Yamaha WR250F Cable Routing Diagram

Frame and engine (front left side view)

Components

1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Handlebar switch lead (left)
5. Start switch lead
6. Cable holder
7. Handlebar switch coupler (left) (black, 6-pin)
8. Start switch coupler (black, 2-pin)
9. Rectifier/regulator coupler
10. Tension arm
11. Gear position switch lead
12. Crankcase cover bolt (left)
13. Radiator hose
14. Stator coil assembly lead
15. Gear position switch coupler (white, 3-pin)
16. Stator coil assembly coupler (gray, 2-pin)
17. Grommet
18. Crankcase breather hose
19. Lower engine bracket
20. Radiator breather hose
21. Holder
22. Bracket

Instructions

A. Adjust slack in the handlebar switch lead (left) and start switch lead at the vehicle’s front side of the cable holder.

B. Pass the handlebar switch lead (left) and the start switch lead between the frame and the cable holder. Pass the handlebar switch lead (left) above the start switch lead.

C. Insert the handlebar switch 6-pin coupler (left) (black) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

D. Insert the rectifier/regulator 2-pin coupler (not colored) and rectifier/regulator 3-pin coupler (not colored) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

E. Pass the rectifier/regulator lead (wire harness side) to the inside of the tension arm (the side of the vehicle).

F. Route the gear position switch lead along the crankcase cover while making sure that there is no looseness of the lead.

G. Fasten the clutch cable and stator coil assembly lead with a plastic locking tie. The fastening position should be between the crankcase cover bolt (left) and the crankcase cover bolt (left), as shown. Place the lock portion of the plastic locking tie to the outside of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

H. Bring the protector of the clutch cable into contact with the radiator hose, and pass it to the outside of the gear position switch lead and the stator coil assembly lead (the outside of the vehicle).

I. Pass the stator coil assembly lead behind the radiator. Be sure the lead will not be pinched between the radiator and the tension arm. Make sure that the stator coil assembly lead does not get caught between the radiator and the gear position switch 3-pin coupler (white).

J. After connecting the gear position switch 3-pin coupler (white), attach the coupler cover.

K. After connecting the stator coil assembly 2-pin coupler (gray), attach the coupler cover.

L. Fasten the clutch cable, gear position switch lead, and stator coil assembly lead over the grommet with the plastic locking tie. Place the lock portion of the plastic locking tie to the front of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

M. Route the crankcase breather hose between the radiator and the frame, and in front of the lower boss of the radiator.

N. Route the crankcase breather hose at the rear of the vehicle where the radiator breather hose is located.

O. Route the radiator breather hose between the radiator hose and the crankcase breather hose. Then, route it inside the vehicle’s lower engine bracket.

P. Clamp the clutch cable at the front of the lead (the front of the vehicle).

Q. Insert the clip portion of the clamp into the frame. The lock part should face toward the front of the vehicle. Cut off the end of the remaining portion. (The direction of the end does not matter.)

R. When installing the dampers and the lower handlebar holders in the front hole, be sure to route the handlebar switch lead (left) as shown in the illustration.

Frame and engine (rear left side view)

Components

1. Wire harness
2. Rear frame
3. Plastic locking tie
4. Starter relay coupler (black, 4-pin)
5. Negative battery lead
6. Starter relay
7. Starter motor lead
8. Taillight lead
9. CCU (Communication Control Unit)
10. Taillight coupler
11. Starter relay cover
12. Diode
13. Engine mounting bracket boss
14. Wire harness (resistor lead)
15. Resistor
16. Rear fender (projection)
17. Positive battery lead
18. CCU coupler
19. Starter motor
20. Clamp

Instructions

A. Fasten the resistor lead, starter motor lead, negative battery lead, and starter relay lead to the rear frame with the plastic locking tie between the branch of the wire harness and the battery bracket. Point the end of the lock portion and end of the plastic locking tie to the lower side of the vehicle.

B. Route the negative battery lead inside the vehicle along the starter motor lead.

C. Insert the starter relay into the battery bracket, and secure it.

D. Route the starter motor lead between the starter relay and the rear frame. Adjust any slack between the starter relay and the plastic locking tie of the rear frame.

E. No slack to the rear side of the vehicle.

F. Place the taillight coupler inside the frame.

G. Install the starter relay cover over the starter relay.

H. Route the starter motor lead through the inside of the engine mounting bracket boss and along the front side of the vehicle behind the engine mounting bracket boss.

I. Insert the clip of the clamp into the rear frame. Fasten the starter motor lead and wire harness at the green tape position of the wire harness. Place the starter motor lead under the vehicle’s wire harness. Place the lock portion of the plastic locking tie to the lower part of the vehicle, and then cut off the end by pointing it to the outside of the vehicle.

J. Point the lock portion of the plastic locking tie toward the lower side of the vehicle and the end toward the outside of the vehicle, and then cut off the end.

K. Point the starter motor lead to the outside, and then install it.

L. Insert the projection of the resistor rubber band into the battery bracket. Then, fasten the resistor securely by sliding it to the front side of the vehicle.

M. Route the positive battery lead on the outside of the projection on the rear fender (outside the vehicle).

N. Insert the clip of the CCU coupler into the battery bracket from the rear side of the vehicle. When doing so, fasten the CCU coupler so that it is positioned as shown.

Frame and engine (front right side view)

Components

1. Cylinder head breather hose
2. High tension cord
3. Radiator fan motor lead
4. Radiator fan motor lead coupler
5. Upper radiator boss
6. Throttle position sensor lead
7. Air filter breather hose
8. Clip
9. 3-way joint
10. Crankcase breather hose
11. Lower radiator boss
12. Radiator breather hose
13. Throttle position sensor coupler (black, 3-pin)
14. Radiator hose
15. Tension arm

Instructions

A. Route the cylinder head breather hose through the inside of the coolant temperature sensor lead.

B. Route the throttle position sensor lead on the outside of the air filter breather hose and cylinder head breather hose, inside the vehicle along the ignition coil.

C. Install the clips as shown in the illustration. Then install the lower clip above the radiator stay.

D. Align the red paint mark on the hose with the convex mark on the 3-way joint, and then install the cylinder head breather hoses.

E. The radiator breather hose should be routed in the following order and via each mentioned point:

• Upper radiator boss: At the rear of the vehicle.
• Lower radiator boss: At the front of the vehicle.
• Outside the vehicle: Past the cylinder head breather hose (when doing so, cross them at the bottom of the radiator).
• For routing the remaining leads, refer to the diagram “Frame and engine (front left side view)”.

F. After connecting the throttle position sensor 3-pin coupler (black), install the cover over it.

G. Route the radiator fan motor lead inside the vehicle along the high tension cord.

Frame and engine (rear right side view)

Components

1. Fuel pump coupler (black, 5-pin)
2. Coolant temperature sensor coupler (black, 2-pin)
3. High tension cord
4. ECU lead
5. Radiator fan motor relay lead
6. Taillight coupler
7. CCU sub-lead
8. CCU (Communication Control Unit)
9. Wire harness
10. Resistor coupler
11. Positive battery lead
12. Radiator fan motor fuse
13. ECU (Engine Control Unit)
14. Radiator fan motor relay

Instructions

A. After connecting, install the cover over the fuel pump 5-pin coupler (black).

B. Route the engine ground lead outside the vehicle past the high tension cord. When installing the engine ground lead terminal, it can face either way. Point the engine ground lead to the upper side of the vehicle, and then install it.

C. Route the coolant temperature sensor lead outside the vehicle past the high tension cord. After connecting the coolant temperature sensor 2-pin coupler (black), install the cover over it.

Handlebar (front view)

Components

1. Throttle cable
2. Plastic locking tie
3. Handlebar protector
4. Clutch cable
5. Handlebar switch lead (left)
6. Front brake hose
7. Headlight lead
8. Multi-function display coupler (black, 4-pin)
9. Speed sensor coupler (black, 3-pin)
10. Start switch lead
11. Speed sensor lead
12. Meter bracket
13. Wire harness

Instructions

A. Fasten at the center of both sides of the clamps.

B. Secure the handlebar switch lead (left) to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

C. Pass the throttle cable, clutch cable, handlebar switch lead (left), start switch lead, and speed sensor lead between the wire guide of the meter bracket and the handle crown in no particular order.

D. Fasten the wire harness and speed sensor lead to the meter bracket using the plastic locking tie. When fastening, turn the steering to the left with no slack. The speed sensor lead should be fastened at the gray tape. Face the end of the plastic locking tie to the right side of the vehicle, and cut off the excess.

E. Route the headlight lead along the left side of the vehicle.

F. Connect the headlight lead to the headlight.

G. Route the speed sensor lead in front of the vehicle’s wire harness.

H. Insert the multi-function display 4-pin coupler (black) into the bracket and secure it. After securing, install the cover.

I. Insert the speed sensor 3-pin coupler (black) into the bracket and secure it. After securing, install the cover.

J. After fastening the speed sensor lead, route it in a "U" shape along the start switch lead, passing through the bottom of the front brake hose.

K. Secure the start switch lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

L. Fasten the start switch lead and speed sensor lead with the plastic locking tie at the front side of the handlebar. Place both leads above the lower part of the handlebar.

M. Secure the start switch lead and speed sensor lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle and the end to the front side without cutting it off.

N. Secure the handlebar and handlebar protector with the plastic locking tie. Point the lock portion of the plastic locking tie to the lower side of the vehicle. The direction of the end does not matter.

O. Fasten the speed sensor lead at the painted portion. The placement of the front brake hose does not matter.

P. Ensure a 70–110° angle.

Q. Align the lead in the vertical direction of the vehicle.

R. Maintain a gap of 5 mm (0.20 in).

S. Fasten the painted portion of the speed sensor lead at the shrinking tube of the front brake hose.

Frame and engine (top view)

Components

1. Ignition coil lead
2. Coolant temperature sensor lead
3. Engine ground lead
4. Air filter breather hose
5. Intake air pressure sensor coupler (dark blue, 3-pin)
6. Fuel injector coupler (gray, 2-pin)
7. Intake air temperature sensor coupler (black, 2-pin)
8. Tank rail
9. Air filter case
10. Spark plug cap
11. Cylinder head cover
12. Damper
13. Fuel hose
14. Starter motor lead
15. Wire harness

Instructions

A. Install the terminal so that the lead is positioned above the vehicle. Connect the black cover of the ignition coil lead to the black terminal of the ignition coil, and the white cover to the green terminal.

B. Route the coolant temperature sensor lead, engine ground lead, and high tension cord outside the vehicle, passing the air filter breather hose.

C. Insert the projection of the main harness into the hole in the tank rail.

D. Maintain a ±10° alignment.

E. Position components on the right side of the vehicle.

F. Insert the spark plug cap fully into the cylinder head cover, ensuring there is no clearance between the cap and the cover.

G. Place the fuel hose on the flat surface on the upper side of the damper.

H. Route the starter motor lead along the damper and secure it with a clamp.

I. Place the wire harness on the flat surface on the upper side of the damper.

J. Insert the clip portion of the clamp into the air filter case.

Frame and battery (top view)

Components

1. Radiator fan motor relay lead
2. ECU lead
3. Battery
4. Radiator fan motor fuse
5. Negative battery lead
6. CCU (Communication Control Unit)
7. Positive battery lead
8. ECU (Engine Control Unit)
9. Radiator fan motor relay
10. Holder
11. Rear frame
12. Radiator fan motor fuse lead
13. Wire harness (resistor lead)
14. Plastic locking tie

Instructions

A. Install the radiator fan motor fuse to the battery bracket.

B. Point the terminal of the negative battery lead to the inside of the vehicle and install it.

C. After connecting the positive battery lead in the direction shown in the illustration, place the cover over it.

D. After connecting the ECU coupler, secure the coupler cover over it.

E. After connecting the radiator fan motor relay to the wire harness, install the cover over the radiator fan motor relay. Point the portion connected to the wire harness toward the left side of the vehicle, then secure the radiator fan motor relay to the holder.

F. Insert the holder with the ECU installed into the battery box bracket. When doing so, secure the ECU so that its connector points to the left side of the vehicle.

G. Install the terminal in the specified direction as shown in the diagram.

H. Ensure the radiator fan motor fuse lead has sufficient slack at the rear side of the vehicle, routed past the plastic locking tie.

I. Route the positive battery lead under the lower part of the vehicle’s negative battery lead and over the resistor lead.

J. Ensure the resistor lead has sufficient slack at the rear side of the vehicle, routed past the plastic locking tie.

K. Align components towards the rear side of the vehicle.

Rear brake (right side view)

Components

1. Protector
2. Rear brake caliper
3. Bleed screw
4. Rear brake hose
5. Brake pedal
6. Rear brake master cylinder assembly
7. Swingarm
8. Rear shock absorber assembly

Instructions

A. The orientation of the spring (upward or downward) does not matter when installed.

B. Pass the rear brake hose into the designated rear brake hose holders.

C. Route the rear brake hose so that it avoids interference with the spring of the rear shock absorber assembly.

D. Ensure the rear brake hose is not excessively twisted during installation.

E. Install the rear brake hose with the bended portion of the metal part facing as illustrated in the diagram.

F. Ensure the metal part of the rear brake hose makes contact with the stopper of the rear brake master cylinder.

G. Ensure the metal part of the rear brake hose makes contact with the stopper of the rear brake caliper.

Front brake (front view and left side view)

Components

1. Speed sensor lead
2. Front brake hose
3. Clamp
4. Protector
5. Speed sensor

Instructions

A. Clamp the shrinking tube portion of the speed sensor lead securely.

B. Ensure any slack in this section is properly absorbed.

C. Pass the front brake hose and speed sensor lead through the guide on the headlight body. Scratching during this process is acceptable.

D. Align the paint mark on the front brake hose with the upper end of the clamp during installation. The orientation around the circumference does not matter.

E. Ensure the metal part of the front brake hose contacts the stopper of the front brake caliper.

F. Securely clamp the speed sensor lead to the hooks on the protector at three specified locations.

Taillight (top view and left side view)

Components

1. Taillight lead
2. Taillight
3. Clamp
4. Rear fender (projection)

Instructions

A. Ensure there is no slack in the taillight lead.

B. Route the taillight lead inside the projection of the rear fender.

C. Insert the taillight lead all the way through.

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