Yamaha Wr250r 2008 Manual

							 
LUBRICATION SYSTEM CHART AND DIAGRAMS 
2-26 
1. Camshaft
2.  Timing chain tensioner
3. Piston cooler
4. Oil filter
5. Main axle
6. Delivery pipe
7. Drive axle
8. Oil pump
9. Relief valve
10. Oil strainer
11. Oil pan 
						

							 
LUBRICATION SYSTEM CHART AND DIAGRAMS 
2-27 
						

							 
LUBRICATION SYSTEM CHART AND DIAGRAMS 
2-28 
1.  Oil pump assembly
2. Relief valve
3. Main axle
4. Delivery pipe
5. Drive axle
6. Crankshaft
7. Oil filter
8. Oil strainer 
						

							 
COOLING SYSTEM DIAGRAMS 
2-29 
EAS20420 
COOLING SYSTEM DIAGRAMS
8
5 1
2
3
4
6
7
9 
						

							 
COOLING SYSTEM DIAGRAMS 
2-30 
1. Radiator cap
2. Radiator
3.  Radiator inlet hose
4.  Radiator outlet hose
5.  Recovery tank hose
6. Cap
7.  Side cover stay
8.  Water pump housing cover
9. Impeller shaft 
						

							 
CABLE ROUTING 
2-31 
EAS20430 
CABLE ROUTING 
						

							 
CABLE ROUTING 
2-32 
1.  Starter motor lead
2.  Coolant temperature sensor lead
3.  Speed sensor lead
4.  Negative battery lead
5. Starter relay
6.  Starter relay probe
7.  Starter relay lead
8.  Intake solenoid lead
9. ECU lead
10. Headlight relay
11.  Turn signal relay
12.  Radiator fan motor relay
13. Relay unit
14.  Positive battery lead
15.  EXUP servo motor lead
16.  Sidestand switch lead
17.  AC magneto lead
18.  Neutral switch lead
19.  Recovery tank hose
20. Rectifier/regulator
21. Fuse box
22.  Air cut-off valve lead
23.  Air induction system pipe
24. Horn lead
25.  Neutral switch lead
26.  Recovery tank hose
27. Cover
28. Clutch cable
29. Wire harness
A.  Dimensions of wire harness fastening.
B.  Fasten the wire harness, clutch cable, clutch 
switch lead, and left handlebar switch lead 
using a cable tie. Place the clutch cable at the 
top position. The others can be in any position.
C.  Route the wire harness under the clutch cable, 
above the throttle cable, and along the right 
side of vehicle.
D.  Pass the ignition lead under the clutch cable, 
above the throttle cable, and through the hole 
inside of frame tank rail.
E.  Wire harness branch (at left side of vehicle) 
connected to the fuse box, AC magneto and 
others.
F.  Securely insert the wire harness clamp into the 
T-stud of cable holder.
G.  Fasten the wire harness, starter motor lead, 
negative battery lead, coolant temperature sen-
sor lead, and speed sensor lead to the frame 
with a cable tie.
H.  Fasten the starter motor lead, negative battery 
lead, coolant temperature sensor lead, and 
speed sensor lead to the frame with a cable tie. 
Fasten them to the outside of RCU mounting 
boss (left).
I. To engine.
J.  Fasten the wire harness, starter motor lead, 
negative battery lead, coolant temperature sen-
sor lead, and speed sensor lead using a cable 
tie.
K.  Securely insert the wire harness clamp into the 
T-stud of the rear frame.L.  Pass the ECU lead between the intake solenoid 
hose and connector.
M.  Wrap the connectors with a cover for protection.
N.  Fasten the starter motor lead, negative battery 
lead, coolant temperature sensor lead, and 
speed sensor lead using a cable tie. Fasten 
them between the battery band and battery ter-
minals, and face their cable lock inward.
O.  Route the sidestand switch lead to the inside of 
battery band.
P.  Fasten the rear frame and sidestand switch 
lead using a cable tie.
Q.  Fasten the rear frame, sidestand switch lead 
using a cable tie. They must be fixed to the 
T-stud of the rear frame. Any locking position 
can be used.
R.  Position the recovery tank hose end between 
the engine bracket and down tube.
S.  Pass the clutch cable through the inside of FID 
hose.
T.  Fasten the neutral switch lead, and recovery 
tank hose to the down tube with a cable tie. An 
excess must face inward.
U.  Fasten the AC magneto lead, neutral switch 
lead, and recovery tank hose to the down tube 
with a cable tie. They must be fixed to the T-stud 
of down tube. Any locking position can be used.
V.  Fasten the recovery tank hose to the down tube 
with clamps. They must be fixed to the T-stud of 
down tube. Any locking position can be used.
W.  After cable connection, place the connectors in 
the cover, and mount them in a hole of the 
frame.
X.  Clamp the wire harness, clultch cable and 
clutch switch lead (6-pin natural color) at the top 
of sidecover stay mount boss.
Y.  Fix the fuse box lead to the side cover stay.
Z.  Pass the AC magneto lead and neutral switch 
lead through the behind of rectifier regulator.
AA.  Pass the horn lead through the behind of recti-
fier regulator.
AB.  Fasten the magneto lead, horn lead, and the 
top of cover (for AC magneto lead and neutral 
switch lead) using a cable tie. An excess must 
face inward. (The bare conductors of lead can 
be clamped.)
AC.  Fasten the sidecover stay, AC magneto lead, 
neutral switch lead, and horn lead using a cable 
tie. An excess must face forward.
AD.  The AC magneto lead and neutral switch lead 
must not contact with the horn.
AE.  After connecting the AC magneto lead and 
neutral switch lead, place their connectors in 
the cover.
AF.  Fasten the sidecover stay, AC magneto lead, 
and neutral switch lead using a cable tie.
AG.  Rotate the AC magneto lead to the cover.
AH.  Fasten the rear frame cover using a cable tie. 
The clamp lock must face downwards.
AI.  Fasten the sidestand switch lead to the rear 
frame with a cable tie. Pass the lead through 
the hole of rear frame bracket, and direct the 
clamp lock to the inside of the frame.
AJ.  Install the cover between of the wire harness 
(inside) and clutch cable (outside).
AK.  Do not route the AC magneto lead, neutral 
switch lead, horn lead and air induction lead 
above the air cut-off valve assembly. 
						

							 
CABLE ROUTING 
2-33 
						

							 
CABLE ROUTING 
2-34 
1. Clamp
2.  Throttle position sensor lead
3.  Fan motor lead
A.  Fasten the breather hose using a clamp.
B.  Fasten the throttle position sensor connector 
cover and the rear brake switch lead using a 
cable tie.
C.  Insert the fan motor lead into the concave sec-
tion of guide air, and pass them backward 
through the hole.
D.  After connecting the main switch lead, front 
brake switch lead, and handlebar right lead, 
and place their connectors in the cover.
E.  Fasten the main switch lead, front brake switch 
lead, and handlebar switch right lead using a 
clamp. They must be placed between the front 
edge of the cable guide and below the “H”, 
within the range of the handlebar turns from 
straight ahead to the fully left.
F.  Slightly pull out the end of rear brake switch 
lead backward.
G.  Fasten the rear brake switch lead to the frame 
with a clamp. The clamp must be securely 
inserted into the frame hole. Any locking posi-
tion can be used.
H.  The position is a between the halfway from the 
cable guide and the upperend of the frame 
number.
I.  Front edge of the cable guide 
						

							 
CABLE ROUTING 
2-35