Yamaha Wr250r 2008 Manual

							 
STEERING HEAD 
4-51 
EAS23110 
REMOVING THE LOWER BRACKET 
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: 
 
Upper ring nut 
 
Lower ring nut “1”
NOTE:
 
Hold the lower ring nut with the exhaust and
steering nut wrench, and then remove the upper 
ring nut with the ring nut wrench.
WARNING
 
EWA13730  
Securely support the lower bracket so that 
there is no danger of it falling. 
EAS23120 
CHECKING THE STEERING HEAD 
1. Wash: 
 
Bearings 
 
Bearing races
2. Check: 
 
Bearings 
 
Bearing races
Damage/pitting  
→ 
 Replace.
3. Replace: 
 
Bearings 
 
Bearing races

 
a. Remove the bearing races from the steering
head pipe with a long rod “1” and hammer.
b. Remove the bearing race from the lowerbracket with a floor chisel “2” and hammer.
c. Install a new bearing races.
CAUTION:
 
 ECA14270 
If the bearing race is not installed properly, 
the steering head pipe could be damaged.
NOTE:
 
Always replace the bearings and bearing races 
as a set.

 
4. Check: 
 
Upper bracket 
 
Lower bracket
(along with the steering stem)
Bends/cracks/damage  
→  
 Replace. 
EAS23140 
INSTALLING THE STEERING HEAD 
1. Lubricate: 
 
Upper bearing 
 
Lower bearing 
 
Bearing races
2. Install: 
 
Lower bracket 
 
Lower ring nut “1” 
 
Rubber washer “2” 
 
Upper ring nut “3” 
 
Special washer “4” 
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Recommended cleaning solvent
Kerosene
1
 
Recommended lubricant
Lithium-soap-based grease 
						

							 
STEERING HEAD 
4-52 
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 1-27.
3. Install: 
 
Upper bracket 
 
Steering stem nut
NOTE:
 
Temporarily tighten the steering stem nut.
4. Install: 
 
Front fork legs
Refer to “FRONT FORK” on page 4-39.
NOTE:
 
Temporarily tighten the upper and lower bracket 
pinch bolts.
5. Tighten: 
 
Steering stem nut 
Steering stem nut
120 Nm (12.0 m•kg, 87 ft•lb)
3
2
1 4
TR.. 
						

							 
REAR SHOCK ABSORBER ASSEMBLY 
4-53 
EAS23160 
REAR SHOCK ABSORBER ASSEMBLY 
Removing the rear shock absorber assembly
Order Job/Parts to remove Q’ty Remarks  
Left slide cover/Right slide cover Refer to“GENERAL CHASSIS” on page 4-1.
Drive chain tensioner top Refer to“CHAIN DRIVE” on page 4-59.
1 Rear shock absorber assembly 1
2 Connection rod 1
3 Relay arm 1
4 Collar (short) 1
5 Collar (long) 1
6 Oil seal 4
7 Bearing 2
8 Collar 1
9 Oil seal 2
10 Bearing 2
11 Collar 1
12 Bearing 1
13 Oil seal 2
For installation, reverse the removal proce-
dure.
2
3 14
566 6
7
7
89
91010
11 12
1313
LS
LS
LS
LS
LS
LS
LS
LS
T R..53 Nm (5.3 m • kg, 38 ft • Ib) 
T R..80 Nm (8.0 m • kg, 58 ft • Ib) 
T R..80 Nm (8.0 m • kg, 58 ft • Ib) 
T R..70 Nm (7.0 m • kg, 51 ft • Ib) 
T R..40 Nm (4.0 m • kg, 29 ft • Ib)  
						

							 
REAR SHOCK ABSORBER ASSEMBLY 
4-54 
EAS23180 
HANDLING THE REAR SHOCK ABSORBER
WARNING
 
EWA13740  
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber. 
 
Do not tamper or attempt to open the rear
shock absorber. 
 
Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure. 
 
Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- 
mance. 
EAS23190 
DISPOSING OF A REAR SHOCK ABSORBER 
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release
the gas pressure, drill a 2 
– 
3-mm hole through
the rear shock absorber at a point 30 
– 
35 mm
from its end as shown.
WARNING
 
EWA13760  
Wear eye protection to prevent eye damage 
from released gas or metal chips. 
EAS23230 
REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY 
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. Remove: 
 
Connecting arm bolt “1” 
 
Rear shock absorber assembly lower bolt “2”
NOTE:
 
While removing the rear shock absorber assem-
bly lower bolt, hold the swingarm so that it does 
not drop down.
3. Remove: 
 
Rear shock absorber assembly upper bolt 
 
Rear shock absorber assembly
NOTE:
 
Raise the swingarm and then remove the rear
shock absorber assembly from between the 
swingarm and relay arm. 
EAS23240 
CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY 
1. Check: 
 
Rear shock absorber rod
Bends/damage  
→  
 Replace the rear shock
absorber assembly. 
 
Rear shock absorber
Gas leaks/oil leaks  
→  
 Replace the rear shock
absorber assembly. 
 
Spring
Damage/wear  
→ 
 Replace the rear shock ab-
sorber assembly. 
 
Bushings
Damage/wear  
→ 
 Replace. 
 
Bolts
Bends/damage/wear  
→  
 Replace. 
EAS23260 
CHECKING THE CONNECTING ARM AND 
RELAY ARM 
1. Check: 
 
Connecting rod 
 
Relay arm
21 
						

							 
REAR SHOCK ABSORBER ASSEMBLY 
4-55 
Damage/wear  
→ 
 Replace.
2. Check: 
 
Bearings 
 
Oil seals
Damage/pitting  
→ 
 Replace.
3. Check: 
 
Collar
Damage/scratches  
→ 
 Replace. 
EAS23270 
INSTALLING THE RELAY ARM 
1. Lubricate: 
 
Oil seal 
 
Bearings 
 
Collar
2. Install: 
 
Bearing “1”
(To connecting rod “2”) 
 
Bearing “3”
(To relay arm “4”) 
 
Bearing “5”
(To rear cushion lower position “6”) 
 
Oil seal “7”
(To the connecting rod, relay arm, and rear
cushion lower position) 
EAS23310 
INSTALLING THE REAR SHOCK 
ABSORBER ASSEMBLY 
1. Install: 
 
Rear shock absorber assembly
NOTE:
 
 
When installing the rear shock absorber as-
sembly, lift up the swingarm. 
 
Install all bolts from the left side.
2. Tighten: 
 
Rear shock absorber assembly upper nut 
 
Nut (Frame and connecting rod) 
 
Nut (Relay arm and connecting rod) 
 
Nut (Relay arm and swingarm) 
 
Nut (Rear shock absorber assembly lower
and Relay arm) 
Recommended lubricant
Lithium-soap-based grease
Installed depth (connecting rod
bearing) “a”
5.0 
– 
5.5 mm (0.20 
– 
0.22 in)
Installed depth (rear cushion low-
er bearing) “b”
4.0 mm (0.16 in)
Installed depth (relay arm bear-
ing) “c”
6 mm (0.24 in)
Installed depth (connecting rod
oil seal, relaly arm oil seal) “d”
0-0.5 mm (0 
– 
0.02 in)
Installed depth (rear cushion low-
er oil seal) “e”
0.5-1.0 mm (0.02 
– 
0.04 in)
adcd
adcd2
1
7
7
7
 
Rear shock absorber assembly
upper nut
40 Nm (4.0 m•kg, 29 ft•lb)
Nut (Frame and connecting rod)
80 Nm (8.0 m•kg, 58 ft•lb)
Nut (Relay arm and connecting
rod)
80 Nm (8.0 m•kg, 58 ft•lb)
Nut (Relay arm and Swingarm)
70 Nm (7.0 m•kg, 51 ft•lb)
Nut (Rear shock absorber assem-
bly lower and Relay arm)
53 Nm (5.3 m•kg, 38 ft•lb)
b
b
cd
cd 4
7
6
3
5
7
e
e
TR..
TR..
TR..
TR..
TR.. 
						

							 
SWINGARM 
4-56 
EAS23330 
SWINGARM 
Removing the swingarm
Order Job/Parts to remove Q’ty Remarks  
Rear wheel Refer to“REAR WHEEL” on page 4-7.
1 Bolt (Swingarm and relay arm) 1
2 Brake hose holder 3
3 Chain case 1
4 Chain cover 1
5 Chain support 1
6 Pivot shaft nut 1
7 Pivot shaft 1
8 Swingarm 1
9 Dust cover 2
10 Front drive chain guide 1
11 Collar 2
12 Oil seal 2
13 Bearing 4
For installation, reverse the removal proce-
dure.
2
2
3
45 6
7
8
99
101111
1212
1313
1313
1
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..2 Nm (0.2 m • kg, 1.4 ft • Ib) 
T R..85 Nm (8.5 m • kg, 62 ft • Ib) 
T R..70 Nm (7.0 m • kg, 51 ft • Ib)  
						

							 
SWINGARM 
4-57 
EAS23350 
REMOVING THE SWINGARM 
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. Measure: 
 
Swingarm side play 
 
Swingarm vertical movement

 
a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, bear-
ings, washers, and dust covers.

 
EAS23360 
CHECKING THE SWINGARM 
1. Check: 
 
Swingarm
Bends/cracks/damage  
→ 
 Replace.2. Check: 
 
Pivot shaft
Roll the pivot shaft on a flat surface.
Bends   
→  
 Replace.
WARNING
 
EWA13770  
Do not attempt to straighten a bent pivot 
shaft. 
3. Wash: 
 
Pivot shaft 
 
Dust covers 
 
Collar 
 
Washers 
 
Bearings
4. Check: 
 
Dust covers 
 
Collar 
 
Washers 
 
Oil seals
Damage/wear  
→  
 Replace. 
 
Bearings
Damage/pitting  
→  
 Replace. 
EAS23380 
INSTALLING THE SWINGARM 
1. Lubricate: 
 
Bearings 
 
Collar 
 
Dust covers 
 
Pivot shaft
2. Install: 
 
Bearing “1” 
 
Oil seal “2” 
 
Collar
(Swingarm) 
Pivot shaft nut
85 Nm (8.5 m•kg, 62 ft•lb)
Swingarm side play (at the end of
the swingarm)
0 mm (0 in)
TR..
 
Recommended cleaning solvent
Kerosene
Recommended lubricant
Lithium-soap-based grease 
						

							 
SWINGARM 
4-58 
3. Install: 
 
Rear shock absorber assembly
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
4. Install: 
 
Swing arm assembly
5. Install: 
 
Rear wheel
Refer to “REAR WHEEL” on page 4-7.
6. Adjust: 
 
Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 1-26. 
Installed depth “a”
15 mm (0.59 in)
Installed depth “b”
8.5 
– 
9.0 mm (0.33 
– 
0.35 in)
Installed depth “c”
0 
– 
0.5 mm (0 
– 
0.02 in)
Pivot shaft nut
85 Nm (8.5 m•kg, 62 ft•lb)
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)
abc
b c
a
c ba
cba 1
12
TR.. 
						

							 
CHAIN DRIVE 
4-59 
EAS23400 
CHAIN DRIVE 
Removing the drive chain
Order Job/Parts to remove Q’ty Remarks  
Swingarm Refer to“SWINGARM” on page 4-56.
1 Drive sprocket cover 1
2 Drive sprocket nut 1
3 Drive sprocket 1
4 Drive chain 1
5 Drive chain tensioner top 1
6 Drive chain tensioner bottom 1
For installation, reverse the removal proce-
dure.
1
2
3 45
6
T R..23 Nm (2.3 m • kg, 17 ft • Ib) 
T R..23 Nm (2.3 m • kg, 17 ft • Ib) 
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) 
T R..95 Nm (9.5 m • kg, 69 ft • Ib)  
						

							 
CHAIN DRIVE 
4-60 
EAS23420 
REMOVING THE DRIVE CHAIN 
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. Remove: 
 
Drive sprocket nut “1”
NOTE:
 
 
Return the bent tab of the locknut. 
 
Operate the rear brake, and loosen the drive
sprocket. 
 
After loosening the drive sprocket, remove the 
rear wheel and swingarm.
3. Remove: 
 
Rear wheel
Refer to “REAR WHEEL” on page 4-7. 
 
Rear shock absorber
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53. 
 
Swingarm
Refer to “SWINGARM” on page 4-56.
4. Remove: 
 
Drive chain 
EAS23441 
CHECKING THE DRIVE CHAIN 
1. Measure: 
 
15-link section “a” of the drive chain
Out of specification  
→ 
 Replace the drive
chain.

 
a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link sectionof the drive chain as shown in the illustration.
b. Calculate the length “c” of the 15-link section
of the drive chain using the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
NOTE:
 
 
When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut. 
 
Perform this procedure 2 
–  
3 times, at a different 
location each time.

 
2. Check: 
 
Drive chain
Stiffness  
→ 
 Clean, lubricate, or replace.
3. Clean: 
 
Drive chain

 
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt. 
15-link length limit
239.3 mm (9.42 in)
1