2002 Yamaha WR250F Service & Repair Manual (P/N 5PH-28199-31)

This 690-page official Yamaha factory publication (P/N 5PH-28199-31) is the primary reference for the original 2002 WR250F(P) competition model launch. It covers regional variants for the USA, Europe, Canada, Australia, New Zealand, and South Africa. You get baseline factory tolerances, torque specifications, and 46 detailed exploded-view diagrams detailing internal engine and chassis components. The manual also maps out 14 electrical connector and continuity procedures alongside 7 comprehensive technical specification tables.

Manual Organization

Mechanics and DIYers will find a logical breakdown of technical data and assembly documentation. The manual details general machine identification, routine inspection schedules, and essential maintenance guidelines for the engine, chassis, and electrical systems. It provides a professional reference for assembly, disassembly, and component inspection operations, covering everything from carburetor tuning to cooling system specs and torque-check points.

It dives deep into the technical weeds. You will find exact valve clearance ranges (0.10–0.22 mm), piston-to-cylinder clearance limits, and torque settings for critical fasteners like the M9 cylinder head bolts (38 Nm) and the crankshaft assembly. The documentation also lists the primary reduction ratio (57/17) and maps out specialized data for suspension tuning, detailing front fork oil capacity and rear shock gas pressure requirements.

Specification Previews

Engine oil capacity is marked at 1.5 liters for periodic changes. For USA models, the Keihin FCR-MX37 carburetor main jet is specified as #175. The maintenance section lists the spark plug gap at 0.7–0.8 mm. Keep in mind that working on competition motorcycles involves inherent risks. Always rely on qualified technicians and the complete OEM documentation as your definitive guide before attempting any hands-on maintenance or adjustments.