This document is an Owner's Service Manual for the Yamaha WR250FR motorcycle, specifically the 2002 1st Edition model. It covers operation, inspection, basic maintenance, and tuning. The manual emphasizes that the machine is designed strictly for competition use on closed courses and is not legal for public roads. It also highlights the importance of experienced riders, protective apparel, proper maintenance, and safe refueling practices due to gasoline's flammability and exhaust fume toxicity.
Function Description:
The Yamaha WR250FR is a liquid-cooled, 4-stroke, DOHC, single-cylinder, forward-inclined competition motorcycle. It features a constant-mesh 5-speed transmission with left foot operation and a primary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged. The ignition system is a map-controlled CDI unit that optimizes ignition timing based on engine speed and throttle position for quick throttle response across various riding conditions. It also includes an electric starting system.
Important Technical Specifications:
- Model Name: WR250FR (USA), WR250F (EUROPE), WR250F(R) (CDN, AUS, NZ, ZA)
- Model Code Number: 5UM1 (USA), 5UM2 (EUROPE), 5UM4 (CDN, AUS, NZ, ZA)
- Dimensions:
- Overall Length: 2,165 mm (85.2 in)
- Overall Width: 827 mm (32.6 in)
- Overall Height: 1,303 mm (51.3 in)
- Seat Height: 998 mm (39.3 in)
- Wheelbase: 1,475 mm (58.1 in)
- Minimum Ground Clearance: 382 mm (15.0 in)
- Basic Weight (with oil and full fuel tank): 115.1 kg (253.7 lb)
- Engine:
- Displacement: 249 cm³ (8.76 Imp oz, 8.42 US oz)
- Bore × Stroke: 77.0 × 53.6 mm (3.03 × 2.11 in)
- Compression Ratio: 12.5 : 1
- Lubrication System: Dry sump
- Oil Type/Grade (Engine Oil):
- At 5 °C (40 °F) or higher: Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified)
- At 15 °C (60 °F) or lower: Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified)
- (Except for USA and CDN): API “SG” or higher grade
- Oil Capacity:
- Periodic oil change: 1.2 L (1.06 Imp qt, 1.27 US qt)
- With oil filter replacement: 1.3 L (1.14 Imp qt, 1.37 US qt)
- Total amount: 1.4 L (1.23 Imp qt, 1.48 US qt)
- Coolant Capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt)
- Fuel: Premium unleaded gasoline (research octane number 95 or higher, except ZA which uses Premium gasoline).
- Tank Capacity: 10 L (2.2 Imp gal, 2.64 US gal)
- Reserve: 1.2 L (0.26 Imp gal, 0.32 US gal)
- Spark Plug: CR8E/NGK (resistance type), Gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
- Clutch Type: Wet, multiple-disc
- Transmission: Constant mesh, 5-speed
- Primary Reduction Ratio: 57/17 (3.353)
- Secondary Reduction Ratio: 52/13 (4.000)
- Brakes: Single disc brake (front and rear)
- Suspension: Telescopic fork (front), Swingarm (link type monocross suspension) (rear)
- Wheel Travel: 300 mm (11.8 in) (front), 315 mm (12.4 in) (rear)
- Tires: With tube
- Front: 80/100-21 51M (USA, CDN, ZA) / 90/90-21 54R (EUROPE, AUS, NZ)
- Rear: 100/100-18 59M (USA, CDN, ZA) / 130/90-18 69R (EUROPE, AUS, NZ)
- Tire Pressure: 100 kPa (1.0 kgf/cm², 15 psi) (front and rear)
- Electrical:
- Ignition System: CDI
- Generator System: AC magneto
- Battery: YTX5L-BS, 12 V/4 AH, Specific Gravity 1.320
- Headlight: Quartz bulb (halogen), 12 V 60/55 W × 1
- Taillight: 12 V 21/5 W × 1
- Engine Idle Speed: 1,900 ~ 2,100 r/min
- Valve Clearance (cold): Intake: 0.10 ~ 0.15 mm, Exhaust: 0.17 ~ 0.22 mm
- Throttle Grip Free Play: 3 ~ 5 mm (0.12 ~ 0.20 in)
- Clutch Lever Free Play: 8 ~ 13 mm (0.31 ~ 0.51 in)
- Brake Pedal Height: 5 mm (0.20 in)
Usage Features:
- Controls: Clutch lever (left handlebar), Shift pedal (left side of engine), Kickstarter crank, Throttle grip (right handlebar), Front brake lever (right handlebar), Rear brake pedal (right side of machine), Fuel cock (ON/OFF/RES positions), Cold starter knob, Hot starter lever, Engine stop switch (left handlebar), Start switch (right handlebar), Light switch (handlebar), Trip meter.
- Starting: Equipped with an ignition circuit cut-off system; engine can be started in neutral or in any gear with the clutch disengaged. Cold starting requires fully opening the cold starter knob. Warm starting uses the hot starter lever.
- Break-in Procedures: Detailed instructions for initial operation, including warming up, moderate throttle use in lower gears, and checking for loose fittings/fasteners. Specific break-in times are provided for replaced engine parts (cylinder, crankshaft, piston, rings, valves, camshafts, gears).
- Carburetor Tuning: Comprehensive guide for adjusting the main jet, pilot screw, and jet needle based on atmospheric conditions and engine performance (throttle response, spark plug discoloration). Includes reference charts for various settings.
- Suspension Setting: Instructions for adjusting front fork oil level, spring preload, compression damping, and rebound damping. Rear shock absorber adjustments for spring preload, rebound damping, and low/high compression damping are also detailed.
Maintenance Features:
- Regular Inspections: A detailed maintenance interval schedule covers engine oil, valves, valve springs, valve lifters, camshafts, timing chain, piston, piston ring, piston pin, cylinder head, cylinder, clutch, transmission, shift fork, shift cam, guide bar, rotor nut, exhaust pipe, spark arrester, crank, carburetor, spark plug, drive chain, cooling system, nuts/bolts, air filter, oil filter, oil strainer, frame, fuel tank/cock, brakes, front forks, rear shock absorber, steering head, tires/wheels, cables, hot starter/clutch lever, and battery.
- Coolant System: Inspection and replacement procedures for coolant level, radiator cap, and cooling system components.
- Engine Oil: Inspection and replacement procedures for engine oil level, oil filter, and oil strainer.
- Spark Plug: Inspection, cleaning, and gap adjustment.
- Ignition Timing: Check procedure using a timing light and inductive tachometer.
- Battery: Inspection and charging methods for MF batteries, including voltage measurement and charging flowcharts.
- Brakes: Adjustment of front brake lever position and rear brake pedal height. Inspection and replacement of brake pads. Bleeding the brake system.
- Drive Chain: Inspection of sprockets, chain slack adjustment, cleaning, lubrication, and replacement.
- Front Fork: Inspection of smooth action, oil seal/dust seal cleaning, internal pressure relieving, and rebound/compression damping force adjustment.
- Rear Shock Absorber: Inspection of smooth action, spring preload adjustment, and rebound/compression damping force adjustment. Includes warnings regarding high-pressure nitrogen gas.
- Steering Head: Inspection of bearing free play and smooth action, and steering ring nut adjustment.
- Lubrication: General lubrication points for cables, pivots, and drive chain.
- Special Tools: A comprehensive list of special tools with part numbers and illustrations for various maintenance tasks.
- Cleaning and Storage: Guidelines for frequent cleaning and long-term storage to prevent deterioration.
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