Yamaha Wr250r 2008 Manual
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CHASSIS 3-29 a. Turn the adjusting screw “1” in direction “a” or “b”. EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressure Out of specification → Regulate. WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperatureequals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. WARNING EWA13190 It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfaces Damage/wear → Replace the tire. Direction “a” Compression damping is increased (sus- pension is harder). Direction “b” Compression damping is decreased (sus- pension is softer). Compression damping Maximum (hard) 1 click(s) out* Standard 10 click(s) out* (WR250R) 7 click(s) out* (WR250X) Minimum (soft) 12 click(s) out* * With the adjusting screw fully turned in 1 a b Loading condition 0 – 90 (0 – 198 lb) Tire air pressure (measured on cold tires) Loading condition 0 – 90 kg (0 – 198 lb) Front WR250R 125 kPa (18 psi) (1.25 kgf/cm 2 ) WR250X 200 kPa (29 psi) (2.00 kgf/cm 2 ) Rear WR250R 175 kPa (25 psi) (1.75 kgf/cm 2 ) WR250X 200 kPa (29 psi) (2.00 kgf/cm 2 ) Loading condition 90 – 185 kg (198 – 408 lb) Front WR250R 150 kPa (22 psi) (1.50 kgf/cm 2 ) WR250X 200 kPa (29 psi) (2.00 kgf/cm 2 ) Rear WR250R 200 kPa (29 psi) (2.00 kgf/cm 2 ) WR250X 225 kPa (33 psi) (2.25 kgf/cm 2 ) Maximum load 185 kg (408 lb) * Total weight of rider, passenger, cargo and accessories
CHASSIS 3-30 WARNING 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 sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality re- placement. WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: In- stall the tire with the mark pointing in the direc- tion of wheel rotation. Align the mark “2” with the valve installation point. 1. Tire tread depth 2. Side wall 3. Wear indicator Wear limit (front) 0.8 mm (0.03 in) Wear limit (rear) 0.8 mm (0.03 in) A. Tube wheel B. Tubeless wheel 1 2 3 AB Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Front tire Size WR250R 80/100-21M/C 51P WR250X 110/70R17M/C 54H Manufacturer/model WR250R BRIDGESTONE/ TW-301 F WR250X BRIDGESTONE/ BT090F RADIAL G Rear tire Size WR250R 120/80-18M/C 62P WR250X 140/70R17M/C 66H Manufacturer/model WR250R BRIDGESTONE/ TW-302 F WR250X BRIDGESTONE/ BT090R RADIAL G
CHASSIS 3-31 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel. EAS21680 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: Spoke Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: (front/rear) Spoke (with a spoke nipple wrench “1”) NOTE: Be sure to tighten the spokes before and after break-in. EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: Outer cable Damage → Replace. 2. Check: Cable operation Rough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. 2 1 Spoke nipple wrench (8 – 9) 90890-01522 YM-01522 Spoke (front/rear) 3 Nm (0.3 m•kg, 2.2 ft•lb) Recommended lubricant Engine oil or a suitable cable lu- bricant 1 TR..
CHASSIS 3-32 EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Brake lever Silicone grease Clutch lever Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease Recommented lubricant Lithium-soap-based grease
ELECTRICAL SYSTEM 3-33 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-59. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-59. EAS21780 REPLACING THE HEADLIGHT BULB WARNING EWA13320 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 1. Remove: Headlight unit bolt “1” NOTE: After you have removed the headlight unit bolts, lift and remove the headlight unit from front fend- er grommet “2”. 2. Remove: Headlight coupler “1” Bulb cover “2” 3. Remove: Headlight bulb holder “1” Headlight bulb “2”4. Install: Headlight bulb Fasten the new headlight bulb with the head- light bulb holder. CAUTION: ECA13690 Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 5. Install: Headlight bulb holder Bulb cover Headlight coupler 6. Install: Headlight unit EAS21800 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: Headlight beam (vertically) a. Turn the adjusting screw “1” in direction “a” or “b”. 1 2 1 2 1 2 Headlight unit bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. 1 2 New TR..
1 2 3 4 5 6 7 8 9 CHASSIS GENERAL CHASSIS .....................................................................................4-1 FRONT WHEEL .............................................................................................4-2 REMOVING THE FRONT WHEEL ..........................................................4-4 CHECKING THE FRONT WHEEL ...........................................................4-4 DISASSEMBLING THE FRONT WHEEL.................................................4-5 ASSEMBLING THE FRONT WHEEL.......................................................4-5 INSTALLING THE FRONT WHEEL (DISC) .............................................4-5 REAR WHEEL................................................................................................4-7 REMOVING THE REAR WHEEL .............................................................4-9 DISASSEMBLING THE REAR WHEEL ...................................................4-9 CHECKING THE REAR WHEEL .............................................................4-9 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..........4-9 ASSEMBLING THE REAR WHEEL .........................................................4-10 INSTALLING THE REAR WHEEL (DISC) ...............................................4-10 FRONT BRAKE..............................................................................................4-11 INTRODUCTION ......................................................................................4-16 CHECKING THE FRONT BRAKE DISC ..................................................4-16 REPLACING THE FRONT BRAKE PADS ...............................................4-17 REMOVING THE FRONT BRAKE CALIPER...........................................4-18 DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-18 CHECKING THE FRONT BRAKE CALIPER ...........................................4-18 ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-19 INSTALLING THE FRONT BRAKE CALIPER .........................................4-19 REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-20 CHECKING THE FRONT BRAKE MASTER CYLINDER ........................4-20 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....................4-21 INSTALLING THE FRONT BRAKE MASTER CYLINDER ......................4-21 REAR BRAKE ................................................................................................4-23 INTRODUCTION ......................................................................................4-28 CHECKING THE REAR BRAKE DISC ....................................................4-28 REPLACING THE REAR BRAKE PADS .................................................4-28 REMOVING THE REAR BRAKE CALIPER .............................................4-29 DISASSEMBLING THE REAR BRAKE CALIPER ...................................4-29 CHECKING THE REAR BRAKE CALIPER..............................................4-30 ASSEMBLING THE REAR BRAKE CALIPER .........................................4-30 INSTALLING THE REAR BRAKE CALIPER............................................4-30 REMOVING THE REAR BRAKE MASTER CYLINDER ..........................4-31 CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-31 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ......................4-32 INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-32 HANDLEBAR .................................................................................................4-34 REMOVING THE HANDLEBARS ............................................................4-36 CHECKING THE HANDLEBAR ...............................................................4-36 INSTALLING THE HANDLEBAR .............................................................4-36
FRONT FORK ................................................................................................4-39 REMOVING THE FRONT FORK LEGS...................................................4-42 DISASSEMBLING THE FRONT FORK LEGS .........................................4-42 CHECKING THE FRONT FORK LEGS ...................................................4-43 ASSEMBLING THE FRONT FORK LEGS ...............................................4-43 INSTALLING THE FRONT FORK LEGS .................................................4-47 STEERING HEAD ..........................................................................................4-49 REMOVING THE LOWER BRACKET .....................................................4-51 CHECKING THE STEERING HEAD ........................................................4-51 INSTALLING THE STEERING HEAD ......................................................4-51 REAR SHOCK ABSORBER ASSEMBLY .....................................................4-53 HANDLING THE REAR SHOCK ABSORBER .........................................4-54 DISPOSING OF A REAR SHOCK ABSORBER ......................................4-54 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-54 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....................4-54 CHECKING THE CONNECTING ARM AND RELAY ARM......................4-54 INSTALLING THE RELAY ARM ..............................................................4-55 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..................4-55 SWINGARM ...................................................................................................4-56 REMOVING THE SWINGARM ................................................................4-57 CHECKING THE SWINGARM .................................................................4-57 INSTALLING THE SWINGARM ...............................................................4-57 CHAIN DRIVE ................................................................................................4-59 REMOVING THE DRIVE CHAIN .............................................................4-60 CHECKING THE DRIVE CHAIN ..............................................................4-60 CHECKING THE DRIVE SPROCKET .....................................................4-61 CHECKING THE REAR WHEEL SPROCKET.........................................4-61 INSTALLING THE DRIVE CHAIN ............................................................4-61