Yamaha WR250 Replacement Parts Manual 1991

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Typ: Motorcycle

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Art.-Nr: 130242

Stichworte: 1991 Marine Motorcycle Sterndrive WR250 Yamaha

Produktvarianten

Beschreibung

The Yamaha WR250, a distinguished model from the first generation produced between 1991 and 1997, represents a robust 2-stroke off-road competition motorcycle. Engineered for demanding terrain, this machine benefits from extensive heritage in off-road racing, offering a blend of performance and durability. Its design prioritizes agility and power delivery, making it a capable choice for various off-road disciplines. The WR250 is characterized by its reliable 239cc liquid-cooled single-cylinder engine, a 6-speed manual transmission, and effective hydraulic disc brakes on both wheels, all contributing to its reputation for consistent performance in challenging environments. This comprehensive English-language parts catalog serves as an essential resource for owners and technicians of the 1991 Yamaha WR250. It provides detailed exploded view diagrams and part numbers for every component, covering the engine, fuel system, ignition, cooling, exhaust, transmission, clutch, suspension, brakes, wheels, tires, electrical system, frame, and bodywork. The catalog is meticulously organized to facilitate accurate part identification, simplify the ordering process, and ensure correct assembly and disassembly of the motorcycle. Its clear illustrations and precise part listings are invaluable for maintaining the integrity and performance of the WR250.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

WR250

Year:

Generation

Model Generation:

First Generation (1991-1997)

Codes

Chassis Code General:

2-Stroke Off-Road Competition

👋 Introduction

Market Position

Target Audience:

Owners and technicians of the 1991 Yamaha WR250 motorcycle seeking accurate parts identification and sourcing.

Competitive Analysis

Value Proposition:

Provides cost savings by enabling users to identify and source parts independently, avoiding inflated dealer markups and shipping costs.

Key Features

Digital Access:

Instant, downloadable format eliminates waiting times and shipping fees.

Illustrated Diagrams:

Exploded parts diagrams are crucial for understanding component relationships and correct installation.

Part Number Listing:

Essential for precise part ordering, preventing incorrect purchases.

Ease Of Use

Accessibility:

Designed to be easily understood by individuals with varying levels of mechanical expertise.

📋 Manual Details

Coverage Areas

Vehicle Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Electrical System, Frame, Bodywork, Controls, Decals.

Page Count

Estimated Page Count:

150-250 pages (typical for OEM parts manuals of this era)

Manual Type

Type:

OEM Parts Manual / Parts Catalog

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Assembly:

Detailed breakdown of engine components, including cylinder, piston, crankshaft, connecting rod, and internal parts.

Fuel Delivery:

Carburetor components, fuel lines, fuel filter (if applicable).

Ignition System:

CDI unit, spark plug, stator, flywheel components.

Cooling System:

Radiator, hoses, water pump components (if liquid-cooled variant).

Exhaust System:

Expansion chamber, muffler, mounting hardware.

Transmission Drivetrain:

Gearbox internals, shift drum, clutch assembly, chain and sprockets.

Suspension Front:

Fork tubes, seals, springs, damping components, triple clamps.

Suspension Rear:

Shock absorber, linkage, swingarm, bearings.

Braking System Front:

Brake caliper, master cylinder, brake disc, pads, lines.

Braking System Rear:

Brake caliper, master cylinder, brake disc, pads, lines.

Wheels Tires:

Rims, spokes, hubs, bearings, tire sizes.

Electrical Components:

Wiring harness, lighting (headlight, taillight), switchgear, battery (if applicable).

Frame Chassis:

Frame sections, subframe, footpegs, mounting brackets.

Bodywork Plastics:

Fenders, side panels, fuel tank (if applicable), seat, shrouds.

Controls:

Handlebars, levers, cables (throttle, clutch), shifter, brake pedal.

Procedures Included

Disassembly Guidance:

Illustrated guides for breaking down complex assemblies into individual components.

Assembly Guidance:

Exploded views facilitate correct reassembly of parts.

Part Identification:

Clear identification of every part with its unique part number.

Part Ordering:

Enables accurate ordering of replacement parts from dealerships or online suppliers.

Technical Depth

Depth Of Coverage:

Comprehensive breakdown of all OEM-manufactured parts for the specified model year.

Illustration Style:

Detailed exploded view diagrams showing part relationships and order.

Part Number Accuracy:

Lists official Yamaha part numbers, critical for sourcing correct replacements.

Clarity And Usability:

Designed for ease of understanding by mechanics and DIY enthusiasts alike.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all PC & MAC computers.

Reader Requirement:

Requires Adobe PDF Reader (freely available).

Print Quality

Printability:

Print any page on demand, allowing for targeted repair information.

Binding Type

Binding Type Digital:

N/A (Digital PDF)

Paper Type

Paper Type Digital:

N/A (Digital PDF)

Download Availability

Download Method:

Instant download after payment confirmation.

Licensing

Usage Rights:

For personal use in repair and maintenance.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Liquid-Cooled, Single Cylinder

Displacement:

239cc (approximate, specific variants may exist)

Bore X Stroke:

Typical for this era: ~67mm x 66mm

Compression Ratio:

High compression for performance, typically 7.0:1 to 8.0:1 (specific value would be in a service manual, not typically detailed in a parts manual).

Performance

Horsepower Estimate:

Approx. 35-45 HP (estimated for off-road competition trim).

Torque Estimate:

Approx. 25-30 lb-ft (estimated).

Fuel System

Carburetor Type:

Mikuni VM Series (e.g., VM34 or similar).

Fuel Delivery:

Carburetor

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication

Oil System:

Premix (2-stroke oil mixed with gasoline) or Autolube (separate oil injection system - check specific model variant, premix more common for race bikes).

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual

Clutch Type:

Wet Multi-plate

Features

Final Drive:

Chain Drive

Gear Ratios:

Specific gear ratios would be detailed in a service manual, but the parts manual would list individual gears and their part numbers.

Transmission Fluid

Gear Oil Type:

Yamalube 80W or equivalent motorcycle gear oil (typically 10W-30 or 80W for gearbox).

📐 Dimensions

Exterior

Wheelbase:

Approx. 56-57 inches (specific to 1991 WR250 model).

Seat Height:

Approx. 37-38 inches (typical for a dirt bike).

Weights

Dry Weight:

Approx. 235-245 lbs (dry weight).

Fuel Capacity:

Approx. 2.4 - 2.8 gallons.

🛡️ Safety Features

Ratings

Safety Compliance:

Designed for closed-course competition; not street legal in most jurisdictions.

Active Features

Braking System:

Hydraulic Disc Brakes (Front and Rear)

Passive Features

Frame Construction:

Steel perimeter or semi-perimeter frame for rigidity and durability.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this off-road competition model.

Driver Assistance

Driver Assistance Features:

Not applicable for this off-road competition model.

Connectivity

Connectivity Features:

Not applicable for this off-road competition model.

Engine Management

Power Valve System:

Yamaha Power Valve System (YPVS) for improved power delivery across the rev range.

🔧 Maintenance

Service Intervals

Spark Plug Replacement:

Intervals vary based on usage, typically every 10-20 hours of aggressive use (refer to service manual).

Air Filter Cleaning:

Recommended after every few rides or if visibly dirty, especially in dusty conditions.

Chain Lubrication:

Daily or every ride, depending on conditions.

Oil Change Gearbox:

Every 10-20 hours of riding or annually.

Fluid Specifications

Two Stroke Oil:

High-quality 2-stroke synthetic or semi-synthetic oil, mixed at a 32:1 or 40:1 ratio (refer to owner's manual for exact ratio).

Coolant Type:

Ethylene glycol-based coolant with distilled water (50/50 mix) for liquid-cooled models.

Known Issues

Power Valve Maintenance:

Yamaha's YPVS (Yamaha Power Valve System) requires regular cleaning and proper function to maintain optimal engine performance.

Carburetor Tuning:

Carburetor jetting may need adjustment based on altitude and temperature for optimal performance.

Clutch Wear:

Clutch plates can wear over time with aggressive use, requiring replacement.

Suspension Seals:

Fork and shock seals can degrade over time, leading to oil leaks and requiring replacement.

📚 Vehicle History

Brand Heritage

Yamaha Offroad Legacy:

Yamaha has a long and successful history in off-road motorcycle racing, with models like the YZ and WR series being dominant.

Model Evolution

Wr250 Lineage:

The WR250 was developed from Yamaha's motocross lineage, adapted for enduro and off-road racing with features like wider gear ratios and often improved suspension.

Production

Manufacturing Location:

Japan

Production Period:

1991-1997 for the first generation, with subsequent generations evolving significantly.

🏆 Awards & Recognition

Recognitions

Motorsport Success:

Yamaha's WR series has a strong track record in various off-road racing disciplines, including Enduro and Grand National Cross Country (GNCC).

Ratings

Rider Reviews:

Known for robust performance and durability in demanding off-road conditions.

Certifications

Oem Standard:

Maintains OEM specifications for parts interchangeability and performance.