Yamaha Wr250r 2008 Manual
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GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the cowling Order Job/Parts to remove Q’ty Remarks 1 Seat 1 2 Left side cover 1 3 Right side cover 1 4 Left air panel 1 5 Left air scoop 1 6 Right air panel 1 7 Right air scoop 1 For installation, reverse the removal proce- dure. 1 2 3 45 67 T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..4 Nm (0.4 m • kg, 2.9 ft • Ib) 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..10 Nm (1.0 m • kg, 7.2 ft • Ib)
FRONT WHEEL 4-2 EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. 1 Front wheel axle pinch bolt 4 Loosen. 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Cap 1 For Europe 5 Front wheel assembly 1 6 Collar 1 7 Collar 1 8 Front brake disc 1 9 Wheel ring 1 Only WR250R For installation, reverse the removal proce- dure. LT (WR250X) (WR250R) 2 4 3 (4)1 5 6 8 (6)(6) 9 T R..23 Nm (2.3 m • kg, 17 ft • Ib) T R..12 Nm (1.2 m • kg, 8.7 ft • Ib) T R..23 Nm (2.3 m • kg, 17 ft • Ib) T R..63 Nm (6.3 m • kg, 46 ft • Ib) T R..23 Nm (2.3 m • kg, 17 ft • Ib) 7
FRONT WHEEL 4-3 Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks 1 Oil seal 2 2 Bearing 2 3 Spacer 1 For assembly, reverse the disassembly pro- cedure. 1 2 2 3 1
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 there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: Front wheel NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. EAS21930 CHECKING THE FRONT WHEEL 1. Check: Wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING EWA13460 Do not attempt to straighten a bent wheel ax- le. 2. Check: Tire Front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 1-31 and “CHECKING THE WHEELS” on page 1-33. 3. Check: Spokes 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. 4. Tighten: Spokes Refer to “CHECKING AND TIGHTENING THE SPOKES” on page 1-33. NOTE: After tightening the spokes, measure the front wheel runout. 5. Measure: Front wheel radial runout “a” Front wheel lateral runout “b” Over the specified limits → Replace. 6. Check: Collars Damage/wear → Replace. 7. Check: Wheel bearings Front wheel turns roughly or is loose → Re- place the wheel bearings. Oil seals Damage/wear → Replace. Spoke 3 Nm (0.3 m•kg, 2.2 ft•lb) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) TR.. ab
FRONT WHEEL 4-5 EAS21910 DISASSEMBLING THE FRONT WHEEL 1. Remove: Oil seals Wheel bearings a. Clean the outside of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel surface. c. Remove the wheel bearings with a general bearing puller. EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: Wheel bearings Oil seals a. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: ECA14130 Do not contact the wheel bearing inner race or balls. Contact should be made only with the outer race. NOTE: Use a socket “1” that matches the diameter of the wheel bearing outer race and oil seal. EAS22000 INSTALLING THE FRONT WHEEL (DISC) The following procedure applies to both of the brake discs. 1. Lubricate: Wheel axle Oil seal lips 2. Tighten: Wheel axle nut “1” Wheel axle pinch bolt CAUTION: ECA14140 Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- ly. 12 Recommended lubricant Lithium-soap-based grease Wheel axle nut 63 Nm (6.3 m•kg, 46 ft•lb) Wheel axle pinch bolt 23 Nm (2.3 m•kg, 17 ft•lb) New 1 TR..
REAR WHEEL 4-7 EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. 1 Rear wheel axle nut 1 2 Locknut 2It loosens and adjusting bolt is tightened fully. 3 Rear wheel axle 1 4 Chain puller (left/right) 1/1 5 Drive chain 1 6 Rear wheel assembly 1 7 Collar left/Dust cover 1/1 8 Collar right/Dust cover 1/1 9 Rear brake disc 1 10 Rear wheel sprocket 1 For installation, reverse the removal proce- dure. 1 2 3 4 4 5(6) (6) (6) 6 7 89 10 LT T R..125 Nm (12.5 m • kg, 90 ft • Ib) T R..12 Nm (1.2 m • kg, 8.7 ft • Ib) T R..16 Nm (1.6 m • kg, 12 ft • Ib) T R..35 Nm (3.5 m • kg, 25 ft • Ib)
REAR WHEEL 4-8 Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks 1 Oil seal (left/right) 1/1 2 Bearing (left/right) 1/1 3 Spacer 1 For assembly, reverse the disassembly pro- cedure. 1 2 1 2 3
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 is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Elevate: Rear wheel 3. Remove: Rear wheel axle nut “1” 4. Loosen: Locknut 5. Tighten: Adjusting bolt NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 6. Remove: Wheel axle “2” Rear wheel “3” NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. EAS22080 DISASSEMBLING THE REAR WHEEL 1. Remove: Oil seals Wheel bearings Refer to “DISASSEMBLING THE FRONT WHEEL” on page 4-5. EAS22100 CHECKING THE REAR WHEEL 1. Check: Wheel axle Rear wheel Wheel bearings Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-4. 2. Check: Tire Rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 1-31 and “CHECKING THE WHEELS” on page 1-33. 3. Check: Spokes Refer to “CHECKING THE FRONT WHEEL” on page 4-4. 4. Measure: Radial wheel runout Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-4. EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: Rear wheel sprocket More than 1/4 tooth wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprock- et. 2. Replace: Rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. 3 1 2 Radial wheel runout limit 2.0 mm Lateral wheel runout limit 2.0 mm a. Tooth face b. Normal 1. Drive chain roller 2. Rear wheel sprocket 1 2a b
REAR WHEEL 4-10 b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS22140 ASSEMBLING THE REAR WHEEL 1. Install: Wheel bearings Oil seals Refer to “ASSEMBLING THE FRONT WHEEL” on page 4-5. EAS22160 INSTALLING THE REAR WHEEL (DISC) 1. Install: Brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-28 2. Lubricate: Wheel axle Oil seal lips 3. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26.4. Tighten: Wheel axle nut Rear wheel sprocket self-locking nut 35 Nm (3.5 m•kg, 25 ft•lb) Recommended lubricant Lithium-soap-based grease TR.. New Drive chain slack WR250R 38.0 – 48.0 mm (1.50 – 1.89 in) WR250X 40.0 – 50.0 mm (1.57 – 1.97 in) Wheel axle nut 125 Nm (12.5 m•kg, 90 ft•lb) TR..