🏷️ Basic Information Identification Make: Yamaha Model: WR250FR Year: 2003 Codes Chassis Code: DJ021 Engine Code: G401E 👋 Introduction Market Position Segment: Competition Enduro / Off-Road Motorcycle Target Audience: Enthusiast riders, mechanics, and owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Competitors 2003: KTM 250 EXC, Honda CRF250X, Kawasaki KLX250S, Suzuki DR-Z250 Key Features Model Designation: FR - signifies the Factory Replica / Race-Ready trim often associated with enhanced suspension and performance components. 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service / Repair / Workshop Page Count Total Pages: 343 Manual Type Type: Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, and reassembly of the engine. Fuel System: Carburetor service, fuel pump, fuel lines, and fuel tank maintenance. Cooling System: Radiator, coolant, water pump, and thermostat service. Ignition System: CDI unit, spark plug, ignition coil, and wiring checks. Transmission Clutch: Clutch operation, clutch plates, transmission gears, shift mechanism, and lubrication. Suspension Front: Front fork service, oil levels, seals, springs, and damper adjustments. Suspension Rear: Monoshock absorber service, linkage, bearings, and adjustability. Braking System Front: Brake caliper service, master cylinder, brake pads, rotors, and fluid. Braking System Rear: Rear brake caliper service, master cylinder, brake pads, rotor, and fluid. Electrical System: Wiring diagrams, battery, lighting, starter motor, charging system, and fuses. Frame Chassis: Frame inspection, swingarm, steering head bearings, and wheel bearings. Bodywork: Fairing removal, plastics, seat, and fuel tank installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, and lubrication points. Troubleshooting Diagnostics: Step-by-step guides for identifying and resolving common problems. Engine Rebuild Procedures: Detailed instructions for engine disassembly, cleaning, part replacement, and reassembly. Carburetor Tuning: Adjustments for idle speed, jetting, and mixture for optimal performance. Suspension Setup: Sag adjustment, damping control, and oil weight recommendations. Brake Bleeding: Proper procedure for removing air from the hydraulic brake system. Electrical Troubleshooting: Using wiring diagrams to diagnose electrical faults. Wheel Bearing Replacement: Instructions for removing and installing wheel bearings. Steering Head Service: Inspection and replacement of steering head bearings. Technical Depth Depth Level: Comprehensive Workshop Manual Detail Level: Factory-level repair and maintenance procedures. Specifications Accuracy: Includes all critical torque specifications, clearances, and measurements. Diagnostic Charts: Detailed diagnostic flowcharts for common issues. Special Tools: Lists and descriptions of special tools required for specific repairs. 📊 Manual Specifications File Format Format: PDF Searchable: Yes Print Quality Quality: Factory Zoom Functionality: Yes Printable: Yes Binding Type Binding: Digital Download (PDF) Paper Type Paper Quality Simulated: High-resolution digital reproduction of original factory document. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, 4-valve Displacement: 250cc Bore X Stroke: 74.0 mm x 57.7 mm Cooling Method: Liquid-cooled Performance Horsepower Estimated: Approximately 30-35 HP (stock, may vary) Torque Estimated: Approximately 20-23 Nm (stock, may vary) Fuel System Carburetor Type: Mikuni VM34SS (or similar 34mm flat-slide carburetor) Fuel Type: Unleaded gasoline (Octane rating as specified in manual) Ignition Ignition System: Digital CDI Lubrication Oil Type: Yamaha Genuine 4-Stroke Motor Oil or equivalent SAE 10W-30 or 20W-40 API SE, SF, SG Oil Capacity W Filter: 1.00 L (1.05 US qt) Oil Capacity Wo Filter: 0.90 L (0.95 US qt) 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed Clutch Type: Wet, multiple disc, cable-operated Features Gear Ratios: Detailed gear ratios for each speed are specified within the manual. Final Drive: O-ring sealed chain Transmission Oil Type: Yamalube SAE 80 Hypoid Gear Oil or API GL-4 SAE 80 Transmission Oil Capacity: 0.55 L (0.58 US qt) 📐 Dimensions Exterior Length: 2180 mm (85.8 in) Width: 825 mm (32.5 in) Height: 1260 mm (49.6 in) Seat Height: 970 mm (38.2 in) Wheelbase: 1475 mm (58.1 in) Ground Clearance: 365 mm (14.4 in) Weights Wet Weight Approx: 119 kg (262 lbs) (fully fueled, ready to ride) Dry Weight Approx: 112 kg (247 lbs) Fuel Tank Capacity: 9.0 L (2.4 US gal) Fuel Reserve Capacity: 2.2 L (0.6 US gal) 🛡️ Safety Features Ratings Crash Safety Standard: Not applicable to off-road motorcycles in the same manner as passenger vehicles. Active Features Brakes: Hydraulic disc brakes front and rear for effective stopping power. Suspension: Advanced suspension systems designed for stability and control on varied terrain. Passive Features Frame Construction: Robust frame designed for durability and rider confidence. Ergonomics: Rider-focused design for control and fatigue reduction. 💡 Technology Features Infotainment Display Type: Analog speedometer, odometer, trip meter, and basic indicator lights. Driver Assistance ABS: No ABS (Anti-lock Braking System) equipped on this model. Connectivity Bluetooth Usb: No Bluetooth or USB connectivity; a pure off-road experience. 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km or 6 months, whichever comes first (refer to manual for exact recommendations). Air Filter Cleaning: Inspect and clean every 1000 km or more frequently in dusty conditions. Spark Plug Replacement: Inspect every 1000 km, replace...