Yamaha WR250 Replacement Parts Manual 1996

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Type: Motorcycle

Vendor:

Sku: 130259

Tags: 1996 Marine Motorcycle Sterndrive WR250 Yamaha

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Description

This manual pertains to the 1996 WR250, a robust off-road competition motorcycle renowned for its performance and durability. Evolving from a successful motocross lineage, the WR250 was engineered for demanding enduro and cross-country riding. Its 2-stroke, liquid-cooled engine, typically producing around 40-45 horsepower, coupled with a 6-speed transmission and capable suspension, made it a formidable machine for its era. The model's design prioritizes agility and power, reflecting a commitment to off-road excellence and an extensive history in racing. This Replacement Parts Manual provides essential information for owners and technicians seeking to identify and source genuine components for the 1996 WR250. It offers detailed parts breakdown, illustrated exploded diagrams, and comprehensive part number listings covering all major systems, including the engine, fuel system, chassis, brakes, and electrical components. The manual's primary purpose is to facilitate accurate parts identification, enabling efficient maintenance, repair, and restoration, thereby supporting the longevity and optimal performance of the motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

WR250

Year:

Model Designation:

WR250

👋 Introduction

Market Position

Market Position:

Essential reference for owners and technicians of the 1996 Yamaha WR250, enabling cost-effective parts sourcing and DIY maintenance.

Competitive Analysis

Competitive Advantage:

Provides instant access to OEM part information, eliminating the need for physical manuals or expensive dealer consultations for parts identification. Significant cost savings by enabling users to find and order parts independently.

Key Features

Key Features:

Illustrated exploded parts diagrams, comprehensive part number listings, clear and user-friendly format, instant download availability, cost-saving potential.

📋 Manual Details

Coverage Areas

Manual Type:

OEM Replacement Parts Manual

Language:

English

File Format:

Compatibility:

All PC & MAC Computers

Page Count

Page Count Estimated:

Detailed page count not specified, but implies comprehensive coverage for parts identification.

📖 Manual Coverage

Systems Covered

Covered Systems:

Engine (internal and external components), Fuel System, Intake System, Exhaust System, Cooling System, Chassis, Suspension (front and rear), Brakes (front and rear), Wheels and Tires, Electrical System (lighting, ignition, starting), Controls (throttle, clutch, brakes), Bodywork and Plastics, Drive Train (chain, sprockets).

Procedures Included

Included Procedures:

Parts Identification, Disassembly Reference, Assembly Reference, Component Breakdown.

Technical Depth

Technical Depth:

Parts-level detail with exploded diagrams and part numbers for accurate replacement. Focuses on component identification rather than repair procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Printable pages with clear illustrations and part numbers.

Binding Type

Binding Type:

Digital Download (Printable PDF)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Liquid-Cooled

Displacement:

239cc (approximate, actual may vary slightly based on specific sub-model)

Bore X Stroke:

Specifications found within the manual's engine sections.

Compression Ratio:

Specifications found within the manual's engine sections.

Performance

Horsepower Estimated:

Typically in the 40-45 HP range for this era of competition 250cc off-road bikes. Exact figures would be in a service manual.

Torque Estimated:

Specifications found within the manual's engine sections if available, or service manual.

Fuel System

Fuel Delivery:

Carburetor

Carburetor Type:

Mikuni VM Series (likely a VM28 or VM30, specific model in manual)

Fuel Type:

Unleaded gasoline with appropriate octane rating for high-performance 2-stroke engines (e.g., 91+ octane).

Oil Mixing Ratio:

Typically 20:1 or 32:1 (fuel to 2-stroke oil), specific recommendation in manual.

🔧 Transmission

Standard

Transmission Type:

6-Speed Constant Mesh

Clutch Type:

Wet, Multi-plate

Final Drive:

Chain Driven

Features

Gear Ratios:

Specific gear ratios for each of the 6 speeds are detailed in the full service manual, but parts for the gearbox are covered here.

Transmission Oil Type:

Yamalube or equivalent SAE 10W-30 or SAE 20W-40 API SE, SF, SG, SH, SJ classification (specific grade in manual).

📐 Dimensions

Exterior

Length Overall:

Specifications found in the manual's chassis section.

Width Overall:

Specifications found in the manual's chassis section.

Height Overall:

Specifications found in the manual's chassis section.

Weights

Dry Weight Estimated:

Approximately 220-230 lbs (100-105 kg) for a competition 250cc off-road bike of this era.

Fuel Capacity:

Approximately 2.5 - 3.0 gallons (9.5 - 11.3 liters), specific capacity in manual.

🛡️ Safety Features

Ratings

Safety Ratings:

As an off-road competition motorcycle, it is not subject to standard road safety ratings (e.g., NHTSA, Euro NCAP). Safety is derived from rider skill and proper maintenance.

Active Features

Active Safety Features:

Responsive braking system (disc brakes front and rear), capable suspension for stability.

Passive Features

Passive Safety Features:

Durable frame construction.

💡 Technology Features

Infotainment

Infotainment Features:

N/A - This is a competition off-road motorcycle and does not feature infotainment systems.

Driver Assistance

Driver Assistance Features:

N/A - This is a competition off-road motorcycle and does not feature electronic driver assistance systems.

Connectivity

Connectivity Features:

N/A - This is a competition off-road motorcycle and does not feature connectivity.

🔧 Maintenance

Service Intervals

Air Filter Cleaning:

Frequent cleaning recommended, especially after dusty conditions (e.g., every few rides). Specific interval and procedure in service manual.

Spark Plug Inspection:

Inspect every 10-15 hours of riding, replace as needed. Specific type required (e.g., NGK BR8ES or similar).

Chain Lubrication:

Lubricate after every wash or every few rides, depending on conditions.

Transmission Oil Change:

Recommended every 20-30 hours of riding or annually. Specifications for oil type and capacity are crucial and found in the manual.

Fluid Specifications

Coolant Type:

Mixture of distilled water and permanent antifreeze (ethylene glycol-based) with corrosion inhibitors for aluminum engines. 50/50 mix is standard. Capacity detailed in manual.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Specific type and bleeding procedure in service manual.

Known Issues

Known Issues Common:

Typical for 2-stroke off-road bikes of this era: Piston/ring wear with high mileage, carburetor jetting adjustments for varying altitudes/conditions, occasional stator or CDI unit failure, chain and sprocket wear, suspension seal leaks. The parts manual helps identify and source replacement components for these common wear items.

Top End Rebuild:

A 2-stroke engine's top end (piston, rings, cylinder) is a wear item and requires periodic rebuilding based on usage hours. This manual facilitates sourcing all necessary components.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Yamaha has a long and successful history in off-road motorcycle racing, particularly with its 'Works Replica' (WR) line, known for performance and durability.

Model Evolution

Model Evolution:

The WR250 line evolved from Yamaha's motocross (YZ) platform, adapted for wider-ratio gearing, more comfortable ergonomics, and features suitable for enduro and cross-country riding. The 1996 model represents a key iteration in this development.

Production

Production Period:

The WR250 was produced across various iterations from the early 1990s through the early 2000s. The 1996 model is a specific variant within this lineage.

Manufacturing Location:

Yamaha Motor Corporation, Japan (primary manufacturing, assembly may vary).

🏆 Awards & Recognition

Recognitions

Recognitions:

Specific awards for the 1996 WR250 are not readily documented in general historical reviews, but the WR line itself has a reputation for strong performance in its class during its production years.

Ratings

Rider Reviews:

Generally well-regarded for its power delivery, suspension performance, and reliability for its intended off-road use. Owners appreciate its competition-focused design.