2010 YAMAHA WR 250R maintenance
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
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.
EAU48372
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Slide the rubber cover back at the
clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free
play, turn the clutch lever free play
adjusting bolt in direction (a). Todecrease the clutch lever free play,
turn the adjusting bolt in direction
(b).
TIPIf the specified clutch lever free play
could be obtained as described above,
skip steps 4–7.4. Fully turn the adjusting bolt in di-
rection (a) to loosen the clutch ca-
ble.
5. Slide the rubber cover back further
down the clutch cable, and then
loosen the locknut.
1. Clutch lever free play
2. Locknut (clutch lever)
3. Clutch lever free play adjusting bolt
4. Rubber cover
3 2
1
4
(a)(b)
1. Locknut (clutch cable)
2. Clutch lever free play adjusting nut (clutch
cable)
3. Rubber cover
1 2
3
(a)
(b)
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Page 63 of 96
PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6 6. To increase the clutch lever free
play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,
turn the adjusting nut in direction
(b).
7. Tighten the locknut at the clutch
cable, and then slide the rubber
cover to its original position.
8. Tighten the locknut at the clutch le-
ver, and then slide the rubber cov-
er to its original position.
EAU48440
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. Slide the rubber cover back at the
brake lever.
2. Loosen the locknut.
3. To increase the brake lever free
play, turn the brake lever free play
adjusting screw in direction (a). Todecrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).
4. Tighten the locknut, and then slide
the rubber cover to its original po-
sition.
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.
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
4. Rubber cover
3
1
2
4
(b)
(a)
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Page 64 of 96
PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22273
Brake light switches The brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, adjust the rear brake
light switch as follows, but the front
brake light switch should be adjusted
by a Yamaha dealer.
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).
EAU22392
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 wear
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2(b) (a)
1. Brake pad wear indicator groove11
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Page 65 of 96
PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6 indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU48070
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove almost appears, 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
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.
1. Brake pad wear indicator groove
1
1. Minimum level mark
1. Minimum level mark
11
Recommended brake fluid:
DOT 4
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Page 66 of 96
PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6
Be careful that water does not en-
ter the brake fluid reservoir when
refilling. 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.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU47222
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the neu-
tral position.
3. Push on the drive chain at the cen-
ter point between the chain ten-
sioner and the chain support
mounting bolt with a force of 50 N
(5.0 kgf, 11 lbf).
4. Measure drive chain slack be-
tween the swingarm and the top of
the chain link closest to the swing-
arm as shown.Drive chain slack:
8.0–13.0 mm (0.31–0.51 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU22945
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting bolt on
each side of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt on each side
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital partsof the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.3. Tighten the axle nut, then the lock-
nuts to their specified torques.
1. Drive chain slack
2. Chain support mounting bolt
3. Chain tensioner
1
3
2
1. Axle nut
2. Locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
5. Drive chain puller
15
32
4
(b)
(a)
Tightening torque:
Axle nut:
125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
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Page 68 of 96
PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
6
EAU23025
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11121]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as theymay contain substances that
could damage the O-rings.
[ECA11111]EAU23101
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! Damage to the outer
sheath may interfere with proper ca-
ble operation and will cause the in-
ner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions.
[EWA10721]
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
6
EAU23112
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 by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
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 lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
U32DE4E0.book Page 28 Monday, December 14, 2009 2:24 PM