Yamaha Wr250r 2008 Manual
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TIGHTENING TORQUES 2-16 Timing chain guide bolt M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb) Plate (impeller shaft side) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil filter element cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil pump bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil pump cover bolt – 1 2 Nm (0.2 m•kg, 1.4 ft•lb) Oil strainer housing bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Delivery pipe bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Throttle body joint clamp screw M5 2 3 Nm (0.3 m•kg, 2.2 ft•lb) Air filter clamp screw M4 1 2 Nm (0.2 m•kg, 1.4 ft•lb) Exhaust pipe nut M8 2 20 Nm (2.0 m•kg, 14 ft•lb) Muffler and exhaust pipe M8 1 20 Nm (2.0 m•kg, 14 ft•lb) Muffler bolt M10 2 42 Nm (4.2 m•kg, 30 ft•lb) Muffler protector bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb) Spark arrester bolt M6 3 12 Nm (1.2 m•kg, 8.7 ft•lb) EXUP cable pulley double-nut M6 2 6 Nm (0.6 m•kg, 4.3 ft•lb) EXUP pully bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) EXUP servo motor bolt M6 2 6 Nm (0.6 m•kg, 4.3 ft•lb) EXUP servo motor cover bolt M5 2 2 Nm (0.2 m•kg, 1.4 ft•lb) Bearing cover plate bolt M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb) Crankcase bolts M6 12 10 Nm (1.0 m•kg, 7.2 ft•lb) Crankcase and holder screw M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Timing mark accessing screw M14 1 2 Nm (0.2 m•kg, 1.4 ft•lb) Crankshaft end cover M32 1 2 Nm (0.2 m•kg, 1.4 ft•lb) Crankcase cover bolt (left) M6 11 10 Nm (1.0 m•kg, 7.2 ft•lb) Crankcase cover bolt (right) M6 12 10 Nm (1.0 m•kg, 7.2 ft•lb) Engine oil drain bolt M12 1 20 Nm (2.0 m•kg, 14 ft•lb) Crankcase and nozzle bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Primary drive gear nut M16 1 80 Nm (8.0 m•kg, 58 ft•lb)Lock washer use Clutch spring bolts M6 5 8 Nm (0.8 m•kg, 5.8 ft•lb) Locknut (push lever adjusting screw) M6 1 8 Nm (0.8 m•kg, 5.8 ft•lb) Clutch boss nut M16 1 75 Nm (7.5 m•kg, 54 ft•lb)Lock washer use ItemThread sizeQ’ty Tightening torque Remarks LT LT LT LT LT LT LT
TIGHTENING TORQUES 2-17 EAS20350 CHASSIS TIGHTENING TORQUES Drive sprocket nut M18 1 95 Nm (9.5 m•kg, 69 ft•lb)Stake the nut Stopper screw (stopper lever) M8 1 22 Nm (2.2 m•kg, 16 ft•lb) Shift pedal bolt M8 1 18 Nm (1.8 m•kg, 13 ft•lb) Stator assembly bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb) Crankshaft position sensor bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Neutral switch M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb) Thermosensor bolt M12 1 18 Nm (1.8 m•kg, 13 ft•lb) Drive sprocket cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb) Right side cover bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Side cover stay bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Cylinder bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Water pump housing cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb) Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Clutch cable holder bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Speed sensor bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Radiator hose clamp screw—6 2 Nm (0.2 m•kg, 1.4 ft•lb) Radiator fan bolt M6 3 8 Nm (0.8 m•kg, 5.8 ft•lb) Radiator M6 1/1 10 Nm (1.0 m•kg, 7.2 ft•lb) Radiator cover bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Thermostat cover bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Seat guide screw M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Throttle position sensor screw M5 2 3.5 Nm (0.35 m•kg, 2.5 ft•lb) Air induction system pipe bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Wire harness holder bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) ItemThread sizeQ’ty Tightening torque Remarks LT LT LT LT ItemThread sizeQ’ty Tightening torque Remarks Engine mounting nut (front upper) M10 1 67 Nm (6.7 m•kg, 48 ft•lb) Engine mounting nut (front, front lower)M10 1/1 56 Nm (5.6 m•kg, 41 ft•lb) Down tube nut M12 3 113 Nm (11.3 m•kg, 82 ft•lb) Main frame and rear frame M10 4 56 Nm (5.6 m•kg, 41 ft•lb) Engine protector bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Drive chain tensioner bolt M8 2 23 Nm (2.3 m•kg, 17 ft•lb)
TIGHTENING TORQUES 2-18 Taillight cover bolt M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb) Helmet hanger screw M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Front fender bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb) Sidecover screw M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Sidecover stay bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Horn bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Air scoop stay bolt M8 2 16 Nm (1.6 m•kg, 12 ft•lb) Air scoop bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb) Air scoop and right air panel M6 2 4 Nm (0.4 m•kg, 2.9 ft•lb) Rectifier/regulator bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Recovery tank screw M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Starter motor leads nut M6 2 5 Nm (0.5 m•kg, 3.6 ft•lb) Starter motor bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Pivot shaft nut M16 1 85 Nm (8.5 m•kg, 62 ft•lb) Rear shock absorber locknut—1 42 Nm (4.2 m•kg, 30 ft•lb) Rear shock absorber nut (upper) M10 1 40 Nm (4.0 m•kg, 29 ft•lb) Rear shock absorber nut (lower) M10 1 53 Nm (5.3 m•kg, 38 ft•lb) Frame and connecting rod nut M14 1 80 Nm (8.0 m•kg, 58 ft•lb) Connecting rod and relay arm nut M14 1 80 Nm (8.0 m•kg, 58 ft•lb) Relay arm and swing arm nut M14 1 70 Nm (7.0 m•kg, 51 ft•lb) Chain case bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Chain cover bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb) Sidestand nut M10 1 64 Nm (6.4 m•kg, 46 ft•lb) Sidestand switch screw M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb) Steering stem nut M24 1 120 Nm (12.0 m•kg, 87 ft•lb) Lower ring nut M28 1 – See NOTE Upper bracket pinch bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb) Lower bracket pinch bolt M8 4 20 Nm (2.0 m•kg, 14 ft•lb) Fuel tank bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb) Fuel tank bracket bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb) Fuel pump bolt M5 6 4 Nm (0.4 m•kg, 2.9 ft•lb) Meter nut M5 3 4 Nm (0.4 m•kg, 2.9 ft•lb) Meter bracket nut M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Handlebar upper holder bolt M8 4 28 Nm (2.8 m•kg, 20 ft•lb) Handlebar lower holder nut M12 2 40 Nm (4.0 m•kg, 29 ft•lb) Front fork cap bolt M48 2 30 Nm (30. m•kg, 22 ft•lb) ItemThread sizeQ’ty Tightening torque Remarks
TIGHTENING TORQUES 2-19 Front fork base valve M22 2 55 Nm (5.5 m•kg, 40 ft•lb) Front fork axle nut M16 1 63 Nm (6.3 m•kg, 46 ft•lb) Front wheel axle pinch bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb) Front brake disc bolt (WR250R) M6 6 12 Nm (1.2 m•kg, 8.7 ft•lb) Front brake disc bolt (WR250X) M8 6 23 Nm (2.3 m•kg, 17 ft•lb) Spoke (front, rear) BC4 72 3 Nm (0.3 m•kg, 2.2 ft•lb) Rear wheel axle nut M20 1 125 Nm (12.5 m•kg, 90 ft•lb) Rear brake disc bolt M6 6 12 Nm (1.2 m•kg, 8.7 ft•lb) Rear wheel sprocket nut M8 6 35 Nm (3.5 m•kg, 25 ft•lb) Front brake caliper bolt M8 2 23 Nm (2.3 m•kg, 17 ft•lb) Union bolt M10 4 30 Nm (30. m•kg, 22 ft•lb) Bleed screw M7 2 6 Nm (0.6 m•kg, 4.3 ft•lb) Front caliper support bolt M8 2 17 Nm (1.7 m•kg, 12 ft•lb) Front caliper pin plug M8 1 2.5 Nm (0.25 m•kg, 1.8 ft•lb)WR250X only Front master cylinder holder bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Front brake lever nut M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear master cylinder bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Rear caliper protector bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear brake caliper support bolt M8 2 17 Nm (1.7 m•kg, 12 ft•lb) Rear master cylinder bracket bolt M8 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Passenger footrest bolt (left) M8 1 23 Nm (2.3 m•kg, 17 ft•lb) Passenger footrest bolt (right) M8 1 30 Nm (30. m•kg, 22 ft•lb) Drive chain tensioner bolt (upper, lower)M8 2 23 Nm (2.3 m•kg, 17 ft•lb) Drive chain adjuster locknut M8 1 16 Nm (1.6 m•kg, 12 ft•lb) Front fork protector bolt M6 6 7 Nm (0.7 m•kg, 5.1 ft•lb) Seat bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Front brake lever adjusting locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb) Front brake master cylinder cap M4 2 4 Nm (0.4 m•kg, 2.9 ft•lb) Front brake hose holder bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Rear brake caliper pin plug M10 1 2.5 Nm (0.25 m•kg, 1.8 ft•lb) Rear brake master cylinder lock nut M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb) Clutch lever holder bolt M5 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Brake hose holder nut M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Damper rod nut M10 2 15 Nm (1.5 m•kg, 11 ft•lb) ItemThread sizeQ’ty Tightening torque Remarks LT LT LT LT
TIGHTENING TORQUES 2-20 NOTE: Tighten the lower ring nut with the 38 Nm (3.8 m•kg, 27 ft•lb) torque. Turn the front fork to the left and right. The rotation motion must be smooth. Fully loosen the lower ring nut, and retighten it with the 7 Nm (0.7 m•kg, 5.1 ft•lb) torque. Headlight unit bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear brake hose holder screw M5 5 2 Nm (0.2 m•kg, 1.4 ft•lb) Front drive chain guide bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Delivery pipe screw M6 2 5 Nm (0.5 m•kg, 3.6 ft•lb) Canister cover bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb) ItemThread sizeQ’ty Tightening torque Remarks
LUBRICATION POINTS AND LUBRICANT TYPES 2-21 EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication points Lubrication types Oil seal lips O-rings Bearings Camshaft cap bolt head Cylinder head bolt threads Camshaft profile, journal Decompression system moving parts Valve stem, stem end Valve lifter surface Crank assembly (crankshaft pin surface) Both sliding surfaces of connecting rod big end Piston pin surface Piston surface Cylinder body inner surface Impeller shaft Oil pump assembly shaft Oil pump assembly drain port Idle gear inner diameter and end, idle gear shaft and end Throttle body joint Rotor boss end surface Thrust gear surface Starter clutch assembly Rotor assembly Shaft surface (crankcase bearings) Idle gear-2 inner surface, thrust surfaces Damper assembly shaft, thrust surfaces LS LS E E M M E M E E E E E E LS E LS E E E E E E E E E
LUBRICATION POINTS AND LUBRICANT TYPES 2-22 EAS20380 CHASSIS Push rod 1 surface, end Ball (push rod) Primary driven gear assembly, inner surface Push lever assembly end Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift fork and shift fork guide bars Shift shaft Shift shaft washer, spacer inner surface Cylinder head cover gasketYamaha bond No. 1215 (Three Bond No. 1215®) Cylinder head semicircular surfaceYamaha bond No. 1215 (Three Bond No. 1215®) Crankcase mating surfaceYamaha bond No. 1215 (Three Bond No. 1215®) Stator assembly lead grommetYamaha bond No. 1215 (Three Bond No. 1215®) Lubrication points Lubrication types E E E E M M E E E E Lubrication points Lubrication types Upper bearings and oil seal lip (steering head) Lower bearings and oil seal lip (steering head) Handle lower holder threads Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Brake pedal bolt, boss Throttle cable end and throttle grip Throttle cable housing inner surface Throttle cable LS LS LS LS LS LS LS LS LS
LUBRICATION POINTS AND LUBRICANT TYPES 2-23 Brake lever bolt Brake lever and front brake master cylinder Adjusting screw (brake lever) Rear brake master cylinder push rod (boot mount groove) Brake caliper piston seal Brake caliper dust seal Brake caliper support bolt Brake pad support bolt Clutch lever cable Clutch lever bolt Clutch lever Pivot shaft Swing arm bearing, collar, spacer, and oil seal Relay arm bearing, collar, and oil seal Connecting rod bearing, collar and oil seal Connecting rod bolt Rear shock absorber assembly lower bolt Rear wheel axle Sidestand switch Sidestand bracket and sidestand Sidestand spring and link Sidestand bolt collar Drive chain tensioner roller collar (upper) Lubrication points Lubrication types S S S S BF S S S LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS