2012 YAMAHA WR 250F Owners Manual

2-26
CABLE ROUTING DIAGRAM
A. Fasten the wire harness, nega-
tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side). Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame.
B. Fasten the wire harness, nega-
tive battery lead and starter mo-
tor lead to the upper engine
bracket (left side). Locate the
clamp end facing toward the up-
per side of the frame with the tie
end cut off on the inside of the
frame. Clamp the wire harness
and negative lead at the mark-
ing.
C. Pass the starter motor lead
through the hole in the relay
holder.
D. Fit the cover securely.
E. Connect the wire harness to the
starter relay.
F. Fasten the catch tank breather
hose and catch tank hose to the
rear frame. Clamp them close to
where they are joined to the
frame. Fasten the pipe tightly
enough not to crush it. Locate
the clamp end facing toward the
rear of the frame with the tie end
facing downward.
G. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the upper side of
the frame and cut off the tie end.
H. Connect the negative battery
lead to the battery negative ter-
minal.
I. Connect the negative battery
lead to the wire harness.
J. Fasten the wire harness to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and the tie end to-
ward the inside of the frame.
Clamp the wire harness at the
marking.
K. Pass the wire harness, starter
relay lead, starting circuit cut-off
relay lead and negative battery
lead through the hole in the relay
holder.
L. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the lower side of
the frame and cut off the tie end.M. Fasten the taillight lead to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and cut off the tie
end.
N. Do not allow the taillight lead to
slacken.
O. Locate the CDI unit lead be-
tween the CDI unit and rear
fender.
P. Locate the CDI unit coupler in
the clearance between the up-
per side of the CDI unit and low-
er side of the catch tank stay.
Q. Locate the CDI unit lead be-
tween the CDI unit and rear
frame.

2-27
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Brake hose
4. Clutch cable
5. Hose guide
6. Main switch coupler
7. Wire harness
8. Headlight coupler
9. Hot starter cable
10. Multi-function display bracket
11. Main switch12. Upper bracket
13. Clutch switch coupler
14. Engine stop switch coupler
15. Multi-function display coupler
16. Start switch coupler
17. Speed sensor coupler
18. Speed sensor lead

2-28
CABLE ROUTING DIAGRAM
A. Fasten the start switch lead to
the handlebar with the plastic
bands.
B. Fasten the engine stop switch
lead and clutch switch lead to
the handlebar with the plastic
bands.
C. Pass the brake hose through
the hose guides.
D. Secure the coupler by inserting
it into the multi-function display
bracket.
E. Pass the throttle cables, clutch
cable and hot starter cable be-
tween the upper bracket and
multi-function display bracket.
F. Fasten the multi-function display
leads to the bracket. Cut off the
tie end.
G. Secure the coupler by pushing it
into the hole in the multi-function
display bracket.
H. Secure the wire harness clip by
pushing it into the hole in the
multi-function display bracket on
the inside.
I. Fasten the wire harness to the
multi-function display bracket.
Cut off the tie end.
J. Fasten the main switch lead
(wire harness side) to the multi-
function display bracket. Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
K. Pass the speed sensor lead
through the guide on the outside
of the front fork.

3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSIONCONTROL SYSTEM (For Canada)
REGULAR INSPECTION AND ADJUSTMENTS
PERIODIC MAINTENANCE CHART FO R THE EMISSION CONTROL SYSTEM (For Canada)
• From 4,200 mi (7,000 km) or 9 months, repeat the maintenanc e intervals starting from 1,800 mi (3,000 km) or 3 months.
• Items marked with an asterisk should be performed by a Yam aha dealer as they require special tools, data and technical
skills.
No. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER
READINGS600 mi (1,000
km) or 1 month 1,800 mi
(3,000
km) or 3 months 3,000 mi
(5,000
km) or 6 months
1 * Fuel line Check fuel hoses for cracks or damage.

Replace if necessary.
2 Spark plug Check condition.

Adjust gap and clean.
3 * Valve clearance Check and adjust valve clearance when en-
gine is cold.

4 * Air filter element Clean with solvent and apply foam air-filter oil
or equivalent oil.

Replace if necessary.
5 * Breather system Check ventilation hose for cracks or damage
and drain any deposits.

Replace if necessary.
6 * Carburetor Check engine idling speed and starter opera-
tion.

Adjust if necessary.
7 Exhaust system Check for leakage.

Tighten if necessary.
Replace gasket(s) if necessary.
8 Engine oil Change (warm engine before draining). 
9 Engine oil filter element Replace. 
10 Engine oil strainer Clean. 
11 * Air induction system Check the hose for damage.

Replace any damaged parts if necessary.

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART (For
Canada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
1 ClutchCheck operation.

Adjust or replace cable.
2 * Cooling systemCheck hoses for cracks of damage.

Replace if necessary.
Replace with ethylene glycol anti-freeze cool-
ant every 1 year.Every 1 year
3 * Spark arrester Clean.
4 * Front brakeCheck operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brakeCheck operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hosesCheck for cracks or damage.
Replace. Every 4 years
7 * WheelsCheck runout, spoke tightness and for dam-
age.

Tighten spokes if necessary.
8*TiresCheck tread depth and for damage.
 Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearingsCheck bearings for smooth operation.

Replace if necessary.
10 * Swingarm pivot bearingsCheck bearing assemblies for looseness.

Moderately repack with lithium-soapbased
grease.
11 Drive chainCheck chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearingsCheck bearing assemblies for looseness.
 Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13Brake and clutch lever pivot
shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.
14 Brake pedal pivot shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.
3

3-3
MAINTENANCE INTERVALS FOR COMPETITION USE
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid
levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
MAINTENANCE INTERVALS FOR COMPETITION USE
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below.
15 Sidestand pivotCheck operation.

Apply lithium-soap-based grease (all-purpose
grease) lightly.
16 * Front forkCheck operation and for oil leakage.

Replace if necessary.
17 * Shock absorber assemblyCheck operation and for oil leakage.

Replace if necessary.
18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly.
19 * Control cablesApply Yamaha chain and cable lube or engine
oil 10W-30 thoroughly.
20 * Throttle grip housing and cableCheck operation and free play.
 Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
21 * Chassis fastenersCheck all chassis fitting and fasteners.

Correct if necessary.
22 Battery Check terminal for looseness and corrosion. No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS
600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks
ENGINE OIL
Replace●●
VALVES
Check the valve clearances●●The engine must be cold.
Inspect●Check the valve seats and valve
stems for wear.
Replace●
VALVE SPRINGS
Inspect●Check the free length and the tilt.
Replace●

3-4
MAINTENANCE INTERVALS FOR COMPETITION USE
VALVE LIFTERS
Inspect●Check for scratches and wear.
Replace●
CAMSHAFTS Inspect the camshaft surface.
Inspect●Inspect the decompression system.
Replace●
CAMSHAFT SPROCKETS
Inspect●Check for wear on the teeth and for
damage.
Replace●
PISTON
Inspect●●Inspect crack.
Clean●Inspect carbon deposits and eliminate
them.
Replace●It is recommended that the piston pin
and ring are also replaced at the same
time.
PISTON RING
Inspect●Check ring end gap.
Replace●●
PISTON PIN
Inspect●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean●Change gasket.
CYLINDER
Inspect and clean●Inspect score marks.
Replace●Inspect wear.
CLUTCH
Inspect and adjust●●Inspect housing, friction plate, clutch
plate and spring.
Replace●
TRANSMISSION
Inspect●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BAR
Inspect●Inspect wear.
ROTOR NUT
Retighten●●
MUFFLER
Inspect and retighten●●
Clean●
Replace● ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks

3-5
MAINTENANCE INTERVALS FOR COMPETITION USE
CRANK
Inspect and clean●●
CARBURETOR
Inspect, adjust and clean●●
AIR INDUCTION SYSTEM
Inspect and clean●● ●●
SPARK PLUG
Inspect and clean●●
Replace●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment●●Chain slack: 48–58 mm (1.9–2.3 in)
Replace●
COOLING SYSTEM
Check coolant level and leakage●●
Check radiator cap operation●
Replace coolant●Every two years
Inspect hoses●
OUTSIDE NUTS AND BOLTS
Retighten●●Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER
Clean and lubricate●●Use foam air-filter oil or equivalent oil.
Replace●
OIL FILTER
Replace●●
ENGINE GUARD
Replace●Breakage
FRAME
Clean and inspect●●
FUEL TANK, COCK
Clean and inspect●●
BRAKES
Adjust lever position and pedal
height●●
Lubricate pivot point●●
Check brake disc surface●●
Check fluid level and leakage●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts●●
Replace pads●
Replace brake fluid●Every one year ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks