2015 YAMAHA WR 250F clutch

PERIODIC MAINTENANCE
3-2
EAS2GB2079GENERAL MAINTENANCE AND LUBRICATION CHART
NO. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER READ-
INGS
600 mi
(1000
km) or 1
month1800 mi
(3000
km) or 3
months3000 mi
(5000
km) or 6
months
1Clutch• Check operation.
• Adjust or replace cable.
2*Cooling sys-
tem• Check hoses for cracks of damage.
• Replace if necessary.
• Replace with ethylene glycol anti-
freeze coolant every 1 year.Every 1 year
3*Spark arrest-
er• Clean.
4*Front brake• Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary.
• Replace brake fluid every 1 year. Every 1 year
5*Rear brake• Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary.
• Replace brake fluid every 1 year. Every 1 year
6*Brake hoses• Check for cracks or damage.
• Replace. Every 4 years
7*Wheels• Check runout, spoke tightness and for
damage.
• Tighten spokes if necessary.
8*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
9*Wheel bear-
ings• Check bearings for smooth operation.
• Replace if necessary.
10*Swingarm
pivot bear-
ings• Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap-
based grease.
11Drive chain• Check chain slack/alignment and con-
dition.
• Adjust and lubricate chain with a spe-
cial O-ring chain lubricant thoroughly.Every ride
12*Steering
bearings• Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap-
based grease every 1200 mi (2000 km)
or 12 months (whichever comes first).

PERIODIC MAINTENANCE
3-3
TIP
• 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.
13
Brake and
clutch lever
pivot shafts• Apply lithium-soap-based grease (all-
purpose grease) lightly.
14Brake pedal
pivot shafts• Apply lithium-soap-based grease (all-
purpose grease) lightly.
15Sidestand
pivot• Check operation.
• Apply lithium-soap-based grease (all-
purpose grease) lightly.
16*Front fork• Check operation and for oil leakage.
• Replace if necessary.
17*Shock ab-
sorber as-
sembly• Check operation and for oil leakage.
• Replace if necessary.
18*Rear suspen-
sion link piv-
ots• Apply molybdenum disulfide grease
lightly.
19*Control ca-
bles• Apply Yamaha chain and cable lube or
engine oil 10W-30 thoroughly.
20*Throttle grip
housing and
cable• Check operation and free play.
• Adjust the throttle cable free play if
necessary.
• Lubricate the throttle grip housing and
cable.
21*Chassis fas-
teners• Check all chassis fitting and fasteners.
• Correct if necessary.
22Battery• Check terminal for looseness and cor-
rosion. NO. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER READ-
INGS
600 mi
(1000
km) or 1
month1800 mi
(3000
km) or 3
months3000 mi
(5000
km) or 6
months

PERIODIC MAINTENANCE
3-5
PISTON PIN
Inspect
Replace
CYLINDER HEAD
Inspect carbon deposits and
eliminate them. Inspect and clean
Change gasket.
CYLINDER
Inspect and cleanInspect score marks.
Inspect wear.
Replace
CLUTCH
Inspect and adjustInspect 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 re-
tighten
Clean
Replace
CRANK
Inspect and clean
THROTTLE BODY
Inspect
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN Use chain lube.
Lubricate, slack,
alignmentChain slack: 50–60 mm
(1.97–2.36 in)
ReplaceITEMAfter
break-
inEvery
raceEvery
third
(or
500
km)Every
fifth
(or
1,000
km)As re-
quiredRemarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GB2081
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GB2082GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.3-10 – 12
FuelCheck that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage.1-32
Engine oilCheck that the oil level is correct. Check the crank-
case and oil line for leakage.3-16 – 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and
that the clutch operates smoothly.3-12 – 13
Throttle grip/HousingCheck that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary.3-13 – 14
BrakesCheck the play of front brake and effect of front and
rear brake.3-24 – 30
Drive chainCheck drive chain slack and alignment. Check that
the drive chain is lubricated properly.3-30
5-68 – 69
WheelsCheck for excessive wear and tire pressure. Check
for loose spokes and have no excessive play.3-35 – 36
SteeringCheck that the handlebar can be turned smoothly and
have no excessive play.3-36 – 37
Front forks and rear
shock absorberCheck that they operate smoothly and there is no oil
leakage.3-31 – 35
Cables (wires)Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and
has no cracks.3-15 – 16
Rear wheel sprocketCheck that the rear wheel sprocket tightening bolt is
not loose.5-10 – 11
LubricationCheck for smooth operation. Lubricate if necessary. 3-13
3-37 – 38
Bolts and nutsCheck the chassis and engine for loose bolts and
nuts.1-36 – 37
Lead connectorsCheck that the AC magneto, ECU and ignition coil are
connected tightly.1-11 – 14
SettingsIs the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?4-1 – 8

ENGINE
3-12
EAS2GB2089CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:
• Coolant level
2. Install:
• Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections
Coolant leaks  Correct or replace.
• Radiator hoses
Bulges  Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GB2090ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”
Out of specification  Regulate.
2. Adjust:
• Clutch lever free play
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Handlebar side
a. Turn the adjuster “1” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
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Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”. Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
Test pressure value
196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
a b
1

ENGINE
3-13
c. Turn the adjuster “2” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
d. Tighten the locknut “1”.
e. Return the clutch cable cover to its original
position.
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EAS2GB2091ADJUSTING THE THROTTLE GRIP FREE
PLAY
TIP
Prior to adjusting throttle grip free play, the en-
gine idling speed should be adjusted.
1. Check:
• Throttle grip free play “a”
Out of specification  Regulate.2. Adjust:
• Throttle grip free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjuster “2” until the specified free
play is obtained.
c. Tighten the locknut.
EWA
WARNING
After adjusting the throttle grip free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
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EAS2GB2092LUBRICATING THE THROTTLE CABLE
1. Remove:
• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3” Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
Locknut
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
T R..
1
2a
b
Direction “a”
Throttle grip free play is increased.
Direction “b”
Throttle grip free play is decreased.
1 2
b
a

ENGINE
3-16
4. Install:
• Exhaust pipe protector
EAS2GB2097CHECKING THE FUEL LINE
1. Remove:
• Seat
• Side cover (left/right)
• Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
2. Check:
• Fuel hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GB2098
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 3 minutes,
and then stop the engine and wait about 5
minute.
3. Check:
• Oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark  Add the
recommended engine oil to the proper level.
ECA
NOTICE
• Since engine oil also lubricates the clutch,
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.
• Do not allow foreign material to enter the
crankcase. Exhaust pipe protector screw
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
4
3
T R..
1
Recommended brand
YAMALUBE
Recommended engine oil type
SAE10W-30, SAE10W-40,
SAE10W-50, SAE15W-40,
SAE20W-40 or SAE20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
a b

CHASSIS
3-37
c. Turn the front fork to the right and left a few
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 5-53.
d. Loosen the ring nut fully turn and then tight-
en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 5-53.
f. Install the washer “1”.
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5. Install:
• Upper bracket
Refer to “STEERING HEAD” on page 5-53.
• Handlebar
Refer to “HANDLEBAR” on page 5-33.
EAS2GB2126
CHECKING AND LUBRICATING THE CA-
BLES
The following procedure applies to all of the in-
ner and outer cables.
EWA
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner ca-
bles as soon as possible.
1. Check:
• Outer cable
Damage  Replace.
2. Check:
• Cable operation
Rough movement  Lubricate.
TIP
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS2GB2127LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS2GB2128LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal. Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Ring nut (initial tightening torque)
38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
T R..
1
Recommended lubricant
Engine oil or a suitable cable lu-
bricant
Recommended lubricant
Silicone grease
Recommended lubricant
Lithium-soap-based grease
Recommended lubricant
Lithium-soap-based grease