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Yamaha WR250F WR250 WR 250F 2008-2012 Service Repair Workshop Manual

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The WR250F, also known as the WR250, with its WR250FX variant, represents a pinnacle of off-road and enduro motorcycle engineering from 2008 to 2012. Renowned for its agile handling, potent...
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Yamaha WR250F WR250 WR 250F 2008-2012 Service Repair Workshop Manual
The WR250F, also known as the WR250, with its WR250FX variant, represents a pinnacle of off-road and enduro motorcycle engineering from 2008 to 2012. Renowned for its agile handling, potent 250cc liquid-cooled, 4-stroke engine equipped with Chip Controlled Fuel Injection (CC-FI), and advanced adjustable suspension, this model is designed for enthusiast riders and amateur racers. The heritage of innovation, dating back to 1955, is evident in the WR250F's robust build quality and performance capabilities, consistently earning praise in off-road publications for its reliability and dynamic off-road prowess. This comprehensive service repair workshop manual provides essential, factory-level detail for maintaining the peak performance and diagnosing complex issues for the WR250F models produced between 2008 and 2012. Covering an estimated 400-600 pages in English, this digital manual details engine overhaul, transmission servicing, chassis components, electrical systems, fuel and exhaust systems, brakes, and bodywork. It includes step-by-step instructions for routine maintenance, troubleshooting common problems, and complete repair procedures, making it an indispensable resource for owners and technicians alike.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
WR250F
Model Alias:
WR250
Model Variant:
WR250FX
Codes
Year Range Covered:
2008-2012
👋 Introduction
Market Position
Segment:
High-performance off-road/enduro motorcycle.
Target User:
Enthusiast riders, amateur racers, mechanics, DIY owners requiring in-depth repair information.
Competitive Analysis
Competitors:
KTM 250 EXC-F, Honda CRF250X, Kawasaki KLX250, Suzuki RM-Z250 (off-road variants).
Key Features
Vehicle Focus:
Agile handling, potent engine, advanced suspension, off-road capability.
Manual Value Proposition:
Provides essential, factory-level detail for maintaining peak performance and diagnosing complex issues.
📋 Manual Details
Coverage Areas
Primary Coverage:
Yamaha WR250F (2008-2012)
Secondary Coverage Notes:
Will work with similar years (2009, 2010, 2011, 2012). Predecessor (2001-2006) covered by separate manual.
Page Count
Estimated Page Count:
400-600
Manual Type
Type:
Complete Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
File Format Details:
High-resolution PDF, fully searchable text, printable pages.
Print Quality
Print Quality:
N/A (Digital Format)
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, top end, bottom end, cylinder, piston, crankshaft, camshaft, valve timing, lubrication system, cooling system, fuel injection, ignition system.
Transmission:
Clutch, gearbox, shift mechanism, internal components, lubrication.
Chassis:
Frame, swingarm, suspension (front forks, rear shock), steering, wheels, tires, hubs, spokes.
Electrical:
Wiring diagrams, lighting, battery, charging system, ignition system, sensors, ECU, diagnostics, fault finding.
Brakes:
Hydraulic systems, calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel filter.
Exhaust System:
Muffler, header pipe, catalytic converter (if applicable), gasket replacement.
Cooling System:
Radiator, hoses, thermostat, coolant, fan (if equipped).
Bodywork:
Plastics, fairings, seat, fuel tank cover, fenders, mounting hardware.
Procedures Included
Maintenance:
Oil change, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant flush, valve clearance check/adjustment.
Troubleshooting:
Diagnostic charts, common problems, solutions, electrical fault finding, mechanical issue diagnosis.
Repair:
Engine rebuild, transmission overhaul, suspension servicing, brake system repair, electrical component replacement, bodywork repair.
Disassembly Assembly:
Detailed step-by-step instructions for component removal and installation.
Technical Depth
Depth:
Comprehensive, from basic rider maintenance to full engine and transmission rebuilds. Includes detailed diagrams and specifications.
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve single cylinder
Displacement:
250cc
Bore X Stroke:
77.0 mm x 53.6 mm
Compression Ratio:
12.5:1 (typical for this generation)
Performance
Horsepower:
Approx. 30-35 HP (at crankshaft, varies by specific tune and year)
Torque:
Approx. 23-26 Nm (at crankshaft, varies by specific tune and year)
Fuel System
Induction:
Fuel Injection (YCC-FI - Yamaha Chip Controlled Fuel Injection)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/96 AKI
Fuel Tank Capacity:
Approx. 2.1 gallons (8.0 Liters)
Lubrication
Oil Type:
Yamalube (or equivalent) SAE 10W-40, API SG or higher, JASO MA certified
Oil Capacity W Filter:
Approx. 1.42 US qt (1.35 L)
Cooling System
Coolant Type:
High-quality ethylene glycol-based coolant, 50/50 mix with distilled water
🔧 Transmission
Standard
Type:
Constant mesh 5-speed sequential
Clutch Type:
Wet, multiple-disc
Features
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st: 2.615, 2nd: 1.875, 3rd: 1.500, 4th: 1.250, 5th: 1.050 - typical for this model).
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube (or equivalent) SAE 80 GL-4 hypoid gear oil
Transmission Oil Capacity:
Approx. 0.73 US qt (0.69 L)
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (85.4 in)
Width:
Approx. 815 mm (32.1 in)
Height:
Approx. 1280 mm (50.4 in)
Seat Height:
Approx. 970 mm (38.2 in)
Wheelbase:
Approx. 1475 mm (58.1 in)
Weights
Dry Weight:
Approx. 114 kg (251.3 lbs)
Wet Weight:
Approx. 120 kg (264.6 lbs) (with all fluids)
Front Tire Size:
80/100-21M/C 51P
Rear Tire Size:
110/90-19M/C 62P
Wheelbase Type:
Spoked wheels
Wheelbase Bolt Pattern:
N/A (Motorcycle - no bolt pattern for wheels)
🛡️ Safety Features
Ratings
Safety Certification:
Not Applicable (Off-road motorcycle)
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Suspension System:
Advanced adjustable suspension for superior control and terrain absorption.
Passive Features
Lighting:
Halogen headlight, LED taillight/brake light.
💡 Technology Features
Infotainment
Features:
Basic LCD display (speedometer, odometer, trip meters, clock). No complex infotainment system typical of street bikes.
Driver Assistance
Features:
N/A (No electronic rider aids like ABS or traction control on this model).
Connectivity
Features:
N/A (No Bluetooth or Wi-Fi connectivity).
Engine Management
System:
Yamaha Chip Controlled Fuel Injection (YCC-FI) and Ignition (YCCI).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km or 3 months (whichever comes first) under normal use. More frequent for severe off-road use.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 500 km or more frequently in dusty conditions.
Spark Plug Replacement:
Refer to manual for specific mileage, typically around 6,000-10,000 km.
Valve Clearance Check:
Every 5,000 km or as specified in the manual.
Fluid Specifications
Engine Oil Specification:
Yamalube 10W-40, API SG/SH/SJ/SL, JASO MA.
Transmission Oil Specification:
Yamalube SAE 80 GL-4 hypoid gear oil.
Coolant Specification:
50/50 mix of high-quality ethylene glycol coolant and distilled water.
Brake Fluid Specification:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch plates, piston rings, valve stem seals, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Potential Faults:
Fuel pump issues (rare), stator output degradation, stator connector overheating (in some earlier models/conditions), potential for stator failure leading to no-spark condition.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, established 1955, renowned for innovation in motorcycles, marine products, and musical instruments.
Model Evolution
Wr Series Introduction:
The WR series has a long lineage of off-road competition bikes, evolving from earlier YZ models.
2008 Model Updates:
This generation (introduced around 2007/2008) featured significant updates including fuel injection and revised chassis geometry for improved performance and handling over previous carbureted models.
Production
Manufacturing Location:
Japan (primary)
🏆 Awards & Recognition
Recognitions
Offroad Magazine Reviews:
Consistently praised in off-road and enduro magazines for its performance, handling, and reliability within its class during its production run.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to robust Yamaha build quality and performance capabilities.
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