Yamaha Wr250r 2008 Manual

 
FRONT FORK 
4-41 
For assembly, reverse the disassembly pro-
cedure.  
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
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 • kg, 11 ft • Ib) 
T R..55 Nm (5.5 m • kg, 40 ft • Ib)  

 
FRONT FORK 
4-42 
EAS22970 
REMOVING THE FRONT FORK LEGS 
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
 
 
Place the vehicle on a suitable stand so that
the front wheel is elevated. 
 
Record the adjusting screw setting position be- 
fore loosening the cap bolt.
2. Loosen: 
 
Upper bracket pinch bolts “1” 
 
Front fork cap bolt “2” 
...

 
FRONT FORK 
4-43 
6. Remove: 
 
Inner tube “1”

 
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but careful-
ly.

 
EAS23010 
CHECKING THE FRONT FORK LEGS 
The following procedure applies to both of the
front fork legs.
1. Check: 
 
Inner tube 
 
Outer tube
Bends/damage/scratches  
→...

 
FRONT FORK 
4-44
WARNING
 
EWA13660  
 
Make sure the oil levels in both front fork
legs are equal. 
 
Uneven oil levels can result in poor han- 
dling and a loss of stability.
NOTE:
 
 
When assembling the front fork leg, be sure to
replace the following parts: 
 
Piston metal 
 
Slide metal 
 
Oil seal 
 
Dust seal 
 
Before assembling the front fork leg, make 
sure all of the components are clean.
1. Install: 
 
Damper rod “1” 
 
Inner tube “2”
CAUTION:
 
 ECA14210 
Allow the damper rod...

 
FRONT FORK 
4-45
CAUTION:
 
 ECA32D1008 
Face stamp a of the oil seal toward the 
front caliper mount during assembling.
NOTE:
 
 
Before installing the oil seal, lubricate its lips
with lithium soap base grease. 
 
Lubricate the outer surface of the inner tube
with fork oil. 
 
To protect the oil seal, cover it using polyethyl- 
ene bag “b”, and mount the oil seal.
6. Install: 
 
Piston metal “1” 
(on the inner tube)
7. Install: 
 
Outer tube “1”
(on the inner tube “2”)8. Install: 
 
Slide metal...

 
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.Check: 
 
Inner tube for sliding
Unsmooth sliding  
→ 
 Disassemble and
check.13.Lubricate: 
 
Front fork
CAUTION:
 
 ECA14230 
 
Be sure to use the recommended fork 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...

 
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 the oil. If the oil is be-
low this level, each part is not lubricated and
you cannot get the desired spring perfor- 
mance. 
17.Measure: 
 
Front fork oil level “a” (at highest pressure)
Out of specification  
→ 
 Adjust.
18.Install: 
 
Fork spring “1” 
 
Push rod“ 2” 
 
Spring guide “3” 
 
Nut “4” 
 
Cap bolt...

 
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: 
 
Upper bracket pinch bolt “3”
WARNING
 
EWA32D1003  
Check to see that the brake hose is installed
correctly.  
Refer to “CABLE ROUTING” on page 2-30. 
5. Adjust: 
 
Rebound damping 
 
Compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” on page 1-28. 
Lower bracket pinch bolt
20 Nm (2.0 m•kg, 14 ft•lb)
Cap bolt
30 Nm (30. m•kg, 22...

 
STEERING HEAD 
4-49 
EAS23090 
STEERING HEAD 
Removing the headlight unit, meter assembly and front fender
Order Job/Parts to remove Q’ty Remarks  
Fuel tank Refer to“FUEL TANK” on page 7-1.
Handlebar Refer to“HANDLEBAR” on page 4-34.
Front fork Refer to“FRONT FORK” on page 4-39.
1 Brake hose guide 1
2 Headlight assembly 1
3 Headlight coupler 1 Disconnect.
4 Meter assembly coupler 3 Disconnect.
5 Front turn signal light connector (left/right) 2/2 Disconnect.
6 Meter assembly 1
7 Turn signal light...

 
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 1
2 Main switch coupler 2 Disconnect.
3 Steering stem nut 1
4 Upper bracket 1
5 Special washer 1
6 Upper ring nut 1
7 Rubber washer 1
8 Lower ring nut 1
9 Lower bracket 1
10 Bearing cover 1
11 Upper bearing 1
12 Lower bearing 1
13 Bearing races 2
For installation, reverse the removal proce-
dure.
23
4
5
6
7
8
910
11 12
13 13
1
2
T R..120 Nm (12.0 m •...