2009 YAMAHA YFM250R-W check engine

6-5
6 erly lubricated only when the engine is run-
ning. Inadequate lubrication may damage
the transmission.

Always use the clutch when changing gears.
The engine, transmission and drive train are
not designed to withstand the shock of
forced shifting and can be damaged by shift-ing without using the clutch.EBU20672Engine break-in TIP
For ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.
For ATVs not equipped with an odometer orhour meter, follow the figures given in hours.
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an ex-
cessive load on it for the first 320 km (200 mi) or 20
hours. The various parts in the engine wear and
polish themselves to the correct operating clear-ances. During this period, prolonged full-throttle
operation or any condition that might result in en-
gine overheating must be avoided.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary
the speed of the ATV regularly. Do not operate it at
one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine through the gears freely, but do not use
full throttle at any time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
NOTICEECB00220If any engine trouble should occur during the
engine break-in period, immediately have aYamaha dealer check the ATV.EBU20721Parking When parking the ATV, stop the engine, shift into
first gear, apply the parking brake, and then turn
the fuel cock to “OFF”.
U33B70E0.book Page 5 Wednesday, June 11, 2008 1:38 PM

8-3
8
EBU21743Periodic maintenance chart for the emission control system TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
1*Fuel lineCheck fuel hoses for cracks or other damage, and
replace if necessary.√√√
2 Spark plugCheck condition and clean, regap, or replace if
necessary.√√√√√
3*ValvesCheck valve clearance and adjust if necessary.√ √√√
4*CarburetorCheck starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces-
sary.√√√√
5*Crankcase breather
systemCheck breather hose for cracks or other damage,
and replace if necessary.√√√
U33B70E0.book Page 3 Wednesday, June 11, 2008 1:38 PM

8-6
8
10*Swingarm pivots• Check operation and for excessive play, and re-
place bearings if necessary.
 Lubricate with lithium-soap-based grease.√√√
11*Upper and lower
arm pivots Lubricate with lithium-soap-based grease.√√√
12 Drive chain Check chain slack and adjust if necessary.
 Check rear wheel alignment and correct if neces-
sary.
 Clean and lubricate.√√√√√
13*Drive chain rollers Check for wear and replace if necessary.√√√
14*Chassis fasteners Make sure that all nuts, bolts, and screws are
properly tightened.√√√√√
15*Shock absorber as-
semblies Check operation and correct if necessary.
 Check for oil leakage and replace if necessary.√√√
16*Steering shaft Lubricate with lithium-soap-based grease.√√√
17*Steering system Check operation and repair or replace if damaged.
 Check toe-in and adjust if necessary.√√√√√
18*Engine mount Check for cracks or other damage, and replace if
necessary.√√√
19 Engine oil Change.
 Check ATV for oil leakage, and correct if neces-
sary.√ √√√
20Engine oil filter ele-
ment Replace.√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U33B70E0.book Page 6 Wednesday, June 11, 2008 5:44 PM

8-8
8
EBU23211Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
TIPIf the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-stead, have a Yamaha dealer check the ATV.
2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
1. Spark plug cap
1
1. Spark plug wrench
1
U33B70E0.book Page 8 Wednesday, June 11, 2008 1:38 PM

8-9
8 To install the spark plug
1. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.
2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.EBU28953Engine oil and oil filter element The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element must be replaced at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
To check the engine oil level
1. Place the ATV on a level surface. Specified spark plug:
NGK/DR7EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1. Spark plug gap
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
U33B70E0.book Page 9 Wednesday, June 11, 2008 1:38 PM

8-10
82. Check the engine oil level on a cold engine.
TIPIf the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-tles for an accurate reading.
3. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
4. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
TIPThe engine oil should be between the minimumand maximum level marks.
5. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.
6. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
To change the engine oil (with or without oil fil-
ter element replacement)
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place an oil pan under the engine to collect
the used oil.
3. Remove the engine oil filler cap, and then re-
move the engine oil drain bolt to drain the oil
from the crankcase.
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
2
3
4 1
U33B70E0.book Page 10 Wednesday, June 11, 2008 1:38 PM

8-11
8
TIPSkip steps 4–7 if the oil filter element is not beingreplaced.
4. Remove the oil filter element cover by remov-
ing the bolts, and then remove the oil filter el-
ement.5. Check the O-rings for damage and replace
them if necessary.1. Engine oil drain bolt
1
1. Oil filter element cover
2. Bolt
1 2
U33B70E0.book Page 11 Wednesday, June 11, 2008 1:38 PM

8-13
8 a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.

Make sure that no foreign material enters thecrankcase.
10. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
11. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
EBU23704Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.TIPThere is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-ter case.
1. Place the ATV on a level surface.
1.“CD” specification
2.“ENERGY CONSERVING II”
1
2
1. Air filter case check hose
1
U33B70E0.book Page 13 Wednesday, June 11, 2008 1:38 PM