Sandman Parts
Yamaha WR250R
Acerbis Spider Evolution Front Disc Guard Mounting Adapter Installation Instructions:
To install your adapter you will need the following parts and tools:
-Sandman Parts Spacer
-Acerbis #73-6061 Disc Guard Mount Adapter (Purchase from the online store here at TT:
http://shop.thumpert...fault.asp?p=288)

-Acerbis Spider Evolution Disc Guard in your choice of color (Purchase from the online store here at TT:
http://shop.thumpert...fault.asp?p=288)
-Motorcycle lift with safety straps
-10mm wrench or socket
-22mm wrench or socket
-8mm wrench or socket
-3mm Allen wrench
-19mm socket
-36mm or equivalent socket or short piece of pipe
-Bench vise or Shop Press
-Torque wrench
-Clean rags or shop towels
-Lithium-soap-based grease
1) To begin, you will need to loosen the 22mm front axle nut. This is best done with the bike resting on the ground. Loosen but do not remove the nut. Next, loosen the four 10mm bolts that pinch the axle tight, two on each fork leg. See Fig1. (Note: Right and Left sides used in instructions are shown in Fig1)
2) Next, raise the bike on a suitable bike lift so that the front wheel is off the ground. Secure the bike to the lift so it does not fall off.
3) Next, remove the 22mm axle nut you loosened in step one, and push the axle out to the right fork while supporting the front wheel.
4) Now remove the stock left side axle spacer and save for later. Clean the seal area of any debris and add some grease if needed. See Fig2 and Fig3.

5) Remove your Acerbis #73-6061 Disc Guard Mount Adapter from the package and hang on to the included 8mm nuts and 3mm Allen flat head socket screws, you will need them to mount your plastic guard in a few minutes. What we need to do now is press out the stock center adapter from the Acerbis mount adapter. To do this you will need a bench vise and the 36mm socket and the 19mm socket. The stock adapter is held in with a spring clip and can only be popped out in one direction. With the adapter orientated so that you can read the Acerbis Logo, place the 36mm socket under the center of the adapter. Now place the 19mm socket over the adapter as shown in Fig4. Take this assembly to your bench vise or press and push the stock center part out. See Fig5.
Make sure you are pushing the stock adapter out square to the mounting adapter. You should not need to apply great pressure to get the center part out. If you are, take everything out and verify you are not going in the wrong direction.

6) Clean up any burrs caused by pressing out the stock center section and discard the snap ring and old center spacer. See Fig6.

It should look like this when you are done:

7) Using the supplied hardware from Acerbis mount your plastic guard to the center adapter. Tighten the nuts securely using the 3mm Allen wrench and 8mm wrench or socket it should be orientated as shown in Fig7.
8) You are now ready to install your new Disc Guard on your WR250R. Insert the disc guard in to the wheel seal on the left side where you removed the
OEM axle spacer. Place the axle back in to the right side fork leg and while supporting the front wheel push the axle through to the other side, making sure the brake disc is aligned correctly between both brake pads.
9) Replace the 22mm axle nut and hand tighten only. Orientate the disc guard as shown in Fig8. Check for proper wheel operation and lower the bike back to the ground.
http://i687.photobuc...pg?t=1241911437
10) Tighten and torque the right side 10mm axle pinch bolts to 23Nm (17ft-lb)
11) Tighten and torque the 22mm axle nut to 63Nm (46 ft-lb)
12) Tighten and torque the left side 10mm axle pinch bolts to 23Nm (17ft-lb)
13) Pump your front brake lever a few times to re-seat the brake pads.
14) Re-inspect your work and enjoy your new Front Disc Guard!
For ordering info please click here:
http://home.rr.com/vwsandman