2009 YAMAHA WR 250F engine

3-3
MAINTENANCE INTERVALS FOR COMPETITION USE
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• 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.
MAINTENANCE INTERVALS FOR COMPETITION USE
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
15 Sidestand pivot Check operation.
√√√
Apply lithium-soap-based grease (all-purpose
grease) lightly.
16 * Front fork Check operation and for oil leakage.
√√
Replace if necessary.
17 * Shock absorber assembly Check operation and for oil leakage.
√√
Replace if necessary.
18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. √√
19 * Control cables Apply Yamaha chain and cable lube or engine
oil 10W-30 thoroughly. √√√
20 * Throttle grip housing and cable Check operation and free play.
√√√
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
21 * Chassis fasteners Check all chassis fitting and fasteners.
√√√
Correct if necessary.
22 Battery Check terminal for looseness and corrosion. √√
No.
ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER
READINGS
600 mi (1,000
km) or 1
month 1,800 mi
(3,000
km) or 3
months 3,000 mi
(5,000
km) or 6
months
Item After
break-
in Every
race
Every
third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks
ENGINE OIL Replace ●●
VALVES Check the valve clearances ●● The engine must be cold.
Inspect ●Check the valve seats and valve
stems for wear.
Replace ●
VALVE SPRINGS Inspect ●Check the free length and the tilt.
Replace ●

3-5
MAINTENANCE INTERVALS FOR COMPETITION USE
CRANKInspect and clean ●●
CARBURETOR Inspect, adjust and clean ●●
AIR INDUCTION SYSTEM Inspect and clean ●● ●●
SPARK PLUG Inspect and clean ●●
Replace ●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment ●● Chain slack: 48–58 mm (1.9–2.3 in)
Replace ●
COOLING SYSTEM Check coolant level and leakage ●●
Check radiator cap operation ●
Replace coolant ●Every two years
Inspect hoses ●
OUTSIDE NUTS AND BOLTS Retighten ●● Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER Clean and lubricate ●● Use foam air-filter oil or equivalent oil.
Replace ●
OIL FILTER Replace ●●
ENGINE GUARD Replace ●Breakage
FRAME Clean and inspect ●●
FUEL TANK, COCK Clean and inspect ●●
BRAKES Adjust lever position and pedal
height ●●
Lubricate pivot point ●●
Check brake disc surface ●●
Check fluid level and leakage ●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts ●●
Replace pads ●
Replace brake fluid ●Every one year
Item
After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-7
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCEItem RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-11 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.
P.1-14
Engine oil Check that the oil level is correct. Check the crankcase and oil
line for leakage. P.3-14 – 16
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.
P.3-13
Brakes Check the play of front brake and effect of front and rear brake. P.3-19 – 22
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly. P.3-22 – 23
Wheels Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play. P.3-26 – 27
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play.
P.3-27
Front forks and rear shock
absorber Check that they operate smoothly and there is no oil leakage.
P.3-23 – 26
Cables (wires) Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.3-10 – 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are con-
nected tightly. P.1-3
Settings Is the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done? P.4-1 – 9

3-8
ENGINE
ENGINE
REMOVING THE SEAT, FUEL TANK AND SIDE COVERSOrder Part name Q'ty Remarks Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Open the air filter case cover.
6 Right side cover 1 Refer to removal section.
7 Headlight coupler 1
8 Headlight 1

3-9
ENGINE
REMOVING THE SIDE COVER
1. Remove:• Bolt (side cover)
• Right side cover "1"
Draw the side cover backward to re-
move it because its claw "a" is insert-
ed in the air filter case.

3-10
ENGINE
REMOVING THE EXHAUST PIPE AND SILENCEROrder Part name Q'ty Remarks Right side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section.
1 Bolt (silencer clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4Collar 1
5 Silencer 1
6 Silencer clamp 1
7 Nut (exhaust pipe) 2
8 Exhaust pipe 1
9Gasket 2

3-11
ENGINE
CHECKING THE SILENCER AND
EXHAUST PIPE
1. Inspect:•Gasket "1"
Damage →Replace.
INSTALLING THE SILENCER AND
EXHAUST PIPE
1. Install: •Gasket
• Exhaust pipe "1"
• Nut (exhaust pipe) "2"
First, temporarily install both nuts,
then tighten either of these nuts to 13
Nm (1.3 m•kg, 9.4 ft•lb) and the other
to 20 Nm (2.0 m•kg, 14 ft•lb), and
then come back to the first one and
retighten it to 20 Nm (2.0 m•kg, 14
ft•lb).
2. Install:• Silencer clamp "1"
•Gasket "2"
• Silencer "3"
• Washer "4"
• Bolt (silencer) "5" CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level
place, and hold it in an upright po-
sition.
2. Remove: •Radiator cap
3. Check: • Coolant level "a"Coolant level low →Add coolant.
1. Radiator CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en-
gine.
2. Remove: •Seat
• Left side cover
3. Remove the catch tank hose from the catch tank and drain the tank
of its coolant.
4. Remove: • Coolant drain bolt "1"
5. Remove: •Radiator capDrain the coolant completely.
6. Clean: • Cooling systemThoroughly flush the cooling sys-
tem with clean tap water.
7. Install: • Copper washer
• Coolant drain bolt
8. Fill: •Radiator
•EngineTo specified level.
Nut (exhaust pipe):
20 Nm (2.0 m•kg, 14
ft•lb)
Silencer clamp: 16 Nm (1.6 m•kg, 11
ft•lb)
Bolt (silencer): 30 Nm (3.0 m•kg, 22
ft•lb)
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant: High quality ethylene
glycol anti-freeze con-
taining anti-corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio: 50%/50%
Coolant capacity:
0.99 L (0.87 Imp qt, 1.05
US qt)

3-12
ENGINE
• Do not mix more than one type of ethylene glycol antifreeze con-
taining corrosion inhibitors for
aluminum engine.
• Do not use water containing im-
purities or oil.
Handling notes of coolant:
The coolant is harmful so it should be
handled with special care.
• When coolant splashes to your eye.
Thoroughly wash your eye with
water and see your doctor.
• When coolant splashes to your clothes.
Quickly wash it away with water
and then with soap.
• When coolant is swallowed. Quickly make him vomit and take
him to a doctor.
9. Install:
• Radiator capStart the engine and warm it up
for a several minutes.
10. Check: • Coolant levelCoolant level low →Add coolant.
CHECKING THE RADIATOR CAP
1. Inspect: • Seal (radiator cap) "1"
• Valve and valve seat "2"Crack/damage →Replace.
Exist fur deposits "3" →Clean or
replace. CHECKING THE RADIATOR CAP
OPENING PRESSURE
1. Attach:
• Radiator cap tester "1" and adapt-
er "2"
Apply water on the radiator cap seal.
3. Radiator cap
2. Apply the specified pressure.
3. Inspect: •PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Replace.
CHECKING THE COOLING
SYSTEM
1. Inspect: • Coolant level
2. Attach:
• Radiator cap tester "1" and adapt-er "2"
3. Apply the specified pressure.
• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.
4. Inspect: •PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Repair.
•Radiator "1"
• Radiator hose joint "2"
Coolant leakage →Repair or re-
place.
• Radiator hose "3" Swelling →Replace.
ADJUSTING THE CLUTCH CABLE
FREE PLAY
1. Check: • Clutch lever free play "a"Out of specification →Adjust.
2. Adjust: • Clutch lever free play
Clutch lever free play adjustment
steps:
a. Loosen the locknuts "1".
b. Adjust the free play by changing
their tightening position.
c. Tighten the locknuts.
• Make minute adjustment on the le- ver side using the adjuster "2".
• After adjustment, check proper op-
eration of clutch lever.
Radiator cap tester: YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352
Radiator cap opening
pressure: 110 kPa (1.1 kg/cm
2,
15.6 psi)
Radiator cap tester: YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352
Standard pressure: 180 kPa (1.8 kg/cm
2,
25.6 psi)
Clutch lever free play "a"
: 8–13 mm (0.31–0.51 in)
Locknut: 7 Nm (0.7 m•kg, 5.1
ft•lb)