2016 YAMAHA WR 250F oil change

DESCRIPTION
1-4
EAS2GB7009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.1. Clutch lever 12. Headlight
2. Multi-function display 13. Radiator
3. Front brake lever 14. Coolant drain bolt
4. Throttle grip 15. Rear brake pedal
5. Start switch 16. Air filter
6. Radiator cap 17. Drive chain
7. Fuel tank cap 18. Shift pedal
8. Engine stop switch 19. Oil level check window
9. Taillight 20. Starter knob/idle screw
10. Fuel tank 21. Front fork
11. Kickstarter lever
32 1
8
10
91112 1376
54
15 14 21 20 19 18 1716

IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS2GB7020PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment.
See “SPECIAL TOOLS”.
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them.4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS2GB7021REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.

MAINTENANCE AFTER BREAK-IN
1-33
EAS2GB7055
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-9.
EAS2GB7056MAJOR MAINTENANCE
1. For the engine
• Leaks around the engine
Check for pressure leaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the
cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be-
tween the cylinder and the piston are cor-
rect.
• Engine oil change
Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s)
Check the wheel for runout. Check the
spoke for looseness.
• Brake(s)
Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.• Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket
Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.
ECA
NOTICE
After a break-in or before each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-34.)
• Greasing and oiling
Always grease or oil the specified points.

PERIODIC MAINTENANCE
3-1
EAS2GB7074
PERIODIC MAINTENANCE
EAS2GB7075INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2GB7076PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000
km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
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
1*Fuel line• Check fuel hoses for cracks or dam-
age.
• Replace if necessary.
2Spark plug• Check condition.
• Adjust gap and clean.
3*Valve clear-
ance• Check and adjust valve clearance
when engine is cold.
4*Air filter ele-
ment• 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. Every 2 years
6*Fuel injec-
tion• Adjust engine idling speed.
7Exhaust sys-
tem• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
8Engine oil• Change (warm engine before drain-
ing).
9Engine oil fil-
ter element•Replace.
10Engine oil
strainer• Clean.

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 sus-
pension link
pivots• 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

4
TUNING
CHASSIS.......................................................................................................... 4-1
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET) ............................................................................................ 4-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS .................. 4-1
TIRE PRESSURE....................................................................................... 4-1
FRONT FORK SETTING............................................................................ 4-2
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL............ 4-2
SETTING OF SPRING AFTER REPLACEMENT ...................................... 4-2
FRONT FORK SETTING PARTS............................................................... 4-3
REAR SUSPENSION SETTING ................................................................ 4-3
CHOOSING SET LENGTH ........................................................................ 4-3
SETTING OF SPRING AFTER REPLACEMENT ...................................... 4-4
REAR SHOCK ABSORBER SETTING PARTS ......................................... 4-4
SUSPENSION SETTING (FRONT FORK)................................................. 4-6
SUSPENSION SETTING (REAR SHOCK ABSORBER) ........................... 4-7

CHASSIS
4-2
• Under a stony or a hard road condition, the
tire pressure should be higher to prevent a flat
tire.
EAS2GB7140FRONT FORK SETTING
The front fork setting should be made depend-
ing on the rider’s feeling of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.
The spring acts on the load and the damping
force acts on the cushion travel speed.
EAS2GB7141CHANGE IN AMOUNT AND CHARACTERIS-
TICS OF FORK OIL
Damping characteristic near the final stroke
can be changed by changing the fork oil
amount.
EWA
WARNING
Adjust the oil amount in 5 cm3 (0.2 US oz,
0.2 Imp.oz) increments or decrements. Too
small oil amount causes the front fork to
produce a noise at full rebound or the rider
to feel some pressure on his hands or body.
Alternatively, too large oil amount will
cause the air spring characteristics to have
a tendency to be stiffer with the consequent
deteriorated performance and characteris-
tics. Therefore, adjust the front fork within
the specified range.
EAS2GB7142SETTING OF SPRING AFTER REPLACE-
MENT
As the front fork setting can be easily affected
by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
when setting the front fork.
1. Use of soft spring
• Change the rebound damping force.
Turn out one or two clicks.
• Change the compression damping force.
Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring
• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force.
Turn out one or two clicks. Extent of adjustment
100–120 kPa (1.00–1.20 kgf/cm
2,
15–18 psi)
Standard oil amount
340 cm
3 (11.50 US oz, 11.99
lmp.oz)
Extent of adjustment
300–365 cm
3 (10.14–12.34 US
oz, 10.58–12.87 Imp.oz)
A. Air spring characteristics in relation to oil
amount change
B. Load
C. Stroke
1. Max. oil amount
2. Standard oil amount
3. Min. oil amount

CHASSIS
4-6
EAS2GB7148SUSPENSION SETTING (FRONT FORK)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-
ting 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
rangeCompression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil amount Decrease oil amount by about
5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Unsmooth
movement over
entire rangeOuter tube
Inner tubeCheck for any bends, dents,
other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex-
tended use.
Piston metal Replace with a new one for ex-
tended use.
Lower bracket
tightening
torqueRetighten to specified torque.
Poor initial
movementRebound
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil seals Apply grease in oil seal wall.
Soft over entire
range, bottom-
ing outCompression
damping forceTurn adjuster clockwise (about
2 clicks) to increase damping.
Oil amount Increase oil amount by about
5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward
stroke endOil amountDecrease oil amount by about
5 cm
3 (0.2 US oz, 0.2 Imp.oz).
Soft toward
stroke end, bot-
toming outOil amountIncrease oil amount by about 5
cm
3 (0.2 US oz, 0.2 Imp.oz).
Stiff initial
movementCompression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.