2001-2006 Yamaha WR250F Service and Repair Manual

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Type: Motorcycle

Vendor:

Sku: 118403

Tags: 2001 2002 2003 2004 2005 2006 Marine Motorcycle Sterndrive WR250F Yamaha

Product variants

Description

This manual covers the off-road motorcycle, produced for the model years 2001 through 2006. The WR250F is a liquid-cooled, 4-stroke dual-sport/enduro motorcycle known for its performance in competitive off-road events. Built with an aluminum alloy frame for rigidity and a dry weight of approximately 111 kg, it is designed for demanding terrain. Key features include a 249 cc DOHC engine, a 5-speed transmission with a wet, multiple-disc clutch, and hydraulic disc brakes front and rear. The WR250F platform benefits from an extensive heritage in off-road racing, establishing it as a capable and competitive machine in its class. This comprehensive service and repair manual provides detailed information for maintaining and repairing your WR250F. It covers all essential systems, including complete engine overhaul, transmission service, chassis maintenance, and electrical system diagnostics. The manual offers step-by-step instructions for scheduled maintenance, troubleshooting common issues, component repair and replacement, and full disassembly/reassembly procedures. With hundreds of photos, illustrations, and detailed wiring schematics, this resource is designed to assist both do-it-yourself enthusiasts and professional mechanics in keeping the vehicle in optimal working condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

WR250F

Model Codes:

N (2001), P (2002), R (2003), S (2004), T (2005), V (2006)

Vehicle Type:

Off-Road Motorcycle (Dual-Sport/Enduro)

👋 Introduction

Market Position

Target Audience:

Do-it-yourself enthusiasts and experienced mechanics.

Value Proposition:

Inexpensive way to keep the vehicle working properly, comprehensive repair and service information.

Competitive Analysis

Advantage:

Instant download, multilingual support, detailed illustrations and schematics.

Key Features

Uniqueness:

The only service repair workshop manual you will ever need.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Applicable Years:

2001, 2002, 2003, 2004, 2005, 2006

Language:

English, German, French, Italian, Spanish

Delivery Method:

Instant Download

Digital Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, carburetor tuning, internal component inspection and replacement, cooling system.

Transmission:

Gearbox disassembly, clutch service, shift mechanism.

Chassis:

Frame inspection, suspension (forks and shock absorber) service and adjustment, steering system.

Electrical:

Wiring diagrams, ignition system, lighting, battery service, starter system.

Fuel System:

Carburetor removal, cleaning, adjustment, fuel tank and lines.

Exhaust System:

Exhaust pipe and muffler maintenance, seal replacement.

Brakes:

Hydraulic brake system service, pad replacement, caliper maintenance, bleeding procedures.

Wheels And Tires:

Tire inspection and replacement, wheel bearing service, spoke tensioning.

Procedures Included

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, general inspection.

Troubleshooting:

Diagnostic procedures for common performance issues, starting problems, and electrical faults.

Repair:

Step-by-step instructions for component repair and replacement, from minor adjustments to major overhauls.

Disassembly Reassembly:

Detailed guidance on the complete disassembly and reassembly of the motorcycle and its components.

Engine Rebuild:

Detailed steps for complete engine disassembly, inspection, and reassembly, including piston, rings, valve servicing.

Suspension Servicing:

Procedures for front fork seal replacement, oil changes, and rear shock absorber servicing and adjustment.

Electrical Diagnostics:

Troubleshooting electrical issues using wiring diagrams, including ignition timing and charging system checks.

Carburetor Overhaul:

Step-by-step guide for disassembling, cleaning, inspecting, and reassembling the Keihin FCR carburetor.

Wheel And Spoke Truing:

Instructions on checking and adjusting spoke tension for proper wheel alignment and truing.

Cooling System Maintenance:

Procedures for draining, flushing, refilling, and bleeding the liquid cooling system.

Technical Depth

Depth Level:

Comprehensive from basic do-it-yourself to advanced mechanic procedures.

Illustrations:

Hundreds of photos and illustrations guiding each procedure.

Schematics:

Detailed wiring schematics and diagrams included.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully indexed for easy navigation

Requirements:

Adobe PDF Reader

Compatibility:

All Windows & Mac Computers (Windows 7, Vista 32/64, XP, ME, 98, NT, 2000 etc.)

Print Quality

Printability:

All pages are printable

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

77.0 mm x 53.6 mm (3.03 in. x 2.11 in.)

Performance

Horsepower:

Approximately 30-35 HP (varies by year and tuning)

Torque:

Not explicitly stated in product info, but estimated in manual for specific model years.

Fuel System

Carburetor Type:

Keihin FCR 37

Fuel Capacity:

N/A (Specified in manual)

Ignition

Ignition System:

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc

Features

Gear Ratios:

Detailed in manual for specific model years.

📐 Dimensions

Exterior

Length:

N/A (Specified in manual)

Width:

N/A (Specified in manual)

Height:

N/A (Specified in manual)

Weights

Dry Weight:

Approx. 111 kg (244.7 lbs) (varies by year)

Wet Weight:

N/A (Specified in manual)

🛡️ Safety Features

Ratings

Safety Features:

Standard motorcycle safety features; no specific ratings provided for this type of vehicle in product info.

Active Features

Braking System:

Hydraulic disc brakes (front and rear)

Passive Features

Frame Construction:

Aluminum alloy frame for rigidity and weight reduction.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle focused on performance, not infotainment).

Driver Assistance

Electronic Aids:

N/A (Primarily mechanical systems).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/hour intervals (typically every 10-20 hours of riding for off-road use).

Air Filter Cleaning:

Frequent cleaning/replacement recommended based on riding conditions.

Spark Plug Replacement:

Refer to manual for specific intervals.

Fluid Specifications

Engine Oil Type:

Yamaha recommends specific Yamalube oils, SAE 10W-40 or 20W-40 API SG, SG/CD, SF or SF/CD. Manual specifies exact grades.

Coolant Type:

Permanent type antifreeze coolant (50% solution) or equivalent.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, piston rings due to off-road use.

Carburetor Tuning:

Can be sensitive to altitude and temperature changes; requires periodic adjustment.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation, a leading global manufacturer of motorcycles, marine products, and other motorized products.

Model Evolution

Development:

The WR250F is an evolution of Yamaha's off-road racing heritage, designed for competitive enduro and cross-country events.

Production

Production Period:

Covered years: 2001-2006. Model has seen continuous updates and variations since its introduction.

🏆 Awards & Recognition

Recognitions

Racing Success:

The WR250F platform has a strong lineage in off-road racing disciplines, contributing to its reputation.

Ratings

Industry Perception:

Generally regarded as a capable and competitive enduro machine in its class.