![Yamaha WR250F 2003 [220/304] Front brake and rear brake](/img/pdf.png)
Yamaha WR250F 2003 [220/304] Front brake and rear brake
![Yamaha WR250F 2003 [220/304] Front brake and rear brake](/views2/1012986/page220/bgdc.png)
5 - 16
CHAS
Brake caliper
1. Inspect:
● Brake caliper cylinder inner surface a
Wear/score marks → Replace brake
caliper assembly.
Å Front
ı Rear
ı
Å
2. Inspect:
● Brake caliper piston 1
Wear/score marks → Replace brake
caliper piston assembly.
WARNING
Replace the piston seals and dust seals 2
whenever a caliper is disassembled.
EC534301
Brake hose
1. Inspect:
● Brake hose 1
Crack/damage → Replace.
EC5A5000
ASSEMBLY AND INSTALLATION
WARNING
● All internal parts should be cleaned in
new brake fluid only.
● Internal parts should be lubricated with
brake fluid when installed.
● Replace the piston seals and dust seals
whenever a caliper is disassembled.
Brake caliper piston
1. Clean:
● Brake caliper
● Piston seal
● Dust seal
● Brake caliper piston
Clean them with brake fluid.
FRONT BRAKE AND REAR BRAKE
Содержание
- Owner s service manual 1
- Yz250fr 1
- Introduction 4
- Warning 4
- Important notice 6
- Safety information 6
- Notice 8
- To the new owner 8
- Caution 9
- How to use this manual 9
- Particularly important information 9
- Warning 9
- How to read descriptions 10
- Manual format 10
- Gen info spec 11
- Illustrated symbols refer to the illustration 11
- Insp adj eng 11
- Chassis 13
- Electrical 13
- Engine 13
- General information 13
- Regular inspection and adjustments 13
- Specifications 13
- Tuning 13
- Chapter 1 general information 14
- Chapter 2 specifications 14
- Chapter 3 regular inspection and adjustments 14
- Contents 14
- Table of contents 14
- Chapter 4 engine 15
- Chapter 5 chassis 15
- Chapter 6 electrical 16
- Chapter 7 tuning 16
- Description 17
- Gen info 17
- General information 17
- Gen info 18
- Machine identification 18
- Gen info 19
- Important information 19
- Caution 20
- Gen info 20
- Important information 20
- Gen info 21
- Important information 21
- Checking of connection 22
- Gen info 22
- For others use part number starting with 90890 23
- For u s a and canada use part number starting with ym yu or acc 23
- Gen info 23
- Part number tool name how to use illustration 23
- Special tools 23
- The proper special tools are necessary for complete and accurate tune up and assembly using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques the shape and part number used for the special tool differ by country so two types are provided refer to the list provided to avoid errors when placing an order 23
- Gen info 24
- Part number tool name how to use illustration 24
- Special tools 24
- Gen info 25
- Part number tool name how to use illustration 25
- Special tools 25
- Control functions 26
- Gen info 26
- Control functions 27
- Gen info 27
- Caution 28
- Control functions 28
- Gen info 28
- Warning 28
- Caution 29
- Gen info 29
- Warning 29
- Caution 30
- Gen info 30
- Starting and break in 30
- Warning 30
- Caution 31
- Gen info 31
- Starting and break in 31
- Caution 32
- Gen info 32
- Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage 32
- Restarting an engine after a fall pull the hot starter lever and start the engine as soon as the engine starts release the hot starter lever to close the air passage the engine fails to start pull the hot starter lever all the way out and while holding the lever kick the kickstarter crank 10 to 20 times to clear the engine then restart the engine refer to restarting an engine after a fall 32
- Starting a warm engine do not operate the cold starter knob and throt tle pull the hot starter lever 1 and start the engine by kicking the kickstarter crank force fully with a firm stroke as soon as the engine starts release the hot starter lever to close the air passage 32
- Starting and break in 32
- Caution 33
- Gen info 33
- Starting and break in 33
- Gen info 34
- Note concerning the tightening torque refer to maintenance specifications section in the chapter 2 34
- Torque check points 34
- Caution 35
- Cleaning and storage 35
- Gen info 35
- Cleaning and storage 36
- Gen info 36
- General specifications 37
- Specifications 37
- General specifications 38
- General specifications 39
- Maintenance specifications 40
- Maintenance specifications 41
- Maintenance specifications 42
- Maintenance specifications 43
- Maintenance specifications 44
- Maintenance specifications 45
- Maintenance specifications 46
- Maintenance specifications 47
- Maintenance specifications 48
- Maintenance specifications 49
- Maintenance specifications 50
- Maintenance specifications 51
- Maintenance specifications 52
- Definition of units 53
- General torque specifications 53
- General torque specifications definition of units 53
- Cable routing diagram 54
- Cable routing diagram 55
- Cable routing diagram 56
- Cable routing diagram 57
- Cable routing diagram 58
- Insp adj 59
- Maintenance intervals 59
- Regular inspection and adjustments 59
- Insp adj 60
- Maintenance intervals 60
- Insp adj 61
- Maintenance intervals 61
- Before riding for break in operation practice or a race make sure the machine is in good operating condition before using this machine check the following points 62
- General inspection and maintenance 62
- Insp adj 62
- Pre operation inspection and maintenance 62
- Caution 63
- Engine 63
- Engine coolant level inspection 63
- Insp adj 63
- Warning 63
- Caution 64
- Coolant replacement 64
- Insp adj 64
- Warning 64
- Caution 65
- Insp adj 65
- Radiator cap inspection 65
- Warning 65
- Insp adj 66
- Radiator cap opening pressure inspection cooling system inspection 66
- Clutch adjustment 67
- Insp adj 67
- Insp adj 68
- Throttle cable adjustment throttle lubrication 68
- Warning 68
- Caution 69
- Hot starter lever adjustment air filter cleaning 69
- Insp adj 69
- Air filter cleaning 70
- Caution 70
- Insp adj 70
- Engine oil level inspection 71
- Insp adj 71
- Caution 72
- Engine oil level inspection 72
- Insp adj 72
- Engine oil replacement 73
- Insp adj 73
- Engine oil replacement 74
- Insp adj 74
- Insp adj 75
- Oil pressure inspection pilot screw adjustment 75
- Engine idling speed adjustment valve clearance inspection and adjustment 76
- Insp adj 76
- Insp adj 77
- Valve clearance inspection and adjustment 77
- Insp adj 78
- Valve clearance inspection and adjustment 78
- Insp adj 79
- Valve clearance inspection and adjustment 79
- Insp adj 80
- Valve clearance inspection and adjustment 80
- Exhaust 81
- Insp adj 81
- Intake 81
- Valve clearance cold 0 0 0 5 mm example installed is 175 measured clearance is 0 3 mm replace 175 pad with 185 pad pad number example pad no 175 1 5 mm pad no 185 1 5 mm 81
- Valve clearance cold 0 7 0 2 mm example installed is 175 measured clearance is 0 7 mm replace 175 pad with 185 pad pad number example pad no 175 1 5 mm pad no 185 1 5 mm 81
- Valve clearance inspection and adjustment 81
- Chassis 82
- Chassis brake system air bleeding 82
- Insp adj 82
- Warning 82
- Caution 83
- Front brake adjustment 83
- Insp adj 83
- Warning 83
- Insp adj 84
- Rear brake adjustment front brake pad inspection and replacement 84
- Warning 84
- Caution 85
- Front brake pad inspection and replacement 85
- Insp adj 85
- Insp adj 86
- Rear brake pad inspection and replacement 86
- Caution 87
- Insp adj 87
- Rear brake pad inspection and replacement 87
- Insp adj 88
- Rear brake pad insulator inspection brake fluid level inspection 88
- Warning 88
- Insp adj 89
- Sprockets inspection drive chain inspection 89
- Caution 90
- Drive chain slack adjustment 90
- Insp adj 90
- Caution 91
- Front fork inspection 91
- Insp adj 91
- Insp adj 92
- Caution 93
- Front fork compression damping force adjustment 93
- Insp adj 93
- Warning 93
- Caution 94
- Insp adj 94
- Rear shock absorber inspection 94
- Warning 94
- Caution 95
- Insp adj 95
- Rear shock absorber spring preload adjustment 95
- Caution 96
- Insp adj 96
- Rear shock absorber rebound damping force adjustment 96
- Caution 97
- Insp adj 97
- Rear shock absorber low compression damping force adjustment 97
- Caution 98
- Insp adj 98
- Rear shock absorber high compression damping force adjustment 98
- Insp adj 99
- Tire pressure check spokes inspection and tightening wheel inspection 99
- Insp adj 100
- Steering head inspection and adjustment 100
- Caution 101
- Insp adj 101
- Steering head inspection and adjustment 101
- Warning 101
- Caution 102
- Insp adj 102
- Lubrication 102
- Lubrication to ensure smooth operation of all compo nents lubricate your machine during setup after break in and after every race 102
- Wipe off any excess grease and avoid get ting grease on the brake discs 102
- Electrical 103
- Electrical spark plug inspection 103
- Insp adj 103
- Ignition timing check 104
- Insp adj 104
- Engine 105
- Seat fuel tank and side covers 105
- Seat fuel tank and side covers 106
- Except for usa 107
- Exhaust pipe and silencer 107
- Exhaust pipe and silencer 108
- Radiator 109
- Radiator 110
- Warning 110
- Radiator 111
- Carburetor 112
- Carburetor 113
- Carburetor disassembly 113
- Carburetor 114
- Carburetor 115
- Caution 115
- Carburetor 116
- Carburetor 117
- Carburetor 118
- Carburetor 119
- Carburetor 120
- Carburetor 121
- Carburetor 122
- Carburetor 123
- Carburetor 124
- Camshafts 125
- Cylinder head cover 125
- Camshafts 126
- Camshafts 127
- Caution 127
- Camshafts 128
- Camshafts 129
- Camshafts 130
- Camshafts 131
- Caution 131
- Camshafts 132
- Camshafts 133
- Cylinder head 134
- Cylinder head 135
- Cylinder head 136
- Valves and valve springs 137
- Valves and valve springs 138
- Valves and valve springs 139
- Valves and valve springs 140
- Valves and valve springs 141
- Caution 142
- Valves and valve springs 142
- Valves and valve springs 143
- Valves and valve springs 144
- Caution 145
- Valves and valve springs 145
- Cylinder and piston 146
- Caution 147
- Cylinder and piston 147
- Cylinder and piston 148
- Cylinder and piston 149
- Cylinder and piston 150
- Cylinder and piston 151
- Caution 152
- Cylinder and piston 152
- Clutch 153
- Clutch 154
- Clutch 155
- Clutch 156
- Clutch 157
- Clutch 158
- Clutch 159
- Oil filter element water pump and right crankcase cover 160
- Oil filter element water pump and right crankcase cover 161
- Oil filter element water pump and right crankcase cover 162
- Oil filter element water pump and right crankcase cover 163
- Oil filter element water pump and right crankcase cover 164
- Oil filter element water pump and right crankcase cover 165
- Oil filter element water pump and right crankcase cover 166
- Balancer 167
- Balancer 168
- Balancer 169
- Oil pump 170
- Oil pump 171
- Oil pump 172
- Oil pump 173
- Oil pump 174
- Kick shaft and shift shaft 175
- Kick shaft and shift shaft 176
- Kick shaft and shift shaft 177
- Kick shaft and shift shaft 178
- Kick shaft and shift shaft 179
- Kick shaft and shift shaft 180
- Kick shaft and shift shaft 181
- Cdi magneto 182
- Cdi magneto 183
- Cdi magneto 184
- Cdi magneto 185
- Engine removal 186
- Engine removal 187
- Engine removal 188
- Engine removal 189
- Engine removal 190
- Crankcase and crankshaft 191
- Crankcase and crankshaft 192
- Crankcase and crankshaft 193
- Crankcase bearing 193
- Caution 194
- Crankcase and crankshaft 194
- Caution 195
- Crankcase and crankshaft 195
- Crankcase and crankshaft 196
- Caution 197
- Crankcase and crankshaft 197
- Crankcase and crankshaft 198
- Crankcase and crankshaft 199
- Transmission shift cam and shift fork 200
- Transmission shift cam and shift fork 201
- Transmission shift cam and shift fork 202
- Transmission shift cam and shift fork 203
- Transmission shift cam and shift fork 204
- Chassis 205
- Front wheel and rear wheel 205
- Front wheel and rear wheel 206
- Rear wheel 206
- Front wheel and rear wheel 207
- Front wheel and rear wheel 208
- Warning 208
- Caution 209
- Front wheel and rear wheel 209
- Front wheel and rear wheel 210
- Caution 211
- Front wheel and rear wheel 211
- Front wheel and rear wheel 212
- Front wheel and rear wheel 213
- Front brake 214
- Front brake and rear brake 214
- Front brake and rear brake 215
- Rear brake 215
- Brake caliper disassembly 216
- Front brake and rear brake 216
- Å front ı rear 216
- Brake master cylinder disassembly 217
- Front brake and rear brake 217
- Å front ı rear 217
- Caution 218
- Front brake and rear brake 218
- Warning 218
- Caution 219
- Front brake and rear brake 219
- Warning 219
- Front brake and rear brake 220
- Warning 220
- Caution 221
- Front brake and rear brake 221
- Warning 221
- Caution 222
- Front brake and rear brake 222
- Warning 222
- Front brake and rear brake 223
- Warning 223
- Front brake and rear brake 224
- Caution 225
- Front brake and rear brake 225
- Warning 225
- Front brake and rear brake 226
- Caution 227
- Front brake and rear brake 227
- Warning 227
- Caution 228
- Front brake and rear brake 228
- Warning 228
- Caution 229
- Front brake and rear brake 229
- Front fork 230
- Front fork 231
- Front fork disassembly 231
- Caution 232
- Front fork 232
- Caution 233
- Front fork 233
- Front fork 234
- Warning 234
- Caution 235
- Front fork 235
- Front fork 236
- Front fork 237
- Caution 238
- Front fork 238
- Front fork 239
- Warning 239
- Front fork 240
- Front fork 241
- Caution 242
- Front fork 242
- Handlebar 243
- Caution 244
- Handlebar 244
- Warning 244
- Handlebar 245
- Handlebar 246
- Warning 246
- Handlebar 247
- Handlebar 248
- Steering 249
- Caution 250
- Steering 250
- Warning 250
- Steering 251
- Steering 252
- Caution 253
- Steering 253
- Swingarm 254
- Swingarm 255
- Swingarm disassembly 255
- Swingarm 256
- Swingarm 257
- Swingarm 258
- Swingarm 259
- Swingarm 260
- Swingarm 261
- Rear shock absorber 262
- Rear shock absorber 263
- Rear shock absorber 264
- Warning 264
- Rear shock absorber 265
- Caution 266
- Rear shock absorber 266
- Caution 267
- Rear shock absorber 267
- Rear shock absorber 268
- Electrical 269
- Electrical components and wiring diagram 269
- Map controlled cdi unit 270
- Ignition system 271
- Ignition system 272
- Ignition system 273
- Ignition system 274
- Throttle position sensor system 275
- Caution 276
- Throttle position sensor system 276
- Throttle position sensor system 277
- Caution 278
- Throttle position sensor system 278
- Throttle position sensor system 279
- Engine 280
- Setting 280
- Tuning 280
- Warning 280
- Caution 281
- Setting 281
- Setting 282
- Effects of changing the main jet reference 283
- If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eration 283
- Main jet adjustment the richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 283
- Setting 283
- Standard main jet 178 283
- Setting 284
- Setting 285
- Setting 286
- Setting 287
- Setting 288
- Examples of carburetor setting depending on symptom 289
- Setting 289
- This should be taken simply for an example it is necessary to set the carburetor while checking the operating conditions of the engine 289
- Chassis 290
- Setting 290
- Setting 291
- Caution 292
- Setting 292
- Caution 293
- Setting 293
- Warning 293
- Setting 294
- Setting 295
- Setting 296
- Setting 297
- Caution 298
- Setting 298
- Extent of adjustment spring length 299
- For europe 299
- Mm 10 3 in 255 273 mm 10 6 10 7 in 299
- Mm 10 4 in 240 258 mm 9 7 10 8 in 299
- Rear shock absorber setting parts 299
- Rear shock spring 1 equal pitch spring 299
- Setting 299
- Spring 299
- Spring free length extent of adjustment b 299
- The i d color a is marked at the end of the 299
- The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres sion 299
- Unequal pitch spring 299
- Before any change set the rear shock absorber sunken length to the standard figure 90 300
- Front fork 300
- If any of the following symptoms is experienced with the standard position as the base make resetting by reference to the adjustment procedure given in the same chart 300
- Mm 3 3 in 300
- Setting 300
- Suspension setting 300
- Adjust the high compression damping in 1 6 turn increments or decrements 301
- Adjust the low compression damping in 1 click increments or decrements 301
- Adjust the rebound damping in 2 click increments or decrements 301
- If any of the following symptoms is experienced with the standard position as the base make resetting by reference to the adjustment procedure given in the same chart 301
- Rear shock absorber 301
- Setting 301
- Shingai iwata shizuoka japan 304
- Yamaha motor co ltd 304
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