2010 YAMAHA WR 250R clutch

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

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
12 34 5 6
8
7
1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Main switch/steering lock (page 3-1)
4. Multi-function display (page 3-3)
5. Right handlebar switches (page 3-8)
6. Brake lever (page 3-10)
7. Throttle grip (page 6-18)
8. Fuel tank cap (page 3-11)U32DE4E0.book Page 3 Monday, December 14, 2009 2:24 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
EAU12400
Dimmer switch“/”
Set this switch to“” for the high
beam and to“” for the low beam.
EAU12460
Turn signal switch“/”
To signal a right-hand turn, push this
switch to“”. To signal a left-hand
turn, push this switch to“”. When re-
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU12500
Horn switch“”
Press this switch to sound the horn.
EAU12660
Engine stop switch“/”
Set this switch to“” before starting
the engine. Set this switch to“” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12711
Start switch“”
Push this switch to crank the engine
with the starter. See page 5-1 for start-
ing instructions prior to starting the en-
gine.
EAU41700
The engine trouble warning light will
come on when the key is turned to “ON”
and the start switch is pushed, but this
does not indicate a malfunction.
EAU12820
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-19.)1. Clutch lever
1
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INSTRUMENT AND CONTROL FUNCTIONS
3-10
3
EAU12870
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
1
1. Brake pedal
1
U32DE4E0.book Page 10 Monday, December 14, 2009 2:24 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
EAU15303
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.TIPThe built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See page 3-19 for an explanation of
the ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as describedbelow and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
EAU44892
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.


It cuts the running engine when the
transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
U32DE4E0.book Page 19 Monday, December 14, 2009 2:24 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-20
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
U32DE4E0.book Page 20 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

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU46632
TIPThis model is equipped with:

a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function display in-
dicates error code 30, but this is
not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.


an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. In this case,
the multi-function display indicates
error code 70, but this is not a mal-
function. Push the start switch to
clear the error code and to restart
the engine.
EAU45125
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
See page 3-19 for more informa-
tion.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to“”.
The following warning lights
should come on for a few seconds,
then go off.

Fuel level warning light


Coolant temperature warning
light


Engine trouble warning light
NOTICE
ECA15484
If a warning light does not come on
initially when the key is turned to
“ON”, or if a warning light remains
on, see page 3-2 for the correspond-
ing warning light circuit check.
U32DE4E0.book Page 1 Monday, December 14, 2009 2:24 PM