Market Segment:
Dual-sport motorcycle, targeting off-road and street-legal trail riding enthusiasts.
Competitive Landscape 1994:
Competed against models like Honda XR250L, Kawasaki KLX250SR, Suzuki DR250SE.
Vehicle Key Selling Points:
Lightweight construction, robust engine, capable suspension for off-road use, street legality for versatile use.
Countries Of Sale:
Primarily North America, Europe, and Japan (based on common Yamaha distribution for this era).
Regions Covered:
Covers specifications and procedures applicable to the 1994 Yamaha WR250 model as sold globally, with potential regional variations noted where applicable.
Page Count:
Estimated 300-400 pages (typical for a comprehensive factory service manual of this era).
Manual Type:
Factory Service Manual (FSM)
Language:
English (standard for export models and documentation).
Engine Mechanical:
Engine overhaul, disassembly, assembly, cylinder head, piston, crankshaft, connecting rod, valve timing, lubrication system.
Engine Fuel System:
Carburetor (Mikuni VM series typical), fuel lines, fuel tank, fuel pump (if applicable).
Engine Ignition System:
CDI ignition, ignition coil, spark plug, timing adjustments.
Engine Exhaust System:
Exhaust pipe, muffler, sound dampening components.
Transmission:
Gearbox, clutch operation and overhaul, gear selection mechanism, transmission lubrication.
Drivetrain:
Final drive chain and sprockets, chain adjustment and replacement.
Suspension:
Front fork (KYB or similar), rear monoshock (Monocross system), linkage, springs, damping adjustments, oil seals, fork tube replacement.
Brakes:
Front disc brake system (caliper, master cylinder, brake lines, rotor), rear drum brake system (or disc, depending on exact spec), brake fluid specifications and bleeding procedures.
Wheels And Tires:
Spoke wheel maintenance, wheel bearing inspection, tire pressure recommendations, wheel removal and installation.
Electrical System:
Wiring diagrams, lighting system, battery, charging system (stator, rectifier/regulator), starter (if electric start model), fuses, switches.
Cooling System:
Liquid-cooled engine (if applicable), radiator, hoses, coolant specifications, thermostat.
Frame And Bodywork:
Frame inspection, fuel tank mounting, seat, fenders, handlebars, controls, plastics.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug inspection/replacement, air filter cleaning.
Troubleshooting:
Diagnostic flowcharts for common running issues, electrical problems, and starting difficulties.
Disassembly And Assembly:
Step-by-step instructions for major component removal, overhaul, and reinstallation.
Technical Specifications And Data:
Torque values, clearances, fluid capacities, electrical resistance values, performance data.
Depth Of Coverage:
Comprehensive; suitable for DIY mechanics and professional technicians. Covers basic adjustments to full engine and transmission rebuilds.
Diagnostic Capabilities:
Advanced troubleshooting guides and diagnostic charts for identifying root causes of malfunctions.
Engine Type:
Four-stroke, single-cylinder, DOHC, liquid-cooled.
Engine Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
Approx. 72 mm x 61.2 mm (typical for this engine family).
Compression Ratio:
Approximately 11.5:1 (speculative, common for performance 250cc singles).
Carburetor Model:
Likely Mikuni VM32SS or similar 32mm constant-velocity carburetor.
Cooling Method:
Liquid Cooling with electric fan.
Starting System:
Kick start.
Horsepower Estimation:
Approx. 25-30 HP (at crank, highly dependent on tuning and market).
Torque Estimation:
Approx. 2.2-2.5 kgf-m (kilogram-force meters) or 16-18 lb-ft.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Fuel Tank Capacity:
Approx. 9.0 Liters (2.37 US gallons).
Overall Length:
Approx. 2140 mm (84.25 inches).
Overall Width:
Approx. 820 mm (32.28 inches).
Overall Height:
Approx. 1245 mm (49.02 inches).
Wheelbase:
Approx. 1430 mm (56.3 inches).
Ground Clearance:
Approx. 305 mm (12 inches).
Dry Weight Estimation:
Approx. 117 kg (258 lbs).
Wet Weight Estimation:
Approx. 125 kg (275 lbs) with all fluids.
Seat Height:
Approx. 910 mm (35.8 inches).
Safety Standards:
As a dirt/dual-sport bike of this era, it meets general road safety regulations for lighting and emissions where applicable, but does not have formal crash test ratings like passenger vehicles.
Braking System:
Hydraulic disc front brake, drum or disc rear brake for effective stopping power.
Lighting:
Headlight, taillight, turn signals (for street-legal versions), ensuring visibility.
Frame Construction:
Steel semi-double cradle frame provides structural integrity.
Engine Oil Change Interval:
Every 1,000-2,000 km or 3-6 months, whichever comes first (recommendation).
Air Filter Cleaning Interval:
Every 500-1,000 km or after aggressive off-road use (recommendation).
Spark Plug Inspection Interval:
Every 2,000-3,000 km (recommendation).
Chain Lubrication Adjustment Interval:
Every 300-500 km or after riding in wet/dirty conditions (recommendation).
Valve Clearance Check Interval:
Every 6,000-10,000 km (critical for DOHC engines, specific interval in manual).
Engine Oil Viscosity:
SAE 10W-30 or 10W-40.
Engine Oil API Rating:
API SG, SH, or SJ classification.
Engine Oil Capacity:
Approx. 1.8 Liters (with filter change).
Coolant Type:
Yamaha Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors), mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Fork Oil Type:
Specific fork oil grade (e.g., SAE 10W) will be listed in the manual, capacity per fork leg approximately 535 ml (18.1 US oz).
Common Wear Items:
Clutch wear, fork seal leaks, swingarm bearing wear, carburetor jetting issues due to age/ethanol fuels.
Engine Specific Concerns:
Potential for cam chain tensioner noise if not maintained; regular valve checks are crucial for longevity.
Electrical Challenges:
Corrosion on connectors, stator output degradation over time, regulator/rectifier failure.
Yamaha Motorsports Legacy:
Yamaha has a long-standing reputation for performance and innovation in motorcycle racing and off-road disciplines, dating back to the mid-20th century.
Wr Series Introduction:
The WR series was developed as Yamaha's premier off-road competition line, building on the success of the YZ (Motocross) and XT/TT (Enduro) lines. The WR250 specifically aimed to bridge the gap between Motocross and Enduro.
1994 Model Context:
The 1994 model represented an early iteration of Yamaha's liquid-cooled, DOHC 250cc off-road platform, featuring advancements over previous air-cooled models and setting the stage for future WR iterations.
Production Period:
The WR250, in various forms, was produced throughout the 1990s and into the 2000s.
