Yamaha Wr250r 2008 Manual

 
REAR BRAKE 
4-31 
BLE ROUTING” on page 2-30.
CAUTION:
 
 ECA14170 
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake 
caliper. 
3. Install: 
 
Brake pad springs 
 
Brake pads 
 
Brake caliper support bolt 
 
Pin plug
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-28.
4. Fill: 
 
Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
 
EWA13090  
 
Use only the designated brake...

 
REAR BRAKE 
4-32 
Obstruction  
→ 
 Blow out with compressed air.
2. Check: 
 
Brake master cylinder kit
Damage/wear  
→ 
 Replace.
3. Check: 
 
Master cylinder reservoir cap
Cracks/damage  
→ 
 Replace. 
 
Brake master cylinder reservoir diaphragm
holder 
 
Brake master cylinder reservoir diaphragm
Cracks/damage  
→ 
 Replace.
4. Check: 
 
Brake hoses
Cracks/damage/wear  
→ 
 Replace. 
EAS22730 
ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER
WARNING
 
EWA13520  
 
Before installation, all internal...

 
REAR BRAKE 
4-33 
brake performance. 
 
Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance. 
 
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock.
CAUTION:
 
 ECA13540 
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up...

 
HANDLEBAR 
4-34 
EAS22840 
HANDLEBAR 
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks  
1 Rear view mirror (left/right) 1/1
2 Front brake light switch 1
3 Front brake master cylinder holder 1
4 Front brake master cylinder assembly 1
5 Right handlebar switch 1
6 Throttle cable housing 1
7 Throttle cable 2
8 Throttle grip 1
9 Clutch cable 1
10 Clutch switch 1
11 Clutch lever holder 1
12 Clutch lever 1
13 Left handlebar switch 1
14 Handlebar grip 1
15 Special washer 1
16 Handlebar upper...

 
HANDLEBAR 
4-35 
For installation, reverse the removal proce-
dure.  
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks
11
23
45
67
8
91011
12 13
14 15 17
18
16
T R..30 Nm (3.0 m • kg, 22 ft • Ib) 
T R..40 Nm (4.0 m • kg, 29 ft • Ib) 
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 
T R..28 Nm (2.8 m • kg, 20 ft • Ib) 
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)  

 
HANDLEBAR 
4-36 
EAS22860 
REMOVING THE HANDLEBARS 
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over. 
2. Remove: 
 
Front brake switch 
 
Clutch switch
NOTE:
 
Press the projection, and remove them from
front brake master cylinder assembly and clutch 
lever assembly.
3. Remove: 
 
Handlebar grip “1”
NOTE:
 
Blow compressed air between the left handlebar
and the handlebar grip, and gradually push the 
grip off...

 
HANDLEBAR 
4-37

 
a. Slightly coat the handlebar left end with a rub-
ber adhesive. 
 
Install the handlebar grip on the handlebar by
pressing the grip from the left side. 
 
Wipe off any excess rubber adhesive with a
clean rag.
WARNING
 
EWA32D1005  
Do not touch and move the handlebar grip 
until its adhesive dries completely.

 
4. Install: 
 
Left handlebar switch “1”
NOTE:
 
 
Align tab “a” of special washer with slot “b” of
left...

 
HANDLEBAR 
4-38 
9. Adjust: 
 
Clutch cable free play
Refer to “ADJUSTING THE CLUTCH CA-
BLE FREE PLAY” on page 1-14.
10.Adjust: 
 
Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 1-8. 
Clutch lever free play
10.0 
– 
15.0 mm (0.39 
– 
0.59 in)
Throttle cable free play
3.0 
– 
5.0 mm (0.12 
– 
0.20 in)
a
2 1 

 
FRONT FORK 
4-39 
EAS22950 
FRONT FORK 
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks  
Front wheel Refer to“FRONT WHEEL” on page 4-2.
1 Front fork protector 1
2 Brake hose holder 2
3 Front brake caliper 1
4 Upper bracket pinch bolt 2 Loosen.
5 Front fork cap bolt 1 Loosen.
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork 1
For installation, reverse the removal proce-
dure.
1 2
34
5
6
7
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 
T R..23 Nm (2.3 m •...

 
FRONT FORK 
4-40 
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks  
1 Front fork cap bolt 1
2 O-ring 1
3 Rod 1
4 Spring seat 1
5 Fork spring 1
6 Nut 1
7 Spring guide 1
8 Dust seal 1
9 Stopper ring 1
10 Base valve 1
11 Copper washer 1
12 O-ring 2
13 Damper rod 1
14 Outer tube 1
15 Oil seal 1
16 Oil sealWasher 1
17 Slide metal 1
18 Piston metal 1
19 Inner tube 1
20 Rubber cap 1
1
2 3
4 5
6 7
89
101112
1314 15161718
19
LT
20
T R..30 Nm (3.0 m • kg, 22 ft • Ib) 
T R..15 Nm (1.5 m •...