LIT-11626-25-12

1HC-28199-11

OWNER’S SERVICE MANUAL

WR250FB

Read this manual carefully before operating this vehicle.

2012

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

WR250FB

OWNER'S SERVICE MANUAL

©2011 by Yamaha Motor Corporation, U.S.A.

1st Edition, April 2011

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation U.S.A.

is expressly prohibited.

Printed in Japan

P/N. LIT-11626-25-12

INTRODUCTION

Congratulations on your purchase of a Yamaha

WR series. This model is the culmination of Ya-

maha's vast experience in the production of

pacesetting racing machines. It represents the

highest grade of craftsmanship and reliability

that have made Yamaha a leader.

This manual explains operation, inspection, ba-

sic maintenance and tuning of your machine. If

you have any questions about this manual or

your machine, please contact your Yamaha

dealer.

The design and manufacture of this Yamaha

machine fully comply with the emissions stan-

dards for clean air applicable at the date of

manufacture. Yamaha has met these stan-

dards without reducing the performance or

economy of operation of the machine. To main-

tain these high standards, it is important that

you and your Yamaha dealer pay close atten-

tion to the recommended maintenance sched-

ules and operating instructions contained

within this manual.

Yamaha continually seeks advancements in

product design and quality. Therefore, while

this manual contains the most current product

information available at the time of printing,

there may be minor discrepancies between

your machine and this manual. If you have any

questions concerning this manual, please con-

sult your Yamaha dealer.

PLEASE READ THIS MANUAL CAREFULLY

AND COMPLETELY BEFORE OPERATING

THIS MACHINE. DO NOT ATTEMPT TO OP-

ERATE THIS MACHINE UNTIL YOU HAVE

ATTAINED A SATISFACTORY KNOWL-

EDGE OF ITS CONTROLS AND OPERATING

FEATURES AND UNTIL YOU HAVE BEEN

TRAINED IN SAFE AND PROPER RIDING

TECHNIQUES. REGULAR INSPECTIONS

AND CAREFUL MAINTENANCE, ALONG

WITH GOOD RIDING SKILLS, WILL ENSURE

THAT YOU SAFETY ENJOY THE CAPABILI-

TIES AND THE RELIABILITY OF THIS MA-

CHINE.

IMPORTANT MANUAL

INFORMATION

Particularly important information is distin-

guished in this manual by the following nota-

tions.

This is the safety alert symbol. It is used to

alert you to potential personal injury haz-

ards. Obey all safety messages that follow

this symbol to avoid possible injury or

death.

A WARNING indicates a hazardous situa-

tion which, if not avoided, could result in

death or serious injury.

A NOTICE indicates special precautions

that must be taken to avoid damage to the

vehicle or other property.

A TIP provides key information to make proce-

dures easier or clearer.

SAFETY INFORMATION

THIS MACHINE IS DESIGNED STRICTLY

FOR OFF-ROAD USE ONLY. It is illegal for this

machine to be operated on any public street,

road, or highway. Off-road use on public lands

may also be illegal. Please check local regula-

tions before riding.

• THIS MACHINE IS TO BE OPERATED BY

AN EXPERIENCED RIDER ONLY.

Do not attempt to operate this machine at

maximum power until you are totally familiar

with its characteristics.

• THIS MACHINE IS DESIGNED TO BE RID-

DEN BY THE OPERATOR ONLY.

Do not carry passengers on this machine.

• ALWAYS WEAR PROTECTIVE APPAREL.

When operating this machine, always wear an

approved helmet with goggles or a face

shield. Also wear heavy boots, gloves, and

protective clothing. Always wear proper fitting

clothing that will not be caught in any of the

moving parts or controls of the machine.

• ALWAYS MAINTAIN YOUR MACHINE IN

PROPER WORKING ORDER.

For safety and reliability, the machine must be

properly maintained. Always perform the pre-

operation checks indicated in this manual.

Correcting a mechanical problem before you

ride may prevent an accident.

• GASOLINE IS HIGHLY FLAMMABLE.

Always turn off the engine while refueling.

Take care to not spill any gasoline on the en-

gine or exhaust system. Never refuel in the vi-

cinity of an open flame, or while smoking.

• GASOLINE CAN CAUSE INJURY.

If you should swallow some gasoline, inhale

excess gasoline vapors, or allow any gasoline

to get into your eyes, contact a doctor imme-

diately. If any gasoline spills onto your skin or

clothing, immediately wash skin areas with

soap and water, and change your clothes.

• ONLY OPERATE THE MACHINE IN AN

AREA WITH ADEQUATE VENTILATION.

Never start the engine or let it run for any

length of time in an enclosed area. Exhaust

fumes are poisonous. These fumes contain

carbon monoxide, which by itself is odorless

and colorless. Carbon monoxide is a danger-

ous gas which can cause unconsciousness or

can be lethal.

• PARK THE MACHINE CAREFULLY; TURN

OFF THE ENGINE.

Always turn off the engine if you are going to

leave the machine. Do not park the machine

on a slope or soft ground as it may fall over.

• THE ENGINE, EXHAUST PIPE, MUFFLER,

AND OIL TANK WILL BE VERY HOT AFTER

THE ENGINE HAS BEEN RUN.

Be careful not to touch them or to allow any

clothing item to contact them during inspec-

tion or repair.

• PROPERLY SECURE THE MACHINE BE-

FORE TRANSPORTING IT.

When transporting the machine in another ve-

hicle, always be sure it is properly secured

and in an upright position and that the fuel

cock is in the "OFF" position. Otherwise, fuel

may leak out of the carburetor or fuel tank.

YAMAHA MOTOR CORPORATION, U.S.A.

WR MOTORCYCLE LIMITED WARRANTY

HOW TO USE THIS MANUAL

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec-

tion and adjustments", "Tuning", "Engine", "Chassis" and "Electrical".

2. The table of contents is at the beginning of the manual. Look over the general layout of the book

before finding then required chapter and item.

Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page

for required item and description.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been complied to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.,

• Bearings

Pitting/damage →Replace.

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs.

2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

"3". The meanings of the symbol marks are given on the next page.

4. A job instruction chart "4" accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements "5" are given in addition

to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS (Refer

to the illustration)

Illustrated symbols "1" to "7" are used to identi-

fy the specifications appearing in the text.

1.

With engine mounted

2.

Filling fluid

3.

Lubricant

4.

Special tool

5.

Tightening

6.

Specified value, Service limit

7.

Resistance (Ω), Voltage (V), Electric cur-

rent (A)

Illustrated symbols "8" to "13" in the exploded

diagrams indicate grade of lubricant and loca-

tion of lubrication point.

8.

Apply engine oil

9.

Apply molybdenum disulfide oil

10. Apply brake fluid

11. Apply lightweight lithium-soap base grease

12. Apply molybdenum disulfide grease

13. Apply silicone grease

Illustrated symbols "14" to "15" in the exploded

diagrams indicate where to apply a locking

agent and where to install new parts.

14. Apply locking agent (LOCTITE^®)

15. Use new one

MEMO

TABLE OF CONTENTS

GENERAL INFORMATION

1

SPECIFICATIONS

2

REGULAR INSPECTION AND

ADJUSTMENTS

3

TUNING

4

ENGINE

5

CHASSIS

6

ELECTRICAL

7

CONTENTS

CHAPTER 1

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS ..... 1-1

DESCRIPTION ........................................... 1-2

CONSUMER INFORMATION .................... 1-3

INCLUDED PARTS.................................... 1-4

IMPORTANT INFORMATION.................... 1-5

CHECKING OF CONNECTION ................. 1-7

SPECIAL TOOLS....................................... 1-8

CONTROL FUNCTIONS.......................... 1-12

MULTI-FUNCTION DISPLAY .................. 1-15

STARTING AND BREAK-IN.................... 1-22

TORQUE-CHECK POINTS...................... 1-25

CLEANING AND STORAGE ................... 1-26

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS................... 2-1

MAINTENANCE SPECIFICATIONS.......... 2-4

TIGHTENING TORQUES......................... 2-14

LUBRICATION DIAGRAMS .................... 2-22

CABLE ROUTING DIAGRAM.................. 2-26

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM ....... 3-1

GENERAL MAINTENANCE AND

LUBRICATION CHART ............................. 3-2

MAINTENANCE INTERVALS FOR

COMPETITION USE .................................. 3-4

PRE-OPERATION INSPECTION AND

MAINTENANCE ......................................... 3-9

ENGINE.................................................... 3-10

CHASSIS.................................................. 3-27

ELECTRICAL........................................... 3-45

CHAPTER 4

TUNING

CHASSIS.................................................... 4-1

CHAPTER 5

ENGINE

RADIATOR................................................. 5-1

CARBURETOR .......................................... 5-5

AIR INDUCTION SYSTEM....................... 5-16

CAMSHAFTS ........................................... 5-18

CYLINDER HEAD .................................... 5-26

VALVES AND VALVE SPRINGS ............ 5-30

CYLINDER AND PISTON ........................ 5-37

CLUTCH................................................... 5-42

OIL FILTER ELEMENT AND WATER

PUMP ....................................................... 5-49

BALANCER ............................................. 5-55

OIL PUMP ................................................ 5-58

KICK SHAFT AND SHIFT SHAFT........... 5-63

AC MAGNETO AND STARTER

CLUTCH................................................... 5-69

ENGINE REMOVAL................................. 5-76

CRANKCASE AND CRANKSHAFT........ 5-82

TRANSMISSION, SHIFT CAM AND

SHIFT FORK ............................................ 5-90

CHAPTER 6

CHASSIS

FRONT WHEEL AND REAR WHEEL ....... 6-1

FRONT BRAKE AND REAR BRAKE...... 6-10

FRONT FORK .......................................... 6-24

HANDLEBAR........................................... 6-35

STEERING ............................................... 6-42

SWINGARM ............................................. 6-48

REAR SHOCK ABSORBER.................... 6-55

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS AND

WIRING DIAGRAM .................................... 7-1

IGNITION SYSTEM.................................... 7-3

ELECTRIC STARTING SYSTEM............... 7-7

CHARGING SYSTEM .............................. 7-15

THROTTLE POSITION SENSOR

SYSTEM................................................... 7-17

LIGHTING SYSTEM................................. 7-21

SIGNALING SYSTEM.............................. 7-23

1-1

LOCATION OF IMPORTANT LABELS

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.

1