2012 YAMAHA WR 250R Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
2
3
4
567
8
9
turn the adjusting nut in direction
(b).
7. Tighten the locknut at the clutch cable, and then slide the rubber
cover to its original position.
8. Tighten the locknut at the clutch le- ver, and then slide the rubber cov-
er to its original position.
EAU48442
Adjusting the brake lever free
play The brake lever free play should mea-
sure 5.0– 8.0 mm (0.20– 0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows. 1. Slide the rubber cover back at the brake lever.
2. Loosen the locknut.
3. To increase the brake lever free play, turn the brake lever free play
adjusting screw in direction (a). To
decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b). 4. Tighten the locknut, and then slide
the rubber cover back to its original
position.
WARNING
EWA10630

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
1. Locknut (clutch cable)
2. Clutch lever free play adjusting nut (clutch cable)
3. Rubber cover
1
2
3
(a)
(b)
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
4. Rubber cover
3
1 2
4
(b)
(a)
32D-9-E8.book 23 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
1
2
3
4
56
7
8
9dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
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).1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2(b)
(a)
32D-9-E8.book 24 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
2
3
4
567
8
9
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
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.
EAU22581
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Brake pad wear indicator groove1
1
1. Brake pad wear indicator groove
1
1. Minimum level mark1
32D-9-E8.book 25 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
1
2
3
4
56
7
8
9Rear brake
WARNING
EWA15990
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.

Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.

Use only the specified brake flu-
id; otherwise, the rubber seals may deteriorate, causing leak-
age.

Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.

Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vaporlock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always cleanup spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
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.
1. Minimum level markSpecified brake fluid:
DOT 41
32D-9-E8.book 26 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
2
3
4
567
8
9
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU47222
To check the drive chain slack1. Place the motorcycle on the side- stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weighton 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. 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU34317
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing 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 parts
of 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 sameposition for proper wheel alignment.
Drive chain slack: 8.0 –13.0 mm (0.31 –0.51 in)
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)
32D-9-E8.book 27 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
1
2
3
4
56
7
8
93. Tighten the axle nut, then the lock-
nuts to their specified torques.
4. Make sure that the drive chain pull- ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23025
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, ridingin the rain or riding in wet areas.
1. Clean the drive chain with kero- sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11121]

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they may contain substances that
could damage the O-rings.
[ECA11111]

Tightening torques:
Axle nut:125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf)
32D-9-E8.book 28 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
2
3
4
567
8
9
EAU23095
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe condi-
tions.
[EWA10711]

EAU23114
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the cover or cable
when washing the vehicle. If the cable
or cover becomes dirty, wipe clean with
a moist cloth.
EAU23142
Checking and lubricating the
brake and cl utch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
32D-9-E8.book 29 ページ ２０１１年６月２８日　火曜日　午前１０時２７分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-30
1
2
3
4
56
7
8
9
EAU23182
Checking and lubricating the
brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU23202
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-sulting in a possible loss of control.
Recommended lubricants:Brake lever:Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant: Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
32D-9-E8.book 30 ページ ２０１１年６月２８日　火曜日　午前１０時２７分