2008 YAMAHA WR 250R brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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17

Brake pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
18

Clutch lever pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
19

Shift pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
20

Sidestand

Check operation.

Lubricate.
√√√√√
21

*
Sidestand switch

Check operation.
√√√√√√
22

*
Front fork

Check operation and for oil
leakage.
√√√√
23

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
24

*
Rear suspension
relay arm and con-
necting arm pivoting
points

Check operation.
√√√√
25

Engine oil

Change.

Check oil level and vehicle for
oil leakage.
√
Every 5000 km (3000 mi)
√
26

Engine oil filter ele-
ment

Replace.
√√√√√
27

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
28

*
Front and rear brake
switches

Check operation.
√√√√√√
29

Moving parts and
cables

Lubricate.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
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EAU18670
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
30

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
31

*
Air induction system

Check the air cut-off valve,
reed valve, and hose for dam-
age.

Replace any damaged parts if
necessary.
√√√√√
32

*
EXUP system

Check operation, cable free
play and pulley position.
√√√
33

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
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9Tire information
This motorcycle is equipped with tube
tires.
WARNING

EWA10460

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.

After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
WARNING

EWA10570

Have a Yamaha dealer replace
excessively worn tires. Besidesbeing illegal, operating the mo-
torcycle with excessively worn
tires decreases riding stability
and can lead to loss of control.

The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.

It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a
high-quality product.
EAU21940
Spoke wheels
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
80/100-21M/C 51P
Manufacturer/model:
BRIDGESTONE/TW-301 F
Rear tire:
Size:
120/80-18M/C 62P
Manufacturer/model:
BRIDGESTONE/TW-302 F

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
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EAU22093
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the brake lever free play
adjusting screw in direction (a). To
decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).3. Tighten the locknut.
WARNING

EWA10630

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
EAU22271
Adjusting the rear brake light
switch
The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
3
1
2
(b)
(a)

1. Rear brake light switch
2. Adjusting nut
1
2
(b)
(a)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU45300
Rear brake pads
Each rear brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check if the brake
pad has worn to the wear indicator. If a
brake pad has worn to the indicator,
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air to
1. Wear indicator groove
11

1. Wear indicator
1
1. Minimum level mark
1. Minimum level mark
11

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
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enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the brake fluid reservoir whenrefilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
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EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU44271
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
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EAU23142
Checking and lubricating the
brake and clutch levers
Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease