Yamaha Wr250r 2008 Manual

							 
SPECIAL TOOLS 
1-12 
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-910445-63
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-016-2
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-339846-2
Steering nut wrench
90890-01403
Spanner wrench
YU-339753-25
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-93-4
Fork seal driver
90890-01442
Adjustable fork seal driver (36 
– 
46 mm)
YM-014424-45  
Tool name/Tool No. IllustrationReference
pages
YM-91044
YU-24460-01 
						

							 
SPECIAL TOOLS 
1-13 
Damper rod holder
90890-014544-42, 4-44
Spoke nipple wrench (8 
– 
9)
90890-01522
YM-015223-31
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A5-53, 5-54
Compression gauge
90890-03081
Engine compression tester
YU-332233-9
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C1-10, 5-32, 
8-65, 8-66, 
8-67, 8-71, 
8-72, 8-73, 
8-74, 8-75, 
8-76, 8-77, 
8-78, 8-79, 
8-81
Timing light
90890-03141
Inductive clamp timing light
YU-031413-9
Pressure gauge
90890-03153
YU-031537-6
Vacuum/pressure pump gauge set
90890-06756
Mityvac brake bleeding tool
YS-424237-6  
Tool name/Tool No. IllustrationReference
pages 
						

							 
SPECIAL TOOLS 
1-14 
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A19277-7, 8-80, 8-81
Fuel pressure adapter
90890-03176
YM-031767-6
Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-040586-7
Mechanical seal installer
90890-041456-7
Universal clutch holder
90890-04086
YM-910425-38, 5-40
Valve lapper
90890-04101
Valve lapping tool
YM-A89983-5
Valve spring compressor
90890-04019
YM-040195-18, 5-23  
Tool name/Tool No. IllustrationReference
pages 
						

							 
SPECIAL TOOLS 
1-15 
Valve guide remover ( 
ø 
4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-041165-20
Valve guide installer (4.5 
ø 
)
90890-04117
YM-041175-20
Valve guide reamer (4.5 
ø 
)
90890-04118
YM-041185-20
Rotor puller
90890-04142
YM-041425-53
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-344878-74
Digital tachometer
90890-06760
YU-39951-B3-6, 3-9
Yamaha bond No. 1215 (Three Bond 
No.1215®)
90890-855055-60  
Tool name/Tool No. IllustrationReference
pages 
						

							 
1
2
3
4
5
6
7
8
9
 
SPECIFICATIONS 
GENERAL SPECIFICATIONS .......................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS.........................................................................2-9
ELECTRICAL SPECIFICATIONS ..................................................................2-12
TIGHTENING TORQUES ...............................................................................2-15 
GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-15
ENGINE TIGHTENING TORQUES..........................................................2-15
CHASSIS TIGHTENING TORQUES........................................................2-17 
LUBRICATION POINTS AND LUBRICANT TYPES .....................................2-21 
ENGINE....................................................................................................2-21
CHASSIS..................................................................................................2-22 
LUBRICATION SYSTEM CHART AND DIAGRAMS ....................................2-25 
LUBRICATION DIAGRAMS .....................................................................2-25 
COOLING SYSTEM DIAGRAMS...................................................................2-29
CABLE ROUTING ..........................................................................................2-31
Front rear brake hose ...................................................................................2-39
Throttle body .................................................................................................2-41
Canister (for California)................................................................................2-43 
						

							 
GENERAL SPECIFICATIONS 
2-1 
EAS20280 
GENERAL SPECIFICATIONS 
Model 
Model WR250R 32C1 (U49)
WR250R 32C3 (CAL)
WR250X 32C2 (U49)
WR250X 32C4 (CAL) 
Dimensions 
Overall length WR250R 2175 mm (85.6 in)
WR250X 2110 mm (83.1 in)
Overall width 810 mm (31.9 in)
Overall height WR250R 1230 mm (48.4 in)
WR250X 1190 mm (46.9 in)
Seat height WR250R 930 mm (36.6 in)
WR250X 895 mm (35.2 in)
Wheelbase WR250R 1420 mm (55.9 in)
WR250X 1425 mm (56.1 in)
Ground clearance WR250R 295 mm (11.61 in) (CAL)
WR250R 300 mm (11.81 in) (U49)
WR250X 260 mm (10.24 in) (CAL)
WR250X 265 mm (10.43 in) (U49)
Minimum turning radius 2300 mm (90.6 in) 
Weight 
With oil and fuel WR250R 134.0 kg (295 lb) (U49)
WR250R 135.0 kg (298 lb) (CAL)
WR250X 136.0 kg (300 lb) (U49)
WR250X 137.0 kg (302 lb) (CAL)
Maximum load 185 kg (408 lb) 
						

							 
ENGINE SPECIFICATIONS 
2-2 
EAS20290 
ENGINE SPECIFICATIONS 
Engine 
Engine type Liquid cooled 4-stroke, DOHC
Displacement 250.0 cm 
3
 
Cylinder arrangement Forward-inclined single cylinder
Bore  
× 
 stroke 77.0  
×  
 53.6 mm (3.03   
×  
 2.11 in)
Compression ratio 11.80 :1
Starting system Electric starter 
Fuel 
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity WR250R 7.2 L (1.90 US gal) (1.58 Imp.gal) 
(CAL)
 WR250R 7.6 L (2.01 US gal) (1.67 Imp.gal) 
(U49)
 WR250X 7.2 L (1.90 US gal) (1.58 Imp.gal) 
(CAL)
 WR250X 7.6 L (2.01 US gal) (1.67 Imp.gal) 
(U49)
Fuel reserve amount 2.1 L (0.55 US gal) (0.46 Imp.gal) 
Engine oil 
Lubrication system Wet sump
Type YAMALUBE 4, SAE 10W-30 or SAE 20W-40
Recommended engine oil grade API service SG type or higher, JASO standard 
MA
Engine oil quantity
Total amount 1.50 L (1.59 US qt) (1.32 Imp.qt)
Without oil filter element replacement 1.30 L (1.37 US qt) (1.14 Imp.qt)
With oil filter element replacement 1.40 L (1.48 US qt) (1.23 Imp.qt)
Oil filter type Paper 
Oil pump 
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.120 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.090 
–  
0.160 mm (0.0035  
–  
0.0063 in)
Limit 0.230 mm (0.0091 in) 
Oil-pump-housing-to-inner-and-outer-rotor clearance
 
0.030-0.100 mm (0.0012-0.0039 in)
Limit 0.17 mm (0.0067 in)
Bypass valve opening pressure 500.0 
–  
600.0 kPa (72.5  
–  
87.0 psi) (5.00  
–  
6.00 
kgf/cm 
2
 
) 
Cooling system 
Radiator capacity (including all routes) 0.90 L (0.95 US qt) (0.79 Imp.qt)
Radiator capacity 0.32 L (0.34 US qt) (0.28 Imp.qt) 
Coolant reservoir capacity (up to the maximum level mark)
 
0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator cap opening pressure 108.0 
– 
137.4 kPa (15.7 
–  
19.9 psi) (1.08  
–  
1.37 
kgf/cm 
2
 
)
Radiator core
Width 121.4 mm (4.78 in)
Height 246.0 mm (9.69 in)
Depth 28.0 mm (1.10 in) 
						

							 
ENGINE SPECIFICATIONS 
2-3 
Spark plug (s) 
Manufacturer/model NGK/CR9EK
Spark plug gap 0.6 
–  
0.7 mm (0.024  
–  
0.028 in) 
Cylinder head 
Volume 15.36 cm 
3
 
 (0.94 cu.in)
Warpage limit 0.05 mm (0.0020 in) 
Camshaft 
Drive system Chain drive (left)
Camshaft cap inside diameter 22.000 
–  
22.021 mm (0.8661  
–  
0.8670 in)
Camshaft journal diameter 21.959 
–  
21.972 mm (0.8645  
–  
0.8650 in)
Camshaft-journal-to-camshaft-cap clearance 0.028 
–  
0.062 mm (0.0011  
–  
0.0024 in)
Limit 0.08 mm (0.0031 in)
Camshaft lobe dimensions
Intake A 34.550 
–  
34.650 mm (1.3602  
–  
1.3642 in)
Limit 35.450 mm (1.3957 in)
Intake B 25.953 
–  
26.053 mm (1.0218  
–  
1.0257 in)
Limit 25.853 mm (1.0178 in)
Exhaust A 34.850 
–  
34.950 mm (1.3720  
–  
1.3760 in)
Limit 34.750 mm (1.3681 in)
Exhaust B 25.986 
– 
26.086 mm (1.0231 
–  
1.0270 in)
Limit 25.886 mm (1.0191 in)
Camshaft runout limit 0.015 mm (0.0006 in) 
Timing chain 
Model/number of links 98XRH2010-118M
Tensioning system Automatic 
 Valve, valve seat, valve guide 
Valve clearance (cold)
Intake 0.13 
– 
0.20 mm (0.0051 
–  
0.0079 in)
Exhaust 0.23 
– 
0.30 mm (0.0091 
–  
0.0118 in)
Valve dimensions
Valve head diameter A (intake) 29.90 
– 
30.10 mm (1.1772 
–  
1.1850 in)
Valve head diameter A (exhaust) 24.40 
– 
24.60 mm (0.9606 
–  
0.9685 in)
A
B 
						

							 
ENGINE SPECIFICATIONS 
2-4 
Valve face width B (intake) 1.840 mm (0.0724 in)
Valve face width B (exhaust) 2.260 mm (0.0890 in)
Valve seat width C (intake) 0.90 
–  
1.10 mm (0.0354  
–  
0.0433 in)
Valve seat width C (exhaust) 0.90 
–  
1.10 mm (0.0354  
–  
0.0433 in)
Valve margin thickness D (intake) 1.15 
–  
1.45 mm (0.0453  
–  
0.0571 in)
Limit 1.00 mm (0.04 in)
Valve margin thickness D (exhaust) 0.85 
–  
1.15 mm (0.0335  
–  
0.0453 in)
Limit 0.70 mm (0.03 in)
Valve stem diameter (intake) 4.475 
–  
4.490 mm (0.1762  
–  
0.1768 in)
Valve stem diameter (exhaust) 4.460 
–  
4.475 mm (0.1756  
–  
0.1762 in)
Valve guide inside diameter (intake) 4.500 
–  
4.512 mm (0.1772  
–  
0.1776 in)
Valve guide inside diameter (exhaust) 4.500 
–  
4.512 mm (0.1772  
–  
0.1776 in)
Valve-stem-to-valve-guide clearance (intake) 0.010 
– 
0.037 mm (0.0004 
–  
0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025 
– 
0.052 mm (0.0010 
–  
0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Cylinder head valve seat width (intake) 0.90 
– 
1.10 mm (0.0354 
–  
0.0433 in)
Cylinder head valve seat width (exhaust) 0.90 
– 
1.10 mm (0.0354 
–  
0.0433 in) 
Valve spring 
Free length (intake) 36.03 mm (1.42 in)
Limit 34.23 mm (1.35 in)
Free length (exhaust) 36.03 mm (1.42 in)
Limit 34.23 mm (1.35 in)
Installed length (intake) 31.00 mm (1.22 in)
Installed length (exhaust) 31.00 mm (1.22 in)
Spring rate K1 (intake) 31.47 N/mm (179.69 lb/in) (3.21 kgf/mm)
A
B
C
D 
						

							 
ENGINE SPECIFICATIONS 
2-5 
Spring rate K2 (intake) 40.90 N/mm (233.54 lb/in) (4.17 kgf/mm)
Spring rate K1 (exhaust) 31.47 N/mm (179.69 lb/in) (3.21 kgf/mm)
Spring rate K2 (exhaust) 40.90 N/mm (233.54 lb/in) (4.17 kgf/mm)
Installed compression spring force (intake) 147.00 
–  
169.00 N (33.05  
–  
37.99 lbf) 
(14.99  
–  
17.23 kgf)
Installed compression spring force (exhaust) 147.00 
–  
169.00 N (33.05  
–  
37.99 lbf) 
(14.99  
–  
17.23 kgf)
Spring tilt (intake) 2.5  
°/  
1.6 mm
Spring tilt (exhaust) 2.5  
°/  
1.6 mm
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise 
Cylinder 
Bore 77.000 
–  
77.010 mm (3.0315  
–  
3.0319 in)
Wear limit 77.100 mm (3.0354 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in) 
Piston 
Piston-to-cylinder clearance 0.010 
–  
0.035 mm (0.0004  
–  
0.0014 in)
Limit 0.10 mm (0.0039 in)
Diameter D 76.975 
–  
76.990 mm (3.0305  
–  
3.0311 in)
Height H 12.0 mm (0.47 in)
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 17.002 
–  
17.013 mm (0.6694  
–  
0.6698 in)
Limit 17.043 mm (0.6710 in)
Piston pin outside diameter 16.991 
– 
17.000 mm (0.6689 
–  
0.6693 in)
Limit 16.971 mm (0.6681 in)
Piston-pin-to-piston- pin-bore clearance 0.002 
– 
0.022 mm (0.0001 
–  
0.0009 in)
H
D