2010 YAMAHA WR 250R torque

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.


Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU35011
Owner’s tool kit The owner’s tool kit is located inside the
tool box.
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.1. Tool box
1
U32DE4E0.book Page 1 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
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 speci-
fied torque as soon as possible.NOTICE
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.
EAU45143
Engine oil and oil filter ele-
ment The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.TIPThe engine oil should be between the
minimum and maximum level marks.
1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)11
U32DE4E0.book Page 10 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPMake sure that the O-rings are properly
seated.8. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
9. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
10. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
11. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
12. Turn the engine off, wait a few min-
utes until the oil settles, and then
check the oil level and correct it if
necessary.NOTICE
ECA11231
After changing the engine oil, make
sure to check the oil pressure as de-
scribed below.

Loosen the bleed bolt.


Start the engine and keep it
idling until oil flows out. If no oil
comes out after one minute,
turn the engine off immediately
so it will not seize. If this occurs,
have a Yamaha dealer repair the
vehicle.


After checking the oil pressure,
tighten the bleed bolt to the
specified torque.
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
1.30 L (1.37 US qt, 1.14 Imp.qt)
With oil filter element replacement:
1.40 L (1.48 US qt, 1.23 Imp.qt)
U32DE4E0.book Page 12 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20253
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.TIP

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.TIPThe coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, remove pan-
el C (See page 6-7.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the pan-
el. WARNING! Remove only the
coolant reservoir cap. Never at-
tempt to remove the radiator
cap when the engine is hot.
[EWA15161]
NOTICE: If coolant is not
available, use distilled water or
soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.
If water has been used instead
of coolant, replace it with cool-
1. Bleed boltTightening torque:
Bleed bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
1. Maximum level mark
2. Minimum level mark
1
2
U32DE4E0.book Page 13 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
69. Remove the coolant drain bolt and
its gasket to drain the cooling sys-
tem.
10. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
11. Install the coolant drain bolt and its
new gasket, and then tighten the
bolt to the specified torque.
12. Pour the specified amount of the
recommended coolant into the ra-
diator and reservoir.13. Install the coolant reservoir cap.
14. Install the radiator cap.
15. Start the engine, let it idle for sev-
eral minutes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and its retaining bolt.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.18. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
19. Install the panels.
1. Coolant drain bolt
2. GasketTightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
12
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibi-
tors for aluminum engines
Coolant quantity:
Radiator capacity (including all
routes):
0.90 L (0.95 US qt, 0.79 Imp.qt)
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
U32DE4E0.book Page 15 Monday, December 14, 2009 2:24 PM

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)
U32DE4E0.book Page 26 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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
65. Turn the drive chain slack adjust-
ing bolts fully in direction (a).
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the rear wheel.7. While supporting the brake caliper,
pull the wheel axle out.8. 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]
EAU45191
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.TIP

Make sure that the retainer on the
brake caliper bracket is inserted
into the slot in the swingarm.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Install the washer and the axle nut.
4. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
5. Adjust the drive chain slack. (See
page 6-25.)
6. Tighten the axle nut to the speci-
fied torque.
1. Drive chain slack adjusting bolt
2. Locknut
3. Brake caliper
12
3 (a)
1. Wheel axle
1
1. Brake caliper bracket
2. Retainer
3. Slot
1
2
3
U32DE4E0.book Page 39 Monday, December 14, 2009 2:24 PM