Yamaha Wr250r 2008 Manual

							 
CABLE ROUTING 
2-36 
1.  Ignition coil lead
2.  Fuel pump lead
3. Injector lead
4.  Throttle position sensor lead
5.  Rear brake switch lead
6.  Right rear turn signal light lead
7.  License plate light lead
8. Taillight lead
9.  Left rear turn signal light lead
10.  Lean angle sensor lead
11.  Intake air pressure sensor lead
12. Clutch cable
13. Throttle cable
A.  Fasten the radiator fan motor lead and breather 
hose using a clamp. The rightmost end of 
breather hose must be secured (to the front as 
much as possible).
B.  Pass the radiator fan motor lead under the 
breather hose, and pull them out.
C.  Pass the injector lead between the fuel pipe.
D.  Fasten the ECU lead using a clamp.
E.  Fasten the right and rear left turn signal light 
lead, license plate light lead, and taillight lead to 
the rear frame with a clamp. 
F.  Fasten the right and left rear turn signal light 
lead, license plate light lead, and taillight lead to 
the rear frame with a cable tie.
G.  After connection of lead, place the connector in 
the cover so that bare conductors are not 
exposed.
H.  Fasten the frame cover, wire harness, and 
clutch cables to the frame with a cable tie.
I.  A silicone hydrate can be applied when passing 
the clutch cable or throttle cable through the 
internal hole of frame tank rails. 
						

							 
CABLE ROUTING 
2-37 
						

							 
CABLE ROUTING 
2-38 
1.  Throttle cable (accelerator)
2.  Throttle cable (decelerator)
3.  Right handlebar switch lead
4.  Clutch switch lead
5.  Left handlebar switch lead
6. Clutch cable
7.  Front brake switch lead
8.  Left front turn signal light lead
9.  Wire harness (brown connector)
10.  Wire harness (green connector)
11.  Left front turn signal light lead
12.  Meter lead (3-pin black coupler)
13.  Meter lead (4-pin natural color coupler)
14.  Meter lead (3-pin natural color coupler)
15.  Left handlebar switch lead (headlight lead)
16. Cable guide
17.  Main switch lead
18. Clamp
19.  Auxiliary light lead
20.  Wire harness (2-pin natural color coupler)
21.  Stopper (headlight stay)
22.  Wire harness (3-pin natural color coupler)
23.  Wire harness (4-pin natural color coupler)
A.  Clamp near the end of bent handlebar section 
using a clamp.
B.  Route the handlebar switch right lead and front 
brake switch lead through the side of main 
switch, and extend to the side of head pipe.
C.  Place the clutch cable in the right position. The 
others can be in any position.
D.  Pass the throttle cable between the cable 
guides of right turn signal light stay and meter 
stay.
E.  Place the lead in the hose so that bare conduc-
tors are not exposed.
F.  Pass the left handlebar switch lead above the 
meter lead (3-pin natural color coupler) as 
shown, and connect them to the headlight 
assembly.
G.  Pass the wire harness, clutch cable, clutch 
switch lead and handlebar switch left lead 
through the wire guide. Route the clutch cable 
in the top position. The others can be in any 
position.
H.  Pass the throttle cable, front brake switch lead, 
right handlebar switch lead, and main switch 
lead through the wire guide. Place the throttle 
cable in the top position. The others can be in 
any position.
I.  Route the main switch lead upward to the side 
of head pipe. Do not route the main switch lead 
to the outside of meter stay cable guide.
J.  Pass the right front turn signal light lead through 
headlight cowling stay as shown, and then 
through the inside of meter stay cable guide 
from behind the throttle cable, and connect 
them inside of the meter.
K.  Fasten the right and left front turn signal light 
lead and wire harnesses using a cable tie. 
Insert the cable tie into the meter stay, and face 
the lock downward. Cut and remove an excess 
if any.
L.  Insert the meter lead (3-pin natural color cou-
pler) under the meter stay, and connect them.M.  Route the left front turn signal light lead above 
the meter lead from behind the handlebar 
switch left lead, and connect them at the meter 
position.
N.  Insert the wire harness clamps by inserting the 
two harness clamps into the hole of the meter 
stay.
O.  Install the left handlebar switch lead by inserting 
them into the space at the side of meter stay.
P.  Pass the front left turn signal light lead through 
headlight cowling stay as shown, and then 
through the abobe of meter lead (3-pin black) 
from behind the handlebar switch lead (3-pin 
black), and connect them inside of the meter. 
						

							 
Front rear brake hose 
2-39 
Front rear brake hose 
						

							 
Front rear brake hose 
2-40 
1.  Front brake hose
2. Hose guide
3. Union bolt
4. Copper washer
5.  Front brake caliper assembly
6.  Rear brake disc
7.  Rear brake caliper assembly
8. Copper washer
9. Union bolt
10.  Rear brake hose
11.  Rear brake master cylinder
12.  Rear brake switch
13. Brake pedal 
						

							 
Throttle body 
2-41 
Throttle body 
						

							 
Throttle body 
2-42 
1. Breather hose
2. Air filter case assembly
3. Pipe
4.  Throttle body assembly
5.  Radiator inlet hose
6. Radiator
7.  Throttle body joint
8. FID hose
9. Vacuum hose
10. Pressure sensor
11. Bend hose
12.  ITS boost hose
13.  Air induction system hose
14. Surge tank
A.  Face the white paint upward of the vehicle.
B.  Face the white paint mark to the right side of vehi-
cle.
C.  Face the clip holder to the right front of vehicle.
D.  Face the clip holder upward of the vehicle.
E.  Face the white paint mark backward of the vehi-
cle.
F.  Face the clip holder to the front side of vehicle.
G.  Align the throttle body joint with the hose clamp.
H.  Face the white paint mark to the left side of vehi-
cle.
I.  Insert the IST boost hose into position until it is 
stopped.
J.  Install the vacuum hose to the air-filter case until it 
is stopped.
K.  Face the yellow paint mark to the left of vehicle.
L.  Connect the tank surge hose until it is stopped. 
						

							 
Canister (for California) 
2-43 
Canister (for California)
5mm (0.20 in)45˚ 
						

							 
Canister (for California) 
2-44 
1. Fuel tank
2.  Hose (Fuel tank 
– 
roll over valve)
3. Canister cover
4. Canister
5.  A.C. magneto lead
6.  Neutral switch lead
7.  Recovery tank hose
8.  Roll over valve
9. Holder
10. Hose
11. Clip
A.  Face the clip end forward of the vehicle.
B.  Face the clip end backward of the vehicle.
C.  Pass the hose (roll over valve 
– 
canister) between 
the engine head and air cut-off valve assembly.
D.  Route the hose (canister 
– 
throttle body) to the up 
side of the FID hose, and then route it to the 
inside the clutch wire.
E.  Hold the hose (canister 
– 
throttle body) through the 
2 clamps securely.
F.  Fasten the A.C. magneto lead, neutral switch 
lead, recovery tank hose, and the hose (roll over 
valve 
– 
canister) using the clamp. Install the clamp 
to T stud of the down tube securely.
G.  Fasten the recovery tank hose and the hose (roll 
over 
– 
canister). Install the clamp to T stud of the 
down tube. Face the lock part forward of the vehi-
cle.
H.  Align the paint mark with the projection of the bot-
tom of the roll over valve.
I.  Face the paint leftward of the vehicle.
J.  Face the clip end downward of the vehicle.
K.  From the roll over valve.
L.  To the throttle body.
M.  Face the paint upward of the vehicle.
N.  Align the slot of the damper with the pipe of the 
throttle body side.
O.  Insert the projection of the canister damper to the 
hole of canister cover.
P.  Face the clip end upward of the vehicle.
Q.  When the canister cover install, you may spread 
the soapy water to the damper as shown. How-
ever, do not spread the soapy water to the projec-
tion of the damper and the hole of the canister 
cover. 
						

							 
Canister (for California) 
2-45