2002 Yamaha WR250F Service Manual (690 P.)

Technical Scope and Data

• Covers 2002 Yamaha WR250F(P) series performance machines, including regional variants for USA, Europe, Canada, Australia, New Zealand, and South Africa markets
• Official Yamaha publication P/N 5PH-28199-31
• Contains 46 detailed exploded-view diagrams, 14 electrical connector/continuity procedures, and 7 comprehensive technical specification tables
• Accessible from your device as soon as the order is placed
• Permanent availability in your purchase account — no re-buy required
• Suitable for printing individual sections for shop-floor use
• Indexed PDF search covers every chapter and appendix
• This official 2002 first edition is the primary reference for the original WR250F(P) competition model launch, providing baseline factory tolerances and torque specifications for all internal engine and chassis components

Manual Organization

This factory service publication provides technical data and assembly documentation for the 2002 Yamaha WR250F. The manual details general machine identification, routine inspection schedules, and essential maintenance guidelines for the engine, chassis, and electrical systems. It encompasses torque-check points, carburetor tuning, and cooling system specifications, offering a professional reference for assembly, disassembly, and component inspection operations.

The document includes extensive technical data such as valve clearance ranges (0.10–0.22 mm), piston-to-cylinder clearance limits, and torque settings for critical fasteners like the cylinder head (38 Nm for M9 bolts) and crankshaft assembly. The manual also documents the primary reduction ratio (57/17) and provides specialized data for suspension tuning, including front fork oil capacity and rear shock gas pressure requirements.

Specification Previews

Engine oil capacity is documented at 1.5 liters for periodic changes. The Keihin FCR-MX37 carburetor main jet is specified as #175 for USA models. Spark plug gap is listed at 0.7–0.8 mm in the maintenance specification section. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This 690-page Yamaha factory workshop manual covers the 2002 Yamaha WR250F, providing comprehensive engine, chassis, electrical, and fuel-injection specifications for the 5PH-series production models.