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 fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
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 surfacesand plastic parts. Therefore, always clean up 
any spilt brake fluid immediately. 
5. Bleed: 
 
Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 1-25.
6. Check: 
 
Brake fluid level
Below the minimum level mark “a”   
→  
 Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 1-23.
7. Check: 
 
Brake pedal operation
Soft or spongy feeling  
→  
 Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 1-25. 
EAS22700 
REMOVING THE REAR BRAKE MASTER 
CYLINDER
NOTE:
 
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys- 
tem.
1. Remove: 
 
Union bolt 
 
Copper washers 
 
Brake hose
NOTE:
 
To collect any remaining brake fluid, place a
container under the master cylinder and the end 
of the brake hose. 
EAS22710 
CHECKING THE REAR BRAKE MASTER 
CYLINDER 
1. Check: 
 
Brake master cylinder “1”
Damage/scratches/wear  
→  
 Replace. 
 
Brake fluid delivery passages “2”
(brake master cylinder body) 
Brake caliper support bolt
17 Nm (1.7 m•kg, 12 ft•lb)
Recommended fluid
DOT 4
1
a
TR..
a 
						

							 
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 brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid. 
 
Never use solvents on internal brake com- 
ponents. 
1. Install: 
 
Cylinder cup 
 
Master cylinder piston
2. Install: 
 
Spring “1” 
 
Master cylinder piston “2” 
 
Adjusting rod “3” 
 
Circlip “4” 
 
Dust boot “5” 
EAS22750 
INSTALLING THE REAR BRAKE MASTER 
CYLINDER 
1. Install: 
 
Copper washers  
 
Brake hoses 
 
Union bolt
WARNING
 
EWA13530  
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CA- 
BLE ROUTING” on page 2-30.
CAUTION:
 
 ECA32D1002 
When installing the brake hose onto the
brake master cylinder, make sure the brake 
pipe touch the projection “a” as shown.  
2. Fill: 
 
Brake fluid reservoir
WARNING
 
EWA13090  
 
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor Recommended fluid
DOT 4
1
2
New
New
New
New
New
New
 
Brake hose union bolt
30 Nm (30. m•kg, 22 ft•lb)
Recommended fluid
DOT 4
New
TR..
a 
						

							 
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 
any spilt brake fluid immediately. 
3. Bleed: 
 
Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 1-25.
4. Check: 
 
Brake fluid level
Below the minimum level mark “a”  
→ 
 Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 1-23.
5. Check: 
 
Brake pedal operation
Soft or spongy feeling  
→ 
 Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 1-25.
a 
						

							 
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 holder 2
17 Handlebar 1
18 Handlebar lower holder 2
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 
4-35 
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 the handlebar. 
EAS22880 
CHECKING THE HANDLEBAR 
1. Check: 
 
Handlebar
Bends/cracks/damage  
→ 
 Replace.
WARNING
 
EWA13690  
Do not attempt to straighten a bent handle- 
bar as this may dangerously weaken it. 
EAS22921 
INSTALLING THE HANDLEBAR 
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. Install: 
 
Handlebar “1” 
 
Upper handlebar holders “2”
NOTE:
 
 
Align the punch marks “a” on the handlebar
with the upper surface of the lower handlebar
holders. 
 
The upper handlebar holders should be in-
stalled with the punch marks “b” facing for- 
ward.
CAUTION:
 
 ECA14250 
 
First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side. 
 
Turn the handlebar all the way to the left
and right. If there is any contact with the 
fuel tank, adjust the handlebar position. 
3. Install: 
 
Special washer 
 
Handle grip 
Upper handlebar holder bolt
28 Nm (2.8 m•kg, 20 ft•lb)
TR..
22
1
a
b 
						

							 
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 switch. 
 
Align the mating surfaces of the left handlebar
switch with the punch mark “c” on the handle- 
bar.
5. Install: 
 
Clutch lever holder “1” 
 
Clutch lever “2”
NOTE:
 
Align the mating surfaces of the brake lever 
holder with the punch mark “a” on the handlebar.
6. Install: 
 
Throttle grip “1” 
 
Throttle cable housing “2” 
 
Throttle cables “3”
NOTE:
 
 
Align projection “a” of slot cable housing with
hole “b” of the handlebar. 
 
Slightly coat the end of slot cable and inside of
throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle- 
bar.
7. Install: 
 
Right handlebar switch “1”
NOTE:
 
Align projection “a” of the right handlebar switch 
with hole “b” of the handlebar.
8. Install: 
 
Front master cylinder assembly “1” 
 
Front brake master cylinder holder “2”
NOTE:
 
 
Install the front brake master cylinder on the
front brake master cylinder assembly by facing
the cylinder  “UP” mark upward. 
 
Align the matching surface of front brake mas-
ter cylinder holder with mark “a” of handlebar. 
 
Tighten the upper bolt first, and then tighten 
the lower bolt.
1
a
bc
1
a
2
 
Front brake master cylinder hold-
er bolt
7 Nm (0.7 m•kg, 5.1 ft•lb)
b3
a
12
b
a1
TR.. 
						

							 
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 • kg, 17 ft • Ib) 
T R..20 Nm (2.0 m • kg, 14 ft • Ib) 
T R..23 Nm (2.3 m • kg, 17 ft • Ib) 
T R..30 Nm (3.0 m • kg, 22 ft • Ib)  
						

							 
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 • kg, 11 ft • Ib) 
T R..55 Nm (5.5 m • kg, 40 ft • Ib)