Yamaha Wr250 Service Manual 1992
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DESCRIPTION:
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’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, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
This manual will provide you with a good basic understanding of features, Operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please con- sult your Yamaha dealer.
All of the procedures in this manual are organized in a sequential, step-by-step format. The information 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.
TABLE OF CONTENTS:
Yamaha Wr250 Service Manual 1992
DESCRIPTION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
(For USA,CDN andAUSi
FRAME SERIAL NUMBER
(Except for USA, CON and AUSI
ENGINE SERIAL NUMBER
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
AND DISASSEMBLY
ALL REPLACEMENT PARTS
GASKETS, OIL SEALS AND
O-RINGS
LOCK WASHERS/PLATES AND
COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
SPECIALTOOLS
FOR TUNEUP
FOR ENGINE SERVICE
FOR CHASSIS SERVICE
FOR ELECTRICAL SERVICE
CONTROL FUNCTIONS
“ENGINE STOP” BUTTON
CLUTCH LEVER
SHIFT PEDAL
KICK STARTER
THROTTLE GRIP
FRONTBRAKE LEVER
REAR BRAKE PEDAL
FUEL COCK
STARTER KNOB (CHOKE)
AIR FILTER CASE COVER
FUEL AND ENGINE MIXING OIL
PRE-OPERATION CHECK LIST
STARTING AND BREAK-IN
STARTING A COLD ENGINE
STARTING A WARM ENGINE
BREAK-IN PROCEDURES
TORQUE-CHECK POINTS
CLEANING AND STORAGE
CLEANING
STORAGE
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
Engine
Chasis
Electrical
GENERAL TORQUE
SPECIFICATIONS
DEFINITION OF UNITS
CABLE ROUTING DIAGRAM
SETTING PARTS
CARBURETOR
DRIVE AND DRIVEN SPROCKETS
FRONT FORK
REAR SHOCK ABSORBER 2
HANDLE CROWN AND LOWER
HOLDER
CHAPTER 3
REGULAR INSPECTION
AND
ADJUSTMENTS
MAINTENANCE INTERVALS
COOLANT LEVEL INSPECTION
COOLANT REPLACEMENT
RADIATOR CAP INSPECTION
RADIATOR CAP OPENING
PRESSURE INSPECTION
COOLING SYSTEM INSPECTION
CLUTCH ADJUSTMENT
THROTTLE CABLE ADJUSTMENT
AIR FILTER CLEANING
TRANSMISSION OIL LEVEL
CHECK
TRANSMISSION OIL
REPLALCEMENT
AIR SCREW ADJUSTMENT
IDLE SPEED ADJUSTMENT
BRAKE SYSTEM AIR BLEEDING
FRONT BRAKE ADJUSTMENT
BRAKE PAD INSPECTION
BRAKE FLUID LEVEL INSPECTION
REAR BRAKE ADJUSTMENT
SPROCKETS INSPECTION
DRIVE CHAIN INSPECTION
DRIVE CHAIN SLACK
ADJUSTMENT
FRONT FORK INSPECTION
FRONT FORK OIL SEAL AND
DUST SEAL CLEANING
FRONT FORK REBOUND DAMPING
FORCE ADJUSTMENT
FRONT FORK COMPRESSION
DAMPING FORCE ADJUSTMENT
RER SHOCK ABSORBER
INSPECTION
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
REAR SHOCK ABSORBER REBOUNI
DAMPING FORCE ADJUSTMENT
REAR SHOCK ABSORBER
COMPRESSION DAMPING FORCE
ADJUSTMENT
TIRE PRESSURE CHECK
SPOKES INSPECTION AND
TIGHTENING
WHEEL INSPECTION
STEERING HEAD INSPECTION AND
ADJUSTMENT
SILENCER FIBER REPLACEMENT
LUBRICATION
SPARK PLUG INSPECTION
IGNITION TIMING CHECK
SEAT FUEL TANK, SIDE COVERS
EXHAUST PIPE AND SILENCER
PREPARATION FOR REMOVAL
RADIATOR HOSES
PREPARATION FOR REMOVAL
CARBURETOR AND REED VALVE
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY-
REMOVALPOINTS
ThrottIeVaIve
INSPECTION
Carburetor
NeedIeVaIve
ThrottIeValve
FloatArm Height
Float
ReedValve
ASSEMBLY AND INSTALLATION
ReadValve
Carburetor
Carburetorlnstallation
CYLINDER HEAD, CYLINDER AND
PISTON
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVALPOINTS
PushRod
Piston and Piston Ring
PowerValve
INSPECTION
CylinderHead
Cylinder
Piston
Piston Pin and Small End Bearing
Piston Ring
Piston Clearance
Combination of Piston and
Cylinder-
PowerValve
Power Valve Hole on Cylinder
ASSEMBLY AND INSTALLATION
PowerValve
Piston Ring and Piston
Cylinder Head and Cylinder
CLUTCH AND PRIMARY DRIVEN
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Clutch Boss
INSPECTION
Clutch Housing and Boss
Primary Driven Gear
Clutch Spring
Friction Plate
Clutch Plate
Push Rod Axle
ASSEMBLY AND INSTALLATION
Clutch
KICK AXLE, SHIFT SHAFT AND
PRIMARY DRIVE GEAR
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Primary Drive Gear
Kick Axle Assembly
Shift Guide and Shift Lever
Assembly
INSPECTION
Kick Axle and Kick Gear
Kick Gear and Kick Idle Gear
Kick GearClip
ShiftShaft
Shift Guide and Shift Lever
Assembly
StopperLever
Primary Drive Gear and
Driven Gear
ASSEMBLY AND INSTALLATION
StopperLever
Shift Guide and Shift Lever
Assembly
ShiftShaft
KickAxIeAssemny
KIckAxIe
Primary Drive Gear
YPVS GOVERNOR
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Governor
INSPECTION
Governor Groove
ASSEMBLY AND INSTALLATION
Governor
CDI MAGNETO
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Rotor
INSPECTION
CDI Magneto
ASSEMBLY AND INSTALLATION-
CDI Magneto
ENGINE REMOVAL
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY-
REMOVAL POINTS
Drive Sprocket
Brake Pedal
Engine Removal‘
ASSEMBLY AND INSTALLATION
Engine Installation
CRANKCASE AND CRANKSHAFT
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Segment
Crankcase
INSPECTION
Crankcase
Crankshaft
PushAxle
ASSEMBLY AND INSTALLATION
Crankshaft
TRANSMISSION, SHIFT CAM AND
SHFTFORK
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVALPOINTS
Transmission
INSPECTION
Gears
Bearing
Shift Fork, Shift Cam and
Segment
ASSEMBLY AND INSTALLATION
Transmission
Shift Cam and Shift Fork
RADIATOR AND WATER PUMP
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS-
Radiator
Impeller Shaft
Oil Seal
INSPECTION
Radiator
ImpellerShaft
ImpellerShaftGear
Oil Seal
ASSEMBLY AND INSTALLATION
Oil Seal
Impeller Shaft
Radiator
CHAPTER 5
CHASSIS
FRONTWHEEL
PREPARATION FOR REMOVAL
REMOVAL POINTS
Wheel Bearing (If Necessary)
INSPECTION
FrontWheel
ASSEMBLY
FrontWheel
INSTALLATION
FrontWheel
REARWHEEL
PREPARATION FOR REMOVAL
REMOVAL POINTS
RearWheeI
Wheel Bearing (If Necessary)
INSPECTION
RearWheeI
ASSEMBLY AND INSTALLATION
RearWheeI
FRONT BRAKE
PREPARATION FOR REMOVAL
REMOVAL POINTS
Caliper
CaliperPiston
Piston Seal KIt
MasterCylinderKit
INSPECTION
MasterCylinder
Caliper
Brake Disc
BrakeHose
ASSEMBLY AND INSTALLATION
Caliper Piston
Caiiper
MasterCyIinderKit
MasterCylinder
BrakeDisc
Brake Pad Replacement
Brake Fluid
REAR BRAKE
PREPARATION FOR REMOVAL
REMOVAL POINTS-
Caliper
Caliper Piston
Piston Seal Krt
Brake Pedal
MasterCyIinder Kit
INSPECTION
MasterCylinder
Caliper
Brake Disc
BrakeHose
ASSEMBLY AND INSTALLATION
CaliperPiston
Caliper
MasterCylinderKit
MasterCylinder
BrakeDisc
Brake Pad Replacement
Brake Fluid
FRONTFORK
PREPARATION FOR REMOVAL
REMOVALPOINTS
Cap Bolt
Handling Note
BaseValve
OilSeal
INSPECTION
Rod Assembly-
BaseVaIve
InnerTube
OuterTube
Cap Bolt
ASSEMBLY AND INSTALLATION
Front Fork Assembly
Installation
STEERING
PREPARATION FOR REMOVAL
REMOVALPOINTS
Steering ShaftNut
Ring Nut
INSPECTION
Bearing
Steering Shaft
ASSEMBLY AND INSTALLATION
UnderBracket
Handlebar Lower Holder
SWINGARM
PREPARATION FOR REMOVAL
NOTE ON REMOVAL AND
REASSEMBLY
REMOVAL POINTS
Swingarm
INSPECTION
Swingarm
RelayArm
Swingarm Side Clearance
ASSEMBLY AND INSTALLATION
Swingarm
REAR SHOCK ABSORBER
PREPARATION FOR REMOVAL
NOTES ON DISPOSAL (YAMAHA
DEALERS ONLY)
REMOVAL POINTS
Rear Shock Absorber
Spring (Rear Shock Absorber)
INSPECTION
Damper Rod/Shock Absorber]
Spring/Spring Guide
ASSEMBLY AND INSTALLATION
Spring (Rear Shock Absorber]
Rear Shock Absorber
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM
ELECTRICAL COMPONENTS –
WIRING DIAGRAM
IGNITION SYSTEM
INSPECTION STEPS
SPARK GAP TEST
COUPLERS AND LEADS
CONNECTION INSPECTION
“ENGINE STOP” BUTTON
INSPECTION
IGNITION COIL INSPECTION
CDI MAGNETO INSPECTION
CDI UNIT INSPECTION
CHAPTER 7
TUNING
CARBURETOR TUNING
SPARK PLUG
GEARING
SUSPENSION TUNING
INTRODUCTION
FRONTFORK
REAR SHOCK
TROUBLESHOOTING IMPROPER
SETTINGS
SYMPTOMS OF THE FRONT
FORKS
SYMPTOMS OF THE REAR
SHOCK
READJUSTMENT OF THE
SUSPENSION
FRONT AND REAR
COMPATIBILITY
GENERAL SYMPTOMS AND
REMEDY
HANDLEBAR POSITION
SETTING RECORD TABLE
FILE FORMAT:
LANGUAGE:ENGLISH
PAGES:269
DOWNLOADABLE:YES
FILE TYPE:PDF
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