2010 YAMAHA WR 250R brake pads

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Multi-function display ......................3-3
Handlebar switches ........................3-8
Clutch lever .....................................3-9
Shift pedal .....................................3-10
Brake lever ...................................3-10
Brake pedal ..................................3-10
Fuel tank cap ................................3-11
Fuel ...............................................3-11
Catalytic converter ........................3-13
Seat ..............................................3-13
Helmet holder ...............................3-14
Adjusting the front fork ..................3-14
Front fork bleeding ........................3-16
Adjusting the shock absorber
assembly ...................................3-17
EXUP system ...............................3-18
Sidestand ......................................3-19
Ignition circuit cut-off system ........3-19FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance chart for the
emission control system ............. 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing panels ..... 6-7
Checking the spark plug ................. 6-9
Engine oil and oil filter element .... 6-10
Coolant ......................................... 6-13
Cleaning the air filter element and
check hose ................................ 6-16
Adjusting the engine idling
speed ........................................ 6-17
Checking the throttle cable free
play ........................................... 6-18
Valve clearance ............................ 6-18
Tires ............................................. 6-19Spoke wheels .............................. 6-20
Adjusting the clutch lever free
play ........................................... 6-21
Adjusting the brake lever free
play ........................................... 6-22
Checking the shift pedal .............. 6-23
Brake light switches ..................... 6-23
Checking the front and rear brake
pads .......................................... 6-23
Checking the brake fluid level ...... 6-24
Changing the brake fluid .............. 6-25
Drive chain slack .......................... 6-25
Cleaning and lubricating the drive
chain ......................................... 6-27
Checking and lubricating the
cables ....................................... 6-27
Checking and lubricating the
throttle grip and cable ............... 6-28
Checking and lubricating the
brake and clutch levers ............ 6-28
Checking and lubricating the
brake pedal ............................... 6-29
Checking and lubricating the
sidestand .................................. 6-29
Lubricating the swingarm
pivots ........................................ 6-29
Checking the front fork ................. 6-30
Checking the steering .................. 6-30
Checking the wheel bearings ....... 6-31
Battery ......................................... 6-31
Replacing the fuses ..................... 6-32U32DE4E0.book Page 1 Monday, December 14, 2009 2:24 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-11
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23, 6-24
U32DE4E0.book Page 1 Monday, December 14, 2009 2:24 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-23, 6-24
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-21
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-18, 6-28
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-27
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-25, 6-27
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19, 6-20
Shift pedalMake sure that operation is smooth.
Correct if necessary.6-23
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-29
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-28 ITEM CHECKS PAGE
U32DE4E0.book Page 2 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU1770C
General maintenance and lubrication chart 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)
1 Air filter elementClean.√√
Replace.√√
2ClutchCheck operation.
Adjust.√√√√√
3*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.
Adjust brake lever free play.√√√√√√
Replace brake pads. Whenever worn to the limit
4*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
5*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
6*WheelsCheck runout, spoke tightness
and for damage.
Tighten spokes if necessary.√√√√
7*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
8*Wheel bearingsCheck bearing for looseness or
damage.√√√√
U32DE4E0.book Page 3 Monday, December 14, 2009 2:24 PM

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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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
U32DE4E0.book Page 24 Monday, December 14, 2009 2:24 PM

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)
U32DE4E0.book Page 25 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6 2. Lift the front wheel off the ground
according to the procedure on
page 6-37.
3. Remove the axle nut.
4. Pull the wheel axle out, and then
remove the wheel. NOTICE: Do
not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]
EAU49340
To install the front wheel
1. Lift the wheel up between the fork
legs.
TIPMake sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc.2. Insert the wheel axle.
3. Install the axle nut.
4. Lower the front wheel so that it is
on the ground, and then put the
sidestand down.
5. Tighten the axle nut and the wheel
axle pinch bolts to their specified
torques, and then install the rubber
cap.
6. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU45182
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
3. Remove the axle nut and washer.
4. Loosen the locknut on each side of
the swingarm.
1. Front wheel axle pinch bolt
2. Wheel axle
1
2
Tightening torques:
Axle nut:
63 Nm (6.3 m·kgf, 46 ft·lbf)
Wheel axle pinch bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1. Axle nut
2. Washer
1
2
U32DE4E0.book Page 38 Monday, December 14, 2009 2:24 PM