removing the cylinder headOrder Job/Parts to remove Q’ty Remarks Camshaft Refer to“CAMSHAFT” on page 5-6.Ho

CYLINDER HEAD 5-15 EAS24130 REMOVING THE CYLINDER HEAD 1. Remove: ● Cylinder head bolts “1” (M6 × 60) ● Cylinder head bolts “2” (M10 × 154) ● Cylinde

CHECKING THE CONNECTIONS 1-10 EAS20250 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnec

CYLINDER HEAD 5-16 2. Install: ● Cylinder headNOTE: Pass the timing chain through the timing chain cavity.3. Tighten: ● Cylinder head bolts (M10 × 14

VALVES AND VALVE SPRINGS 5-17 EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springsOrder Job/Parts to remove Q’ty Remarks Cylinder

VALVES AND VALVE SPRINGS 5-18 EAS24280 REMOVING THE VALVES The following procedure applies to all of thevalves and related components.NOTE: Before re

VALVES AND VALVE SPRINGS 5-19 EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of thevalves and valve guides.1. M

VALVES AND VALVE SPRINGS 5-20NOTE: After replacing the valve guide, reface the valve seat.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: ● Carbon dep

VALVES AND VALVE SPRINGS 5-21▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b”onto the valve face.b. Install the valve int

VALVES AND VALVE SPRINGS 5-22 h. Install the valve into the cylinder head.i. Press the valve through the valve guide andonto the valve seat to make a

VALVES AND VALVE SPRINGS 5-23 EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of thevalve lifters.1. Check: ● Valve lifter

VALVES AND VALVE SPRINGS 5-24 5. To fasten the valve cotters “1” onto the valvestem, lightly tap the valve tip with a soft-facehammer.CAUTION: ECA13

CYLINDER AND PISTON 5-25 EAS24350 CYLINDER AND PISTON Removing the cylinder and pistonOrder Job/Parts to remove Q’ty Remarks Cylinder head Refer to“C

SPECIAL TOOLS 1-11 EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appro

CYLINDER AND PISTON 5-26 EAS24380 REMOVING THE PISTON 1. Remove: ● Piston pin clips “1” ● Piston pin “2” ● Piston “3”CAUTION: ECA13810 Do not use a

CYLINDER AND PISTON 5-27 d. If out of specification, replace the cylinder,piston and piston rings as a set.e. Calculate the piston-to-cylinder cleara

CYLINDER AND PISTON 5-28 3. Measure: ● Piston pin bore diameter “b”Out of specification → Replace the piston.4. Calculate: ● Piston-pin-to-piston-p

CYLINDER AND PISTON 5-29 4. Lubricate: ● Piston ● Piston rings ● Cylinder(with the recommended lubricant)5. Offset: ● Piston ring end gaps6. Install:

STARTER MOTOR 5-30 EAS24780 STARTER MOTOR Removing the starter motorOrder Job/Parts to remove Q’ty Remarks Seat/Air scoop (left/ritht)Refer to “GENER

STARTER MOTOR 5-31 Disassembling the starter motorOrder Job/Parts to remove Q’ty Remarks 1 Starter motor front cover 12 Lock washer 13 Armature assem

STARTER MOTOR 5-32 EAS24790 CHECKING THE STARTER MOTOR 1. Check: ● CommutatorDirt → Clean with 600 grit sandpaper.2. Measure: ● Commutator diameter

STARTER MOTOR 5-33 7. Check: ● Gear teethDamage/wear → Replace the gear.8. Check: ● Bearing ● Oil sealDamage/wear → Replace the defective part(s)

CLUTCH 5-34 EAS25061 CLUTCH Removing the clutch coverOrder Job/Parts to remove Q’ty Remarks Drain the engine oilRefer to “CHANGING THE ENGINE OIL” on

CLUTCH 5-35 For installation, reverse the removal proce-dure. Removing the clutch coverOrder Job/Parts to remove Q’ty Remarks123456789101112131414T R

SPECIAL TOOLS 1-12 Spacer (crankshaft installer)90890-04081Pot spacerYM-910445-63Radiator cap tester90890-01325Radiator pressure testerYU-24460-016-2

CLUTCH 5-36 Removing the clutchOrder Job/Parts to remove Q’ty Remarks 1 Clutch spring 52 Pressure plate 13 Push rod 14 Locknut 15 Friction plate 76 C

CLUTCH 5-37 Removing the push lever shaftOrder Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-1.Clutch Ref

CLUTCH 5-38 EAS25070 REMOVING THE CLUTCH You need not drain the coolant and engine oil ifyou do not service the primary drive gear.You can reach the

CLUTCH 5-39 EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of theclutch springs.1. Check: ● Clutch springDamage → Repl

CLUTCH 5-40 EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1. Check: ● Primary drive gearDamage/wear → Replace the primary driveand primary driven gears

CLUTCH 5-41 7. Install: ● Friction plates ● Clutch platesNOTE: First, install a friction plate and then alternate be- tween a clutch plate and a fric

CLUTCH 5-42 14.Install: ● Oil cleaner elementRefer to “CHANGING THE ENGINE OIL” onpage 3-11.15.Install: ● Water pump housing coverRefer to “WATER PUM

SHIFT SHAFT 5-43 EAS25410 SHIFT SHAFT Removing the shift shaft and stopper leverOrder Job/Parts to remove Q’ty Remarks Shift pedal Refer to “ENGINE R

SHIFT SHAFT 5-44 EAS25420 CHECKING THE SHIFT SHAFT 1. Check: ● Shift shaft ● Shift leverBends/damage/wear → Replace. ● Shift lever springDamage/wea

OIL PUMP AND BALANCER GEAR 5-45 EAS24911 OIL PUMP AND BALANCER GEAR Removing the oil pumpOrder Job/Parts to remove Q’ty Remarks Clutch/Primary drive

SPECIAL TOOLS 1-13 Damper rod holder90890-014544-42, 4-44Spoke nipple wrench (8 – 9)90890-01522YM-015223-31Sheave holder90890-01701Primary clutch hol

OIL PUMP AND BALANCER GEAR 5-46 Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks 1 Pump cover 12 Outer rotor 13 Inner rotor 14 Dowel

OIL PUMP AND BALANCER GEAR 5-47 EAS24940 REMOVING THE OIL PUMP 1. Drain: ● Engine oil(completely from the crankcase)Refer to “CHANGING THE ENGINE OIL

OIL PUMP AND BALANCER GEAR 5-48 2. Install: ● Oil pump housing “1” ● Relief valve assembly ● Driven gear “2” ● Dowel pin “3” ● Outer rotor “4” ● Inne

OIL PUMP AND BALANCER GEAR 5-49 6. Install:Be sure to bend the lock washer tab along tothe nut side face.123a

GENERATOR AND STARTER CLUTCH 5-50 EAS24480 GENERATOR AND STARTER CLUTCH Removing the generatorOrder Job/Parts to remove Q ’ ty Remarks Drain the engi

GENERATOR AND STARTER CLUTCH 5-51 14 Bearing 115 Starter clutch side plate 116 Starter clutch assembly 1For installation, reverse the removal proce-d

GENERATOR AND STARTER CLUTCH 5-52 Disassembling the damper assemblyOrder Job/Parts to remove Q ’ ty Remarks 1 Circlip 12 Limiter disc 13 Starter redu

GENERATOR AND STARTER CLUTCH 5-53 EAS24490 REMOVING THE GENERATOR 1. Remove: ● Generator rotor nut “1” ● WasherNOTE: ● While holding the generator ro

GENERATOR AND STARTER CLUTCH 5-54▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24600 INSTALLING THE STARTER CLUTCH 1. Install: ● Starter clutch assembly “1”Pus

GENERATOR AND STARTER CLUTCH 5-5512

SPECIAL TOOLS 1-14 Digital circuit tester90890-03174Model 88 Multimeter with tachometerYU-A19277-7, 8-80, 8-81Fuel pressure adapter90890-03176YM-0317

CRANKCASE 5-56 EAS25540 CRANKCASE Separating the crankcaseOrder Job/Parts to remove Q’ty Remarks Engine Refer to“ENGINE REMOVAL” on page 5-1.Cylinder

CRANKCASE 5-57 8 Crankcase Right 19 Dowel pin 210 Oil strainer 111 Nozzle 112 Left crankcase 1For installation, reverse the removal proce-dure. Separ

CRANKCASE 5-58 Removing the bearing and oil sealOrder Job/Parts to remove Q’ty Remarks Crankshaft assemblyRefer to“CRANKSHAFT ASSEMBLY AND BALANCER S

CRANKCASE 5-59 EAS25570 DISASSEMBLING THE CRANKCASE 1. Remove: ● Crankcase boltsNOTE: Loosen each bolt 1/4 of a turn at a time, in stag-es and in a c

CRANKCASE 5-60 2. Thoroughly clean all the gasket mating sur-faces and crankcase mating surfaces.3. Apply: ● Sealant(onto the crankcase mating surfac

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5-61 EAS25970 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaftOrder

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5-62 EAS26000 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: ● Crankshaft assembly “1”NOTE: ● Remove the cranksha

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5-63 “2”, adapter (M12) “3” and spacer “4”.CAUTION: ECA13970 To avoid scratching the crankshaft and toease th

TRANSMISSION 5-64 EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forksOrder Job/Parts to remove Q’ty Remarks Crankca

TRANSMISSION 5-65 Disassembling the transmissionOrder Job/Parts to remove Q’ty Remarks 1 2nd pinion gear 12 6th pinion gear 13 3rd pinion gear 14 Cir

SPECIAL TOOLS 1-15 Valve guide remover ( ø 4.5)90890-04116Valve guide remover (4.5 mm)YM-041165-20Valve guide installer (4.5 ø )90890-04117YM-041175-

TRANSMISSION 5-66 22 Drive axle 1For installation, reverse the removal proce-dure. Disassembling the transmissionOrder Job/Parts to remove Q’ty Remar

TRANSMISSION 5-67 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shiftforks.1. Check: ● Shift fork pawl “2”Bends/dam

TRANSMISSION 5-68 2. Measure: ● Drive axle runout(with a centering device and dial gauge “1”)Out of specification → Replace the drive axle.3. Check

TRANSMISSION 5-69 EAS26340 INSTALLING THE TRANSMISSION 1. Install: ● Transmission2. Check: ● TransmissionRough movement → Repair.NOTE: Oil each gea

TRANSMISSION 5-70

123456789 COOLING SYSTEM RADIATOR...6-1 CHECKING TH

RADIATOR 6-1 EAS26380 RADIATOR Removing the radiatorOrder Job/Parts to remove Q’ty Remarks Seat/Air scoop (left/right) Refer to“GENERAL CHASSIS” on p

RADIATOR 6-2 EAS26390 CHECKING THE RADIATOR 1. Check: ● Radiator fins “1”Obstruction → Clean.Apply compressed air to the rear of the radi-ator.Dama

RADIATOR 6-3 b. Apply the 100 kPa (14.22 psi) (1.0 kg/cm 2 )pressure.c. Measure the indicated pressure with thegauge.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

THERMOSTAT 6-4 EAS26440 THERMOSTAT Removing the thermostatOrder Job/Parts to remove Q’ty Remarks Seat/Air panel (left/right) Refer to“GENERAL CHASSIS

123456789 SPECIFICATIONS GENERAL SPECIFICATIONS ...2-1ENGINE SPECIFICATIONS...

THERMOSTAT 6-5 EAS26450 CHECKING THE THERMOSTAT 1. Check: ● Thermostat “1”Does not open at 70.5 – 73.5 ° C(158.9 – 164.3 ° F) → Replace.▼▼▼▼▼▼▼▼▼▼▼

WATER PUMP 6-6 EAS26500 WATER PUMP Removing the water pumpOrder Job/Parts to remove Q’ty Remarks Drains the coolant.Refer to“CHANGING THE COOLANT” on

WATER PUMP 6-7 EAS26530 CHECKING THE WATER PUMP 1. Check: ● Water pump housing cover ● Impeller shaft ● PlateCracks/damage/wear → Replace.2. Check:

WATER PUMP 6-8 ● CrankcaseRefer to “CHANGING THE ENGINE OIL” onpage 3-11.9. Fill: ● Cooling systemRefer to “CHANGING THE COOLANT” onpage 3-18.

WATER PUMP 6-9

123456789 FUEL SYSTEM FUEL TANK ...7-1 REMOVING THE F

FUEL TANK 7-1 EAS26620 FUEL TANK Removing the fuel tankOrder Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 4-1.Side cover (

FUEL TANK 7-2 EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through thefuel tank cap with a pump.2. Remove: ● Fuel hose couple

FUEL TANK 7-31

THROTTLE BODIES 7-4 EAS26970 THROTTLE BODIES Removing the throttle bodiesOrder Job/Parts to remove Q’ty Remarks SeatRefer to “GENERAL CHASSIS” on pag

GENERAL SPECIFICATIONS 2-1 EAS20280 GENERAL SPECIFICATIONS Model Model WR250R 32C1 (U49)WR250R 32C3 (CAL)WR250X 32C2 (U49)WR250X 32C4 (CAL) Dimension

THROTTLE BODIES 7-5 Disassembling the throttle bodyOrder Job/Parts to remove Q’ty Remarks 1 Delivery pipe 12 Injector 13 Gasket 14 Throttle position

THROTTLE BODIES 7-6 EAS26980 CHECKING THE INJECTORSWARNING EWA32D1009 Replace the fuel injector with a new one if you have dropped or impacted it. 1

THROTTLE BODIES 7-7 EAS27030 ADJUSTING THE THROTTLE POSITION SENSORWARNING EWA32D1011 Replace the throttle position sensor with a new one if you hav

THROTTLE BODIES 7-8

AIR INDUCTION SYSTEM 7-9 EAS27040 AIR INDUCTION SYSTEM2134

AIR INDUCTION SYSTEM 7-10 1. Air filter case2. Air induction system hose3. Air cut-off valve4. Air induction system pipe

AIR INDUCTION SYSTEM 7-11 Removing the air cut-off valve assembly Order Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 4-1.S

AIR INDUCTION SYSTEM 7-12 EAS27060 CHECKING THE AIR INDUCTION SYSTEMAir induction The air induction system burns unburned ex-haust gases by injecting

AIR INDUCTION SYSTEM 7-13 EAS32D12011 CANISTER (FOR CALIFORNIA) Removing the canister Order Job/Parts to remove Q’ty Remarks 1 Canister cover 12 Cani

123456789 ELECTRICAL SYSTEM IGNITION SYSTEM ...8-1 CIRCUIT DIAGR

ENGINE SPECIFICATIONS 2-2 EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHCDisplacement 250.0 cm 3 Cylinder arrangement

CHECKING THE CRANKSHAFT POSITION SENSOR ...8-75CHECKING THE LEAN ANGLE SENSOR ...8-

IGNITION SYSTEM 8-1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM

IGNITION SYSTEM 8-2 1. AC magneto3. Main switch4. Battery5. Main fuse8. Right handlebar switch9. Engine stop switch11. Relay unit12. Sidestand swit

IGNITION SYSTEM 8-3 EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark).NOTE: Before troubleshooting, remo

IGNITION SYSTEM 8-4 10.Check the sidestand switch.Refer to “CHECKING THE SWITCHES” on page 8-63 .NG → Replace the sidestand switch.OK ↓ 11.Check the

ELECTRIC STARTING SYSTEM 8-5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM 8-6 3. Main switch4. Battery5. Main fuse6. Starter relay7. Starter motor8. Right handlebar switch9. Engine stop switch10.

ELECTRIC STARTING SYSTEM 8-7 EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to

ELECTRIC STARTING SYSTEM 8-8 a. WHEN THE TRANSMISSION IS IN NEU-TRALb. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR1. B

ENGINE SPECIFICATIONS 2-3 Spark plug (s) Manufacturer/model NGK/CR9EKSpark plug gap 0.6 – 0.7 mm (0.024 – 0.028 in) Cylinder head Volume 15.36 cm 3

ELECTRIC STARTING SYSTEM 8-9 EAS27190 TROUBLESHOOTING The starter motor fails to turn.NOTE: Before troubleshooting, remove the following part (s):1.

ELECTRIC STARTING SYSTEM 8-10 OK ↓ 11.Check the clutch switch.Refer to “CHECKING THE SWITCHES” on page 8-63 .NG → Replace the clutch switch.OK ↓ 12.

CHARGING SYSTEM 8-11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM

CHARGING SYSTEM 8-12 1. AC magneto2. Rectifier/regulator4. Battery5. Main fuse

CHARGING SYSTEM 8-13 EAS27220 TROUBLESHOOTING The battery is not being charged.NOTE: Before troubleshooting, remove the following part (s):1. Seat2.

CHARGING SYSTEM 8-14

LIGHTING SYSTEM 8-15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM

LIGHTING SYSTEM 8-16 3. Main switch4. Battery5. Main fuse16. ECU34. High beam indicator39. Front right turn signal/position light40. Front left turn

LIGHTING SYSTEM 8-17 EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or m

LIGHTING SYSTEM 8-18

ENGINE SPECIFICATIONS 2-4 Valve face width B (intake) 1.840 mm (0.0724 in)Valve face width B (exhaust) 2.260 mm (0.0890 in)Valve seat width C (intake

SIGNALING SYSTEM 8-19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM

SIGNALING SYSTEM 8-20 3. Main switch4. Battery5. Main fuse11. Relay unit13. Neutral switch15. Fuel pump16. ECU23. Coolant temperature sensor24. Speed

SIGNALING SYSTEM 8-21 EAS27290 TROUBLESHOOTING ● Any of the following fail to light: turn signal light, brake light, turn signal indicator light and

SIGNALING SYSTEM 8-22 The brake light fails to come on.The turn signal light, turn signal indicator light or both fail to blink.The neutral indicator

SIGNALING SYSTEM 8-23 The speedometer fails to operate.The fuel level warning light fails to come.The coolant temperature warning light fails to oper

SIGNALING SYSTEM 8-24

COOLING SYSTEM 8-25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM

COOLING SYSTEM 8-26 3. Main switch4. Battery5. Main fuse16. ECU23. Coolant temperature sensor52. Radiator fan motor relay53. Radiator fan motor56. Ig

COOLING SYSTEM 8-27 EAS27320 TROUBLESHOOTING ● The radiator fan fails to operate.NOTE: Before troubleshooting, remove the following part (s):1. Seat2

COOLING SYSTEM 8-28

EAS20050 WR250RX(C)/WR250XX(C)SERVICE MANUAL©2008 by Yamaha Motor Corporation, U.S.A.First edition, December 2007All rights reserved.Any reproduction

ENGINE SPECIFICATIONS 2-5 Spring rate K2 (intake) 40.90 N/mm (233.54 lb/in) (4.17 kgf/mm)Spring rate K1 (exhaust) 31.47 N/mm (179.69 lb/in) (3.21 kgf

FUEL INJECTION SYSTEM 8-29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM

FUEL INJECTION SYSTEM 8-30 1. AC magneto3. Main switch4. Battery5. Main fuse6. Starter relay8. Right handlebar switch9. Engine stop switch10. Start

FUEL INJECTION SYSTEM 8-31 EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel

FUEL INJECTION SYSTEM 8-32 EAS27393 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sen

FUEL INJECTION SYSTEM 8-33 Communication error with the multifunction meter * If multiple malfunctions have been detected for the ECU, you may not be

FUEL INJECTION SYSTEM 8-34 EAS27400 TROUBLESHOOTING METHODThe engine operation is not normal and theengine trouble warning light comes on. 1. Check:

FUEL INJECTION SYSTEM 8-35 bers.8. Verify the operation of the sensor or actuator. ● Sensor operationThe data representing the operating condi-tions

FUEL INJECTION SYSTEM 8-36 Diagnostic code table Fault code No.Symptom Probable cause of malfunctionDiagnostic code No. 12No normal signals are recei

FUEL INJECTION SYSTEM 8-37 Sensor operation table 42No normal signals are received from the speed sen-sor. ● Open or short circuit in wiring harness.

FUEL INJECTION SYSTEM 8-38 03 Pressure difference(atmospheric pressure-intake air pressure)Displays the intake air pressure.Set “” the engine stop sw

ENGINE SPECIFICATIONS 2-6 Piston ring Top ringRing type BarrelDimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in)End gap (installed) 0.15 – 0.25

FUEL INJECTION SYSTEM 8-39 *1 If it is not possible to check the intake temperature, use the ambient temperature as reference (usethe compared values

FUEL INJECTION SYSTEM 8-40 49 Intake solenoidActuates the intake solenoid for five times every second.Illuminates the engine trouble warning light.Che

FUEL INJECTION SYSTEM 8-41 EAS27480 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry o

FUEL INJECTION SYSTEM 8-42 Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected.Diagnostic monitoring code No.03 Intak

FUEL INJECTION SYSTEM 8-43 Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected.Diagnostic monitoring code No.01 Throttl

FUEL INJECTION SYSTEM 8-44 Fault code No. 16 Symptom Stuck throttle position sensor detected.Diagnostic monitoring code No.01 Throttle position senso

FUEL INJECTION SYSTEM 8-45 Fault code No. 18 Symptom EXUP servo motor is stuck.Diagnostic monitoring code No.53 EXUP servo motorOrderItem/components

FUEL INJECTION SYSTEM 8-46 Fault code No. 21 Symptom Coolant temperature sensor-open or short circuit detected.Diagnostic monitoring code No.06 Coola

FUEL INJECTION SYSTEM 8-47 Fault code No. 22 Symptom Intake air temperature sensor-open or short circuit detected.Diagnostic monitoring code No.05 In

FUEL INJECTION SYSTEM 8-48 Fault code No. 33 Symptom Malfunction detected in the primary wire of the ignition coil.Diagnostic monitoring code No.30 I

ENGINE SPECIFICATIONS 2-7 Friction plate thickness 2.90 – 3.10 mm (0.114 – 0.122 in)Wear limit 2.80 mm (0.1102 in)Plate quantity 7 pcsClutch plate th

FUEL INJECTION SYSTEM 8-49 Fault code No. 42 SymptomA. No normal signals are received from the speed sensor.B. Open or short circuit is detected in t

FUEL INJECTION SYSTEM 8-50 Fault code No. 42 SymptomA. No normal signals are received from the speed sensor.B. Open or short circuit is detected in t

FUEL INJECTION SYSTEM 8-51 Fault code No. 43 Symptom Supply power to the fuel injector and fuel pump is not normal.Diagnostic monitoring code No.09 F

FUEL INJECTION SYSTEM 8-52 Fault code No. 46 Symptom Power supply to the FI system relay is not normal.Diagnostic monitoring code No.——OrderItem/comp

FUEL INJECTION SYSTEM 8-53 Fault code No. Er-1 Symptom No signals are received from the ECU.Diagnostic monitoring code No.——OrderItem/components and

FUEL INJECTION SYSTEM 8-54 Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.Diagnostic monitoring code No.——OrderItem/compo

FUEL PUMP SYSTEM 8-55 EAS27580 FUEL PUMP SYSTEM EAS27590 CIRCUIT DIAGRAM

FUEL PUMP SYSTEM 8-56 3. Main switch4. Battery5. Main fuse8. Right handlebar switch9. Engine stop switch11. Relay unit15. Fuel pump16. ECU56. Ignit

FUEL PUMP SYSTEM 8-57 EAS27600 TROUBLE SHOOTING The fuel pump fails to operate.NOTE: Before troubleshooting, remove the following part(s):1. Seat2. S

FUEL PUMP SYSTEM 8-58

ENGINE SPECIFICATIONS 2-8 Oil temperature 60.0 ° C (140.00 ° F)Throttle cable free play 3.0 – 5.0 mm (0.12 – 0.20 in)

ELECTRICAL COMPONENTS 8-59 EAS27971 ELECTRICAL COMPONENTS EAS32D101123475810121116913

ELECTRICAL COMPONENTS 8-60 1. Main switch2. Battery3. Main fuse4. Starter relay5. ECU6. Lean angle sensor7. Intake solenoid8. Throttle position sen

ELECTRICAL COMPONENTS 8-62 1. Horn2. Fuse box3. Starter motor4. Radiator fan motor relay5. Turn signal relay6. Relay assembly7. Headlight relay8.

ELECTRICAL COMPONENTS 8-63 EAS27980 CHECKING THE SWITCHES7981110423561

ELECTRICAL COMPONENTS 8-64 1. Horn switch2. Dimmer switch3. Turn signal switch4. Clutch switch5. Neutral switch6. Sidestand switch7. Main switch8.

ELECTRICAL COMPONENTS 8-65 Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check thewiring connectio

ELECTRICAL COMPONENTS 8-66 EAS27990 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage orwear, proper connections, and al

ELECTRICAL COMPONENTS 8-67 Checking the condition of the bulb sockets The following procedure applies to all of the bulbsockets.1. Check: ● Bulb sock

ELECTRICAL COMPONENTS 8-68WARNING EWA13310 Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the

CHASSIS SPECIFICATIONS 2-9 EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradleCaster angle WR250R 26.67 ° WR250X 25.33 ° Trail WR

ELECTRICAL COMPONENTS 8-69 3. Remove: ● Battery4. Check: ● Battery charge▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to the battery t

ELECTRICAL COMPONENTS 8-70 tery cool before reconnecting it. Hotbatteries can explode! ● As shown in the following illustration, theopen-circuit volt

ELECTRICAL COMPONENTS 8-71 6. Check: ● Battery terminalsDirt → Clean with a wire brush.Loose connection → Connect properly.7. Install: ● Battery8

ELECTRICAL COMPONENTS 8-72 Headlight relayChecking the turn signal relay▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check: ● Turn signal relay input voltageO

ELECTRICAL COMPONENTS 8-73 Radiator fan motor relay EAS28050 CHECKING THE DIODE 1. Check: ● DiodeOut of specification → Replace.NOTE: The pocket te

ELECTRICAL COMPONENTS 8-74 c. Check the diode for continuity.d. Check the diode for no continuity.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28930 CHECKING

ELECTRICAL COMPONENTS 8-75▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the igni-tion coil.b. Connect the pocket tester ( Ω

ELECTRICAL COMPONENTS 8-76 c. Incline the lean angle sensor.d. Measure the lean angle sensor out put volt-age.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS281

ELECTRICAL COMPONENTS 8-77 c. Start the engine and let it run at approximate-ly 5000 r/min.d. Measure the charging voltage.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ELECTRICAL COMPONENTS 8-78 b. Set the main switch to “ON”.c. Elevate the rear wheel and slowly turn it.d. Measure the voltage (DC 5 V) of white andbl

CHASSIS SPECIFICATIONS 2-10 Front brake Type Single disc brakeOperation Right hand operationFront brake lever free play 5.0 – 8.0 mm (0.20 – 0.31 in)

ELECTRICAL COMPONENTS 8-79 b. Immerse the coolant temperature sensor in acontainer filled with coolant.NOTE: Make sure the coolant temperature sensor

ELECTRICAL COMPONENTS 8-80 sor shaft, check that the throttle position sen-sor voltage is within the specified range.The voltage does not change or i

ELECTRICAL COMPONENTS 8-81 sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: ● Intake air temperature s

123456789 TROUBLESHOOTING TROUBLESHOOTING ...9-1 GENERAL INFORMATION

TROUBLESHOOTING 9-1 EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATIONNOTE: The following guide for troubleshooting does notcover all the possible

TROUBLESHOOTING 9-2 ● Faulty spark plug cap3. Ignition coil (s) ● Faulty ignition coil ● Cracked or broken ignition coil4. Ignition system ● ECU fail

TROUBLESHOOTING 9-3 ● Clogged air filter element Chassis 1. Brake (s) ● Dragging brake Electrical system 1. Spark plug (s) ● Incorrect spark plug gap

TROUBLESHOOTING 9-4 ● Faulty main switch ● Headlight bulb life expired Tail/brake light does not come on ● Too many electrical accessories ● Incorrec

TROUBLESHOOTING 9-5

EAS28740 WIRING DIAGRAMWR250R(X)/WR250X(X) 2008 WIRING DIAGRAM 1.AC magneto2.Rectifier/regulator3.Main switch4.Battery5.Main fuse6.Starter relay7.Sta

CHASSIS SPECIFICATIONS 2-11 Recommended oil Suspension oil 01Quantity 613.0 cm 3 (20.73 US oz) (21.62 Imp.oz)Level 105.0 mm (4.13 in)Rebound damping

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

WR250RX/WR250XX 2008WIRING DIAGRAMWR250RX/WR250XX 2008SCHÉMA DE CÂBLAGEWR250RX/WR250XX 2008 SCHALTPLANSCHEMA ELETTRICOWR250RX/WR250XX 2008 DIAGRAMA EL

WR250RX/WR250XX 2008WIRING DIAGRAMWR250RX/WR250XX 2008SCHÉMA DE CÂBLAGEWR250RX/WR250XX 2008 SCHALTPLANSCHEMA ELETTRICOWR250RX/WR250XX 2008 DIAGRAMA EL

ELECTRICAL SPECIFICATIONS 2-12 EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital)Advancer t

ELECTRICAL SPECIFICATIONS 2-13 Starter motor Model/manufacturer SM-14/MITSUBAPower output 0.50 kWArmature coil resistance 0.0040 – 0.0050 Ω Brush ov

ELECTRICAL SPECIFICATIONS 2-14 Spare fuse 15.0 ASpare fuse 10.0 ASpare fuse 7.5 A

NOTICE 1-1 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanic

TIGHTENING TORQUES 2-15 EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for sta

TIGHTENING TORQUES 2-16 Timing chain guide bolt M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)Plate (impeller shaft side) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)Oil filter

TIGHTENING TORQUES 2-17 EAS20350 CHASSIS TIGHTENING TORQUES Drive sprocket nut M18 1 95 Nm (9.5 m•kg, 69 ft•lb)Stake the nutStopper screw (stopper le

TIGHTENING TORQUES 2-18 Taillight cover bolt M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)Helmet hanger screw M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)Front fender bolt M6

TIGHTENING TORQUES 2-19 Front fork base valve M22 2 55 Nm (5.5 m•kg, 40 ft•lb)Front fork axle nut M16 1 63 Nm (6.3 m•kg, 46 ft•lb)Front wheel axle pi

TIGHTENING TORQUES 2-20NOTE: ● Tighten the lower ring nut with the 38 Nm (3.8 m•kg, 27 ft•lb) torque. ● Turn the front fork to the left and right. Th

LUBRICATION POINTS AND LUBRICANT TYPES 2-21 EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication points Lubrication types Oil

LUBRICATION POINTS AND LUBRICANT TYPES 2-22 EAS20380 CHASSIS Push rod 1 surface, endBall (push rod)Primary driven gear assembly, inner surfacePush le

LUBRICATION POINTS AND LUBRICANT TYPES 2-23 Brake lever boltBrake lever and front brake master cylinderAdjusting screw (brake lever)Rear brake master

LUBRICATION POINTS AND LUBRICANT TYPES 2-24

HOW TO USE THIS MANUAL 1-2 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehe

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-26 1. Camshaft2. Timing chain tensioner3. Piston cooler4. Oil filter5. Main axle6. Delivery pipe7. Drive axle

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-28 1. Oil pump assembly2. Relief valve3. Main axle4. Delivery pipe5. Drive axle6. Crankshaft7. Oil filter8.

COOLING SYSTEM DIAGRAMS 2-29 EAS20420 COOLING SYSTEM DIAGRAMS851234679

COOLING SYSTEM DIAGRAMS 2-30 1. Radiator cap2. Radiator3. Radiator inlet hose4. Radiator outlet hose5. Recovery tank hose6. Cap7. Side cover stay

CABLE ROUTING 2-31 EAS20430 CABLE ROUTING

CABLE ROUTING 2-32 1. Starter motor lead2. Coolant temperature sensor lead3. Speed sensor lead4. Negative battery lead5. Starter relay6. Starter

CABLE ROUTING 2-33

CABLE ROUTING 2-34 1. Clamp2. Throttle position sensor lead3. Fan motor leadA. Fasten the breather hose using a clamp.B. Fasten the throttle posi

SYMBOLS 1-3 EAS20100 SYMBOLS The following symbols are used in this manualfor easier understanding.NOTE: The following symbols are not relevant to ev

CABLE ROUTING 2-35

CABLE ROUTING 2-36 1. Ignition coil lead2. Fuel pump lead3. Injector lead4. Throttle position sensor lead5. Rear brake switch lead6. Right rear

CABLE ROUTING 2-37

CABLE ROUTING 2-38 1. Throttle cable (accelerator)2. Throttle cable (decelerator)3. Right handlebar switch lead4. Clutch switch lead5. Left hand

Front rear brake hose 2-39 Front rear brake hose

Front rear brake hose 2-40 1. Front brake hose2. Hose guide3. Union bolt4. Copper washer5. Front brake caliper assembly6. Rear brake disc7. Rear

Throttle body 2-41 Throttle body

Throttle body 2-42 1. Breather hose2. Air filter case assembly3. Pipe4. Throttle body assembly5. Radiator inlet hose6. Radiator7. Throttle body joi

Canister (for California) 2-43 Canister (for California)5mm (0.20 in)45˚

Canister (for California) 2-44 1. Fuel tank2. Hose (Fuel tank – roll over valve)3. Canister cover4. Canister5. A.C. magneto lead6. Neutral switch

GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS ANDADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUB

Canister (for California) 2-45

123456789 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE...3-1 INTRODUC

ELECTRICAL SYSTEM ...3-33 CHECKING AND CHARGING THE BATTERY...

PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended c

General maintenance and lubrication chart 3-2 EAS32164 General maintenance and lubrication chart No. ITEM ROUTINEINITIAL ODOMETER READINGS600 mi (100

3-3 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE: From 19000 mi (31000 km) or

ENGINE 3-4 EAS20471 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of thevalves.NOTE: ● Valve clearance adjustm

ENGINE 3-5 ● Before removing the cam chain and camshaft,connect the cam chain using a wire so that it does not drop in the crankcase.b. Remove the va

ENGINE 3-6NOTE: ● Refer to “CAMSHAFT” on page 5-6. ● Lubricate the camshaft bearings, camshaftlobes and camshaft journals. ● First, install the exhau

ENGINE 3-7 2. Remove: ● Seat ● Side cover (left/right) ● Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 4-1. ● Fuel tankRefer to “FUEL TANK

ENGINE 3-8 ● SeatRefer to “GENERAL CHASSIS” on page 4-1. EAS20690 CHECKING THE SPARK PLUG 1. Remove: ● Seat ● Side cover (left/right) ● Air scoop (le

ENGINE 3-9 (Red/black ignition coil leads)3. Check: ● Ignition timing▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several min

ENGINE 3-10 7. Measure: ● Compression pressureOut of specification → Refer to steps (c) and(d).▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main swi

ENGINE 3-11CAUTION: ECA13360 ● Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do n

ENGINE 3-12 ter element cover.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: ● Engine oil drain bolt gasket ● Oil filter element drain bolt gasketDamage

ENGINE 3-13 obtained.c. Tighten the locknut “1”.NOTE: If the specified clutch cable free play cannot beobtained on the handlebar side of the cable, u

ENGINE 3-14 9. Install: ● Air filter element frameCAUTION: ECA14401 Never operate the engine without the air filterelement installed. Unfiltered air

ENGINE 3-15 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSE 1. Remove: ● Seat ● Side cover (left/right) ● Air scoop (left/right)Refer to “GENERAL C

ENGINE 3-16 3. Check: ● EXUP system operationNOTE: Check operation by self-diagnostics diagnosismode No.“53”.Refer to “FUEL INJECTION SYSTEM” on page

ENGINE 3-17 d. Insert the tailpipe into the muffler and alignthe bolt holes.e. Insert the bolt and tighten it.▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS210

123456789 GENERAL INFORMATION IDENTIFICATION ...1-1 VEHICLE I

ENGINE 3-18 ● Radiator inlet hose “2” ● Radiator outlet hose “3”Cracks/damage → Replace.Refer to “RADIATOR” on page 6-1, “THER-MOSTAT” on page 6-4

ENGINE 3-19 10.Fill: ● Cooling system(with the specified amount of the recom-mended coolant)Handling notes for coolantCoolant is potentially harmful

CHASSIS 3-20 EAS21140 CHASSIS EAS21170 ADJUSTING THE FRONT DISC BRAKE 1. Check: ● Brake lever free play “a”Out of specification → Adjust.2. Adjust:

CHASSIS 3-21WARNING EWA13050 A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is o

CHASSIS 3-22 EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of thebrake pads.1. Operate the brake.2. Check: ● Rear brak

CHASSIS 3-23▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEMWARNING EWA13100 Bleed the hydraulic brake system whenever:

CHASSIS 3-24▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21420 ADJUSTING THE DRIVE CHAIN SLACKNOTE: The drive chain slack must be checked at the tightest poin

CHASSIS 3-25 vehicle is used in dusty areas.This vehicle has a drive chain with small rubberO-rings between each side plate. Steam clean-ing, high-pr

CHASSIS 3-26 hold the lower ring nut and tighten the upperring nut until their slots are aligned.NOTE: Make sure the special washer tabs “a” sit cor-

CHASSIS 3-27▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression dampingCAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Ad