2012 YAMAHA WR 250F check oil

3-23
CHASSIS
4. Inspect:
• O-ring "1" (drive chain)
Damage→Replace the drive
chain.
•Roller "2"
• Side plate "3"
Damage/wear→Replace the
drive chain.
5. Check:
• Drive chain stiffness "a"
Clean and oil the drive chain and
hold as illustrated.
Stiff→Replace the drive chain.
6. Install:
• Chain joint "1"
• O-ring "2"
• Drive chain "3"
• Link plate "4"
When installing the drive chain, apply
the lithium soap base grease on the
chain joint and O-rings.
7. Install:
• Link plate
• Press the link plate onto the chain
joint using a drive chain riveter "5".
• Rivet the end of the chain joint us-
ing a drive chain riveter.
• After riveting the chain joint, make
sure its movement is smooth.
8. Lubricate:
• Drive chain
ADJUSTING THE DRIVE CHAIN
SLACK
1. Elevate the rear wheel by placing
the suitable stand under the en-
gine.
2. Check:
• Drive chain slack "a"
Above the seal guard installation
bolt.
Out of specification→Adjust.
Before checking and/or adjusting, ro-
tate the rear wheel through several
revolutions and check the slack sev-
eral times to find the tightest point.
Check and/or adjust the drive chain
slack with the rear wheel in this "tight
chain" position.
3. Adjust:
• Drive chain slack
Drive chain slack adjustment
steps:
a. Loosen the axle nut "1" and lock-
nuts "2".b. Adjust the drive chain slack by
turning the adjusters "3".
c. Turn each adjuster exactly the
same amount to maintain correct
axle alignment. (There are marks
"a" on each side of the drive chain
puller alignment.) NOTICE: Im-
proper drive chain slack will
overload the engine as well as
other vital parts of the motorcy-
cle and can lead to chain slip-
page or breakage. To prevent
this from occurring, keep the
drive chain slack within the
specified limits.
Turn the adjuster so that the drive
chain is in line with the sprocket, as
viewed from the rear.
d. Tighten the axle nut while pushing
down the drive chain.
e. Tighten the locknuts.
CHECKING THE FRONT FORK
1. Inspect:
• Front fork smooth action
Operate the front brake and
stroke the front fork.
Unsmooth action/oil leakage→
Repair or replace.
Drive chain lubricant:
SAE 10W-40 motor oil
or suitable chain lubri-
cants
Drive chain slack:
48–58 mm (1.9–2.3 in)
To tighten→Turn the adjuster "3"
counterclockwise.
To loosen→Turn the adjuster "3"
clockwise and push wheel for-
ward.
Axle nut:
125 Nm (12.5 m•kg, 90
ft•lb)
Locknut:
19 Nm (1.9 m•kg, 13
ft•lb)

3-24
CHASSIS
CLEANING THE FRONT FORK OIL
SEAL AND DUST SEAL
1. Remove:
•Protector
• Dust seal "1"
Use a thin screw driver, and be care-
ful not to damage the inner fork tube
and dust seal.
2. Clean:
• Dust seal "a"
• Oil seal "b"
• Clean the dust seal and oil seal af-
ter every run.
• Apply the lithium soap base grease
on the inner tube.
RELIEVING THE FRONT FORK
INTERNAL PRESSURE
If the front fork initial movement feels
stiff during a run, relieve the front fork
internal pressure.
1. Elevate the front wheel by placing
a suitable stand under the engine.
2. Remove the air bleed screw "1"
and release the internal pressure
from the front fork.
3. Install:
• Air bleed screwADJUSTING THE FRONT FORK
REBOUND DAMPING FORCE
1. Adjust:
• Rebound damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
ADJUSTING THE FRONT FORK
COMPRESSION DAMPING FORCE
1. Remove:
• Rubber cap
2. Adjust:
• Compression damping force
By turning the adjuster "1".• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
3. Install:
• Rubber cap
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:
• Swingarm smooth action
Abnormal noise/unsmooth action
→Grease the pivoting points or
repair the pivoting points.
Damage/oil leakage→Replace.
Air bleed screw:
1 Nm (0.1 m•kg, 0.7
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
9 clicks out
Stiffer "a" →Increase the com-
pression damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the com-
pression damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
10 clicks out
* 11 clicks out
* Except for USA and CDN

3-29
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw "1"
2. Attach:
• Timing light
• Digital tachometer
To the ignition coil lead (orange
lead"1").
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range→Check ro-
tor and pickup assembly.
5. Install:
• Timing mark accessing screwCHECKING AND CHARGING THE
BATTERY
Batteries generate explosive hy-
drogen gas and contain electrolyte
which is made of poisonous and
highly caustic sulfuric acid. There-
fore, always follow these preven-
tive measures:
• Wear protective eye gear when
handling or working near batter-
ies.
• Charge batteries in a well-venti-
lated area.
• Keep batteries away from fire,
sparks or open flames (e.g.,
welding equipment, lighted ciga-
rettes).
• DO NOT SMOKE when charging
or handling batteries.
• KEEP BATTERIES AND ELEC-
TROLYTE OUT OF REACH OF
CHILDREN.
• Avoid bodily contact with elec-
trolyte as it can cause severe
burns or permanent eye injury.
FIRST AID IN CASE OF BODILY
CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15
minutes and get immediate med-
ical attention.
INTERNAL
• Drink large quantities of water or
milk followed with milk of magne-
sia, beaten egg or vegetable oil.
Get immediate medical attention.
Charging time, charging amperage
and charging voltage for an MF
battery are different from those of
conventional batteries. The MF
battery should be charged as ex-
plained in the charging method il-
lustrations. If the battery is
overcharged, the electrolyte level
will drop considerably. Therefore,
take special care when charging
the battery.
Since MF batteries are sealed, it is
not possible to check the charge state
of the battery by measuring the spe-
cific gravity of the electrolyte. There-
fore, the charge of the battery has to
be checked by measuring the voltage
at the battery terminals.
Spark plug gap:
0.7–0.8 mm
(0.028–0.031 in)
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:
YM-33277-A/90890-
03141

3-33
ELECTRICAL
6. Install:
•Battery
• Battery band
7. Connect:
• Battery leads
(to the battery terminals)
First, connect the positive lead "1",
then the negative lead "2".
8. Check:
• Battery terminals
Dirt→Clean with a wire brush.
Loose connection→Connect
properly.
9. Lubricate:
• Battery terminal
10. Install:
• Seat
CHECKING THE FUSE
To avoid a short circuit, always set
the main switch to "OFF" when
checking or replacing a fuse.
1. Remove:
• Seat
• Fuse cover
2. Check:
• Continuity
Checking steps:
a. Remove the fuse "1".
b. Connect the pocket tester to the
fuse and check the continuity.
Set the pocket tester selector to " Ω×
1".
2. Reserve fuse
c. If the pocket tester indicates "∞",
replace the fuse.
3. Replace:
• Blown fuse
Replacement steps:
a. Set the main switch to "OFF".
b. Install a new fuse of the correct
amperage.
c. Set on the switches to verify if the
electrical circuit is operational.
d. If the fuse immediately blows
again, check the electrical circuit.
Never use a fuse with an amperage
rating other than that specified. Im-
provising or using a fuse with the
wrong amperage rating may cause
extensive damage to the electrical
system, cause the starting and ig-
nition systems to malfunction and
could possibly cause a fire.
4. Install:
• Fuse cover
•SeatREPLACING THE HEADLIGHT
BULBS
1. Remove:
• Headlight
Refer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section.
2. Remove:
• Headlight bulb holder cover "1"
3. Remove:
• Headlight bulb holder "1"
Remove the headlight bulb holder by
pushing it in and turning it counter-
clockwise.
4. Remove:
• Headlight bulb
Since the headlight bulb gets ex-
tremely hot, keep flammable prod-
ucts and your hands away from the
bulb unit it has cooled down.
5. Install:
• Headlight bulb
Avoid touching the glass part of
the headlight bulb to keep it free
form oil, otherwise the transparen-
cy of the glass, the life of the bulb
and the luminous flux will be ad-
versely affected. If the headlight
bulb gets soiled, thoroughly clean
it with a cloth moistened with alco-
hol or lacquer thinner.
Recommended lubricant:
Lithium soap base
grease
Pocket tester:
YU-3112-C/90890-
03112
Items Amperage
ratingQ'ty
Main fuse 10 A 1

4-9
CHASSIS
SUSPENSION SETTING (FRONT FORK)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedi-
um
gapSmall
gap
Stiff over entire
range○○○Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).
Spring Replace with soft spring.
Unsmooth move-
ment over entire
range○○○○Outer tube Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Inner tube
Under bracket tighten-
ing torqueRetighten to specified torque.
Poor initial move-
ment○Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil seal Apply grease in oil seal wall.
Soft over entire
range, bottoming
out○○Compression damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Oil level (oil amount) Increase oil level by about 5–10 mm (0.2–0.4 in).
Spring Replace with stiff spring.
Stiff toward stroke
end○Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming out○Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial move-
ment○○○○Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front posture○○Compression damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 95–100 mm (3.7–3.9 in)
when one passenger is astride seat (lower rear
posture).
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
"Obtrusive" front,
tending to upper
front posture○○Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90–95 mm (3.5–3.7 in)
when one passenger is astride seat (upper rear
posture).
Spring Replace with soft spring.
Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).

5-17
CAMSHAFTS
4. Measure:
• Camshaft-to-cap clearance
Out of specification→Measure
camshaft outside diameter.
Measurement steps:
a. Install the camshaft onto the cylin-
der head.
b. Position a strip of Plastigauge
®
"1" onto the camshaft.
c. Install the clip, dowel pins and
camshaft caps.
• Tighten the bolts (camshaft cap) in
a crisscross pattern from innermost
to outer caps.
• Do not turn the camshaft when
measuring clearance with the
Plastigauge
®.
d. Remove the camshaft caps and
measure the width of the Plasti-
gauge
® "1".
5. Measure:
• Camshaft outside diameter "a"
Out of specification→Replace the
camshaft.
Within specification→Replace
camshaft case and camshaft
caps as a set.CHECKING THE CAMSHAFT
SPROCKET
1. Inspect:
• Camshaft sprocket "1"
Wear/damage→Replace the
camshaft assembly and timing
chain as a set.
CHECKING THE
DECOMPRESSION SYSTEM
1. Check:
• Decompression system
Checking steps:
a. Check that the decompression
mechanism cam "1" moves
smoothly.
b. Check that the decompression
mechanism cam lever pin "2" proj-
ects from the camshaft.
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver "1" and wind the ten-
sioner rod up fully clockwise.
• When releasing the screwdriver
by pressing lightly with fingers,
make sure that the tensioner rod
will come out smoothly.
• If not, replace the tensioner as-
sembly.INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
• Apply the molybdenum disulfide oil
on the camshafts.
• Apply the engine oil on the decom-
pression system.
• Squeezing the decompression le-
ver allows the crankshaft to be
turned easily.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
c. Fit the timing chain "3" onto both
camshaft sprockets and install the
camshafts on the cylinder head. Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
:0.08 mm (0.003
in)
Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Camshaft outside diame-
ter:
21.959–21.972 mm
(0.8645–0.8650 in)

5-18
CAMSHAFTS
The camshafts should be installed
onto the cylinder head so that the
punch mark "c" on the exhaust cam-
shaft and the punch mark "d" on the
intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
Do not turn the crankshaft during
the camshaft installation. Damage
or improper valve timing will re-
sult.
d. Install the clips, camshaft caps "4"
and bolts (camshaft cap) "5".
• Before installing the clips, cover the
cylinder head with a clean rag to
prevent the clips from into the cylin-
der head cavity.
• Apply the molybdenum disulfide oil
on the thread of the bolts (camshaft
cap).
• Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
The bolts (camshaft cap) must be
tightened evenly, or damage to the
cylinder head, camshaft caps, and
camshaft will result.
2. Install:
• Timing chain tensioner
Installation steps:
a. While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver and wind the tension-
er rod up fully clockwise.
b. With the rod fully wound and the
chain tensioner UP mark "a" fac-
ing upward, install the gasket "1"
and the timing chain tensioner "2",
and tighten the bolt "3" to the
specified torque.
c. Release the screwdriver, check
the tensioner rod to come out and
tighten the gasket "4" and the cap
bolt "5" to the specified torque.
3. Turn:
• Crankshaft
Counterclockwise several turns.
4. Check:
• Rotor T.D.C. mark
Align with the crankcase align
mark.
• Camshaft match marks
Align with the cylinder head sur-
face.
Out of alignment→Adjust.5. Install:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
6. Install:
• Timing chain guide (top side) "1"
• Cylinder head cover gasket "2"
• Cylinder head cover "3"
• Bolt (cylinder head cover) "4"
Apply the sealant on the cylinder
head cover gasket.
7. Install:
• Cylinder head breather hose
• Spark plug Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain ten-
sioner):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Tensioner cap bolt:
7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (cylinder head cov-
er):
10 Nm (1.0 m•kg, 7.2
ft•lb)
YAMAHA Bond No. 1215
(ThreeBond
® No. 1215):
90890-85505
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)

5-20
CYLINDER HEAD
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Carbon deposits (from the com-
bustion chambers)
Use a rounded scraper.
Do not use a sharp instrument to
avoid damaging or scratching:
• Spark plug threads
• Valve seats
2. Inspect:
• Cylinder head
Scratches/damage→Replace.
Replace the titanium valves with the
cylinder head.
Refer to "CHECKING THE
VALVE".
3. Measure:
• Cylinder head warpage
Out of specification→Resurface.
Warpage measurement and resur-
facing steps:
a. Place a straightedge and a feeler
gauge across the cylinder head.
b. Use a feeler gauge to measure
the warpage.
c. If the warpage is out of specifica-
tion, resurface the cylinder head.
d. Place a 400–600 grit wet sandpa-
per on the surface plate, and re-
surface the head using a figure-
eight sanding pattern.
To ensure an even surface rotate the
cylinder head several times.
INSTALLING THE CYLINDER
HEAD
1. Install:
• Dowel pin "1"
• Cylinder head gasket "2"
• Timing chain guide (exhaust side)
"3"
• Cylinder head "4"
While pulling up the timing chain, in-
stall the timing chain guide (exhaust
side) and cylinder head.
2. Install:
• Washer "1"
• Cable guide "2"
• Bolts [L = 145 mm (5.71 in)] "3"
• Bolts [L = 135 mm (5.31 in)] "4"
•Nuts "5"
• Apply the molybdenum disulfide
grease on the thread and contact
surface of the bolts.
• Follow the numerical order shown
in the illustration. Tighten the bolts
and nuts in two stages.
3. Install:
• Copper washer "1"
• Oil delivery pipe "2"
• Union bolt (M8) "3"
• Union bolt (M10) "4"
First tighten the union bolts temporar-
ily. Then retighten them with the width
"a" across flats of the oil delivery pipe
held tight with a spanner.
4. Install:
• Radiator pipe "1"
• Bolt (radiator pipe) "2" Cylinder head warpage:
Less than 0.05 mm
(0.002 in)
Bolts [L = 145 mm (5.71
in)]:
38 Nm (3.8 m•kg, 27
ft•lb)
Bolts [L = 135 mm (5.31
in)]:
38 Nm (3.8 m•kg, 27
ft•lb)
Nuts:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Union bolt (M8):
18 Nm (1.8 m•kg, 13
ft•lb)
Union bolt (M10):
20 Nm (2.0 m•kg, 14
ft•lb)
Bolt (radiator pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)