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” 
 
Lower bracket pinch bolts “3”
WARNING
 
EWA13640  
Before loosening the upper and lower brack- 
et pinch bolts, support the front fork leg. 
3. Remove: 
 
Front fork leg 
EAS22980 
DISASSEMBLING THE FRONT FORK LEGS 
The following procedure applies to both of the
front fork legs.
1. Remove: 
 
Cap bolt “1” (from outer tube)
(by loosening the nut “2”)2. Remove: 
 
Nut 
 
Spring guide 
 
Push rod 
 
Front fork spring 
 
Spring guide
3. Drain: 
 
Fork oil
NOTE:
 
Drain the fork oil by stroking the inner tube sev- 
eral times.
4. Remove: 
 
Dust seal “1” 
 
Stopper ring “2”
(with a flat-head screwdriver)
CAUTION:
 
 ECA14180 
Do not scratch the inner tube. 
5. Remove: 
 
Base valve “1” 
 
Copper washer 
 
Damper rod
NOTE:
 
While holding the damper rod assembly “3” with
the damper rod holder “2”, loosen the damper 
rod assembly bolt.
12
3
 
Damper rod holder
90890-01454 
						

							 
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  
→ 
 Replace.
WARNING
 
EWA13650  
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it. 
2. Measure: 
 
Spring free length “a”
Out of specification  
→ 
 Replace.3. Check: 
 
Damper rod “1”
Damage/wear   
→  
 Replace.
Obstruction   
→  
 Blow out all of the oil passag-
es with compressed air.
4. Check: 
 
Base valve
Damage/wear  
→  
 Replace.
Obstruction  
→  
 Blow out all of the oil passag-
es with compressed air.
5. Check: 
 
Push rod
Bends/damage/wear  
→  
 Replace.
6. Check: 
 
Cap bolt
Damage/wear  
→  
 Replace. 
EAS23020 
ASSEMBLING THE FRONT FORK LEGS 
The following procedure applies to both of the
front fork legs. 
Fork spring free length
450.0 mm (17.72 in)
Limit
441.0 mm (17.36 in) 
						

							 
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 assembly to slide
slowly down the inner tube until it protrudes
from the bottom of the inner tube. Be careful 
not to damage the inner tube. 
2. Lubricate: 
 
Inner tube’s outer surface
3. Install: 
 
O-ring “1” 
 
Copper washer 
 
Base valve “2”4. Tighten: 
 
Base valve “1”
NOTE:
 
While holding the damper rod assembly “3” with
the damper rod holder “2”, tighten the base 
valve.
5. Install: 
 
Dust seal “1” 
 
Stopper ring “2” 
 
Oil seal “3” 
 
Oil seal washer “4” 
 
Slide metal “5”
(on to the inner tube “6”)  
Recommended oil
Suspension oil 01
New
New
 
Base valve
55 Nm (5.5 m•kg, 40 ft•lb)
LOCTITE®
Damper rod holder
90890-01454
1
2
TR..
New
New 
						

							 
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 “1” 
 
Oil washer “2”
(on the outer tube, using fork seal driver “3”)
9. Install: 
 
Oil seal “1”
Using fork seal driver 2, hammer the seal
until you see the stopper ring slot of outer
tube.
123
45
6
(a)
NewNew
New
 
Fork seal driver
90890-01442
Adjstable fork seal driver (36  
–  
46
mm)
YM-01442
Fork seal driver
90890-01442
Adjstable fork seal driver (36  
–  
46
mm)
YM-01442
1 2 
						

							 
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 fork.  
14.When the front fork is filled with oil, slowly
move dumper rod “1” up and down (at least
10 times) for lubrication of fork.
NOTE:
 
Move dumper rod slowly not to leak the fork oil.
15.Slowly move the inner tube up and down for
lubrication again. (1 stroke = Approx. 250
mm)
NOTE:
 
Do not move more than 250 mm as it causes an 
air insertion.
16.Wait for 10 minutes to sediment and deaer- 
Recommended oil
Suspension oil 01
Quantity
613.0 cm 
3
 
 (20.73 US oz) (21.62
Imp.oz) 
						

							 
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

 
a. Install the nut “3” with a finger until it is
stopped.
b. Set adjusting screw “5” to the position before
disassembling.
Refer to “ADJUSTING THE FRONT FORK
LEGS” on page 1-28.c. Tighten cap bolt “5” until it reaches nut “6” us-
ing your fingers.
d. Install the cap bolt on the outer tube, and
tighten it temporarily.

 
EAS23050 
INSTALLING THE FRONT FORK LEGS  
The following procedure applies to both of the
front fork legs.
1. Install: 
 
Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
 
Install the front fork so that difference “a” be-
tween the cap bolt top face and upper bracket 
Oil level
105 mm (4.13 in)
12
34
 
Nut
15 Nm (1.5 m•kg, 11 ft•lb)
TR.. 
						

							 
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 ft•lb)
Upper bracket pinch bolt
23 Nm (2.3 m•kg, 17 ft•lb)
a
TR..
TR..
TR..
12
3 
						

							 
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 (left/right) 1/1
8 Front fender 1
9 Brake hose guide 1
For installation, reverse the removal proce-
dure.
1
2
3
(4)5
56
4 7
7
8
9
4
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..23 Nm (2.3 m • kg, 17 ft • Ib) 
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)  
						

							 
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 • kg, 87 ft • Ib) 
38 Nm (3.8 m 
• kg, 27 ft • Ib) 
7 Nm (0.7 m 
• kg, 5.1 ft • Ib)  Loosen fully 
T R.1st
2nd
T R..20 Nm (2.0 m • kg, 14 ft • Ib)