2009 YAMAHA WR 250F air suspension

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 ●

3-6
MAINTENANCE INTERVALS FOR COMPETITION USE
FRONT FORKSInspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
REAR SHOCK ABSORBER Inspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
SIDESTAND Lubricate ●Lithium base grease
STEERING HEAD Inspect free play and retighten ●●
Clean and lube ●Lithium base grease
Replace bearing ●
TIRE, WHEELS Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness ●●
Retighten sprocket bolt ●●
Inspect bearings ●
Replace bearings ●
Lubricate ●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection ●●
Lubricate ●● Yamaha cable lube or SAE 10W-30
motor oil
HOT STARTER, CLUTCH LEVER Inspect free play ●
BATTERY
Check terminal for looseness
and corrosion ●
Item
After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

4-6
CHASSIS
A. Air spring characteristics in relation to oil level change
B. Load
C. Stroke
1. Max. oil level
2. Standard oil level
3. Min. oil level
ADJUSTING THE SPRING
PRELOAD
The spring preload is adjusted by in-
stalling the adjustment washer "1" be-
tween the fork spring "2" and damper
rod "3".
Do not install three or more adjust-
ment washers for each front fork.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
A. Load
B. Fork stroke
1. Without adjustment washer (standard)
2. 1 adjustment washer
3. 2 adjustment washers
SETTING OF SPRING AFTER
REPLACEMENT
As the front fork setting can be easily
affected by rear suspension, take
care so that the machine front and
rear are balanced (in position, etc.)
when setting the front fork.
1. Use of soft spring • Change the rebound damping.
Turn out one or two clicks.
• Change the compression damp- ing.
Turn in one or two clicks.
Generally a soft spring gives a soft
riding feeling. Rebound damping
tends to become stronger and the
front fork may sink deeply over a se-
ries of gaps.
2. Use of stiff spring• Change the rebound damping.
Turn in one or two clicks.
• Change the compression damp- ing.
Turn out one or two clicks.
Generally a stiff spring gives a stiff
riding feeling. Rebound damping
tends to become weaker, resulting in
lack of a sense of contact with the
road surface or in a vibrating handle-
bar.
FRONT FORK SETTING PARTS
• Adjustment washer "1" • Front fork spring "2"
The I.D. mark (slits) "a" is proved on
the end of the spring.
When using a spring with a spring
rate of 0.469 kg/mm, do not install
two or more adjustment washers
for each front fork.
REAR SUSPENSION SETTING
The rear suspension setting should
be made depending on the rider's
feeling of an actual run and the circuit
conditions.
The rear suspension setting includes
the following two factors:
1. Setting of spring preload
• Change the set length of the spring.
• Change the spring.
2. Setting of damping force • Change the rebound damping.
• Change the compression damp-ing.
Standard washer quanti-
ty:
Zero adjustment wash-
ers
Extent of adjustment: Zero–2 adjustment
washers
TYPE (thick- ness) PART NUMBER
T = 2.3 mm (0.09 in) 5XE-23364-00
TYPESPRI
NG
RATE SPRING
PART
NUMBER (-23141-) I.D.
MARK (slits)
SOFT 0.408 5TJ-00 |
0.418 5TJ-10 ||
0.428 5TJ-20 |||
0.438 5TJ-30 ||||
STD 0.449 5TJ-A0 —
STIFF 0.459 5TJ-50 |-|
0.469 5TJ-60 |-||

6-20
FRONT FORK
7. Install:• Piston metal "1"
Install the piston metal onto the slot
on inner tube.
8. Install:• Outer tube "1"To inner tube "2".
9. Install: • Slide metal "1"
• Oil seal washer "2"To outer tube slot.
Press the slide metal into the outer
tube with fork seal driver "3".
10. Install:
• Oil seal "1"
Press the oil seal into the outer tube
with fork seal driver "2".
11. Install:• Stopper ring "1"
Fit the stopper ring correctly in the
groove in the outer tube.
12. Install:• Dust seal "1"
Apply the lithium soap base grease
on the inner tube.
13. Check:• Inner tube smooth movementTightness/binding/rough spots →
Repeat the steps 2 to 12. 14. Compress the front fork fully.
15. Fill:
• Front fork oilUntil outer tube top surface with
recommended fork oil "1".
• Be sure to use recommended
fork oil. If other oils are used,
they may have an excessively ad-
verse effect on the front fork per-
formance.
• Never allow foreign materials to
enter the front fork.
16. After filling, pump the damper rod "1" slowly up and down more than
10 times to distribute the fork oil.
17. Fill: • Front fork oil
Until outer tube top surface with
recom-mended fork oil once
more.
18. After filling, pump the outer tube "1" slowly up and down (about
200 mm (7.9 in) stroke) to distrib-
ute the fork oil once more.
Be careful not to excessive full stroke.
A stroke of 200 mm (7.9 in) or more
will cause air to enter. In this case, re-
peat the steps 15 to 18.
Fork seal driver:YM-A0948/90890-01502
Fork seal driver:YM-A0948/90890-01502
Recommended oil:
Suspension oil "S1"