2006 Yamaha WR250F(V) Owner's Service Manual (P/N 5UM-28199-53)

This Yamaha Owner's Service Manual, 5UM-28199-53, covers the 2006 WR250F(V) for the U.S., Canada, Europe, Australia, New Zealand, and South Africa. It combines operating guidance with inspection, maintenance, repair, and tuning procedures.

• Engine repair: Engine removal, camshaft timing, cylinder-head and valve service, piston inspection, crankcase separation, and crankshaft installation.

• Clutch and transmission: Clutch disassembly, gear and shift-fork inspection, shift-cam service, kickshaft work, balancer alignment, and starter-clutch checks.

• Fuel system: Keihin FCR-MX37 carburetor disassembly, float-height inspection, accelerator-pump timing adjustment, and air-induction valve testing.

• Cooling and lubrication: Radiator and cooling-system pressure tests, water-pump seal replacement, oil-pump clearance checks, and oil-strainer service.

• Chassis service: Brake caliper and master-cylinder repair, brake bleeding, fork-seal replacement, steering-stem service, wheel-bearing replacement, and swingarm linkage inspection.

• Electrical diagnosis: Ignition, starting, charging, lighting, and speedometer fault charts, plus AC magneto testing, throttle-position sensor adjustment, and starter-motor repair.

The operating sections address owners, while internal repair procedures suit experienced mechanics equipped for precision measurement and the specified special tools.

Engine, Clutch, and Transmission Work

Exploded and sectional views, together with job instruction charts, identify parts, removal scope, lubrication points, and replacement items. Internal work includes valve-guide replacement, camshaft clearance measurement, piston-ring inspection, and crankshaft checks, with separate assembly coverage for the transmission, balancer, and oil pump.

Valve-pad selection tables connect measured clearances with replacement pad sizes. The tool list identifies the crankcase separator as YU-1135-A / 90890-01135 and the valve spring compressor as YM-4019 / 90890-04019.

Component torque tables and torque-check charts cover engine mounts and chassis fasteners. The camshaft section warns that uneven cap-bolt handling can damage the cylinder head, camshafts, and caps.

Carburetor Setup and Display Functions

Carburetor coverage extends to the air-cut valve, accelerator-pump diaphragm, leak jet, and hot-start plunger. Tuning charts relate mixture symptoms and throttle opening to jet and needle selection, with atmospheric-condition guidance and setting-part numbers.

The multi-function display's Basic and Race modes cover clock, tripmeter, and timer operation. A function diagram maps the controls; Race mode provides time and distance measurement.

CDI, Starting, and Electrical Fault Tracing

The map-controlled CDI section explains how throttle-position and pickup-coil signals affect ignition timing. Wiring and cable-routing diagrams, connector test views, and ignition and starting fault charts help distinguish wiring or switch faults from component failures before replacement.

Charging and lighting checks have their own test specifications. Speedometer diagnosis includes display supply/output checks and speed-sensor testing.

Suspension, Steering, and Brake Service

Regional tables distinguish frame geometry, rim and tire specifications, suspension settings, and spring selections. Fork work includes damper-rod removal, seal replacement, oil-level setting, and bleeding; Yamaha recommends dealer servicing for this assembly.

Rear-shock service covers removal, spring and mounting-bearing replacement, and external preload and damping adjustments. The nitrogen-filled cylinder and reservoir must not be opened; leaking or damaged dampers are handled by assembly replacement.

The shock-bearing instructions also warn that grease on the upper bearing's outer race can wear the housing's press-fit surface. Suspension-setting charts connect riding symptoms with fork and shock adjustments.

Examples of Valve Clearances and Service Capacities

These examples show a small selection of the manual's valve-setting and fluid-capacity data.

For the covered WR250F, cold valve clearances are 0.10–0.15 mm at the intake and 0.17–0.22 mm at the exhaust.

The specifications list 1.26 L for the complete cooling circuit. Engine-oil service quantities distinguish a 1.2 L periodic change from 1.3 L with oil-filter replacement.

PDF Navigation, Languages, and Included Pages

Search, bookmarks, and diagram detail: Searchable text and language-grouped PDF bookmarks support navigation. Small wire-color codes and connector labels in the main wiring diagram require zooming for comfortable reading.

Supplied as one printable, 896-page PDF in English, French, German, Italian, and Spanish. The total already includes two cover pages, 22 introductory, index, and contents pages, and 10 memo pages.