YAMAHA WR 250F 2010 Repair Manual

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART (ForCanada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
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 Clutch Check operation.
√√√
Adjust or replace cable.
2 * Cooling system Check 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 brake Check operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brake Check operation, fluid level, and for fluid leak-
age.
√√√
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 dam-
age.
√√√
Tighten spokes if necessary.
8*Tires Check tread depth and for damage.
√√√
Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearings Check bearings for smooth operation.
√√√
Replace if necessary.
10 * Swingarm pivot bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease.
11 Drive chain Check chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearings Check bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13 Brake and clutch lever pivot
shafts Apply lithium-soap-bas
ed grease (all-purpose
grease) lightly. √√√
14 Brake pedal pivot shafts Apply lithium-soap-bas
ed 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 mainten ance 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 mainta ining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the ma chine 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 pivot Check operation.
√√√
Apply lithium-soap-bas ed grease (all-purpose
grease) lightly.
16 * Front fork Check operation and for oil leakage.
√√
Replace if necessary.
17 * Shock absorber assembly Check operation and for oil leakage.
√√
Replace if necessary.
18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. √√
19 * Control cables 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 fasteners Check all chassis fitting and fasteners.
√√√
Correct if necessary.
22 Battery Check terminal for looseness and corrosion. √√
No. ITEM CHECKS AND MAINTENANCE JOBS
INITIAL
ODOMETER
READINGS
600 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
Item After
break-
in Every
race
Every third
(or 500
km) Every
fifth (or 1,000
km)
As re-
quired Remarks
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 LIFTERSInspect ●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 ●
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks

3-5
MAINTENANCE INTERVALS FOR COMPETITION USE
CRANKInspect 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
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks

3-6
MAINTENANCE INTERVALS FOR COMPETITION USE
FRONT FORKSInspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
REAR SHOCK ABSORBER Inspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
SIDESTAND Lubricate ●Lithium base grease
STEERING HEAD Inspect free play and retighten ●●
Clean and lube ●Lithium base grease
Replace bearing ●
TIRE, WHEELS Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness ●●
Retighten sprocket bolt ●●
Inspect bearings ●
Replace bearings ●
Lubricate ●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection ●●
Lubricate ●● Yamaha cable lube or SAE 10W-40
motor oil
HOT STARTER, CLUTCH LEVER Inspect free play ●
BATTERY Check terminal for looseness
and corrosion ●
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks

3-7
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCEItem RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-11 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.
P.1-18
Engine oil Check that the oil level is corre
ct. Check the crankcase and oil
line for leakage. P.3-14 – 15
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.
P.3-13
Brakes Check the play of front brake and ef fect of front and rear brake. P.3-19 – 22
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly. P.3-22 – 23
Wheels Check for excessive wear and ti
re pressure. Check for loose
spokes and have no excessive play. P.3-26 – 27
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play.
P.3-27
Front forks and rear shock
absorber Check that they operate smoothly and there is no oil leakage.
P.3-23 – 26
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 pipe Check that the exhaust pipe is tightly mount ed and has no cracks. P.3-10 – 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-20
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are con-
nected tightly. P.1-7
Settings Is the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done? P.4-1 – 10

3-8
ENGINE
ENGINE
REMOVING THE SEAT, FUEL TANK AND SIDE COVERS
Order Part name Q'ty Remarks Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Open the air filter case cover.
6 Right side cover 1 Refer to removal section.
7 Headlight coupler 1
8 Headlight 1

3-9
ENGINE
REMOVING THE SIDE COVER
1. Remove:• Bolt (side cover)
• Right side cover "1"
Draw the side cover backward to re-
move it because its claw "a" is insert-
ed in the air filter case.

3-10
ENGINE
REMOVING THE EXHAUST PIPE AND SILENCEROrder Part name Q'ty Remarks Right side cover Refer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section.
1 Bolt (silencer clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Collar 1
5 Silencer 1
6 Silencer clamp 1
7 Nut (exhaust pipe) 2
8 Exhaust pipe 1
9 Gasket 2

3-11
ENGINE
CHECKING THE SILENCER AND
EXHAUST PIPE
1. Inspect:• Gasket "1"
Damage →Replace.
INSTALLING THE SILENCER AND
EXHAUST PIPE
1. Install: • Gasket
• Exhaust pipe "1"
• Nut (exhaust pipe) "2"
First, temporarily install both nuts,
then tighten either of these nuts to 13
Nm (1.3 m•kg, 9.4 ft•lb) and the other
to 20 Nm (2.0 m•kg, 14 ft•lb), and
then come back to the first one and
retighten it to 20 Nm (2.0 m•kg, 14
ft•lb).
2. Install: • Silencer clamp "1"
• Gasket "2"
• Silencer "3"
• Washer "4"
• Bolt (silencer) "5" CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level
place, and hold it in an upright po-
sition.
2. Remove: • Radiator cap
3. Check: • Coolant level "a"Coolant level low →Add coolant.
1. Radiator CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en-
gine.
2. Remove:
• Seat
• Left side cover
3. Remove the catch tank hose from
the catch tank and drain the tank
of its coolant.
4. Remove:
• Coolant drain bolt "1"
5. Remove: • Radiator capDrain the coolant completely.
6. Clean: • Cooling systemThoroughly flush the cooling sys-
tem with clean tap water.
7. Install: • Copper washer
• Coolant drain bolt
8. Fill: •Radiator
• Engine
To specified level.
Nut (exhaust pipe):
20 Nm (2.0 m•kg, 14
ft•lb)
Silencer clamp: 16 Nm (1.6 m•kg, 11
ft•lb)
Bolt (silencer): 30 Nm (3.0 m•kg, 22
ft•lb)
Coolant drain bolt:10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant: High quality ethylene
glycol anti-freeze con-
taining anti-corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio: 50%/50%
Coolant capacity: 0.99 L (0.87 Imp qt, 1.05
US qt)