lock YAMAHA WR 250R 2010 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU48372
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Slide the rubber cover back at the
clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free
play, turn the clutch lever free play
adjusting bolt in direction (a). Todecrease the clutch lever free play,
turn the adjusting bolt in direction
(b).
TIPIf the specified clutch lever free play
could be obtained as described above,
skip steps 4–7.4. Fully turn the adjusting bolt in di-
rection (a) to loosen the clutch ca-
ble.
5. Slide the rubber cover back further
down the clutch cable, and then
loosen the locknut.
1. Clutch lever free play
2. Locknut (clutch lever)
3. Clutch lever free play adjusting bolt
4. Rubber cover
3 2
1
4
(a)(b)
1. Locknut (clutch cable)
2. Clutch lever free play adjusting nut (clutch
cable)
3. Rubber cover
1 2
3
(a)
(b)
U32DE4E0.book Page 21 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6 6. To increase the clutch lever free
play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,
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.
EAU48440
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). Todecrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).
4. Tighten the locknut, and then slide
the rubber cover to its original po-
sition.
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
dealer 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.
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
4. Rubber cover
3
1
2
4
(b)
(a)
U32DE4E0.book Page 22 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
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.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU47222
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on 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.Drive chain slack:
8.0–13.0 mm (0.31–0.51 in)
U32DE4E0.book Page 25 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU22945
To adjust 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 partsof 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 same
position for proper wheel alignment.3. Tighten the axle nut, then the lock-
nuts to their specified torques.
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)
Tightening torque:
Axle nut:
125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
U32DE4E0.book Page 26 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-33
6
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15131]
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If a fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
EAU45213
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.NOTICE
ECA10650
Take care not to damage the follow-
ing parts:

Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.


Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of a
wattage higher than specified.
1. Fuel injection system fuse
2. Radiator fan fuse
3. Backup fuse (for clock)
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. Spare fuse
7
123456
Specified fuses:
Main fuse:
30.0 A
Ignition fuse:
7.5 A
Signaling system fuse:
10.0 A
Headlight fuse:
15.0 A
Radiator fan fuse:
7.5 A
Backup fuse:
7.5 A
Fuel injection system fuse:
7.5 A
U32DE4E0.book Page 33 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
6
EAU24181
Tail/brake light This model is equipped with an LED-
type tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU24204
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the burnt-out bulb by
pushing it in and turning it counter-
clockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw. NOTICE: Do not over-
tighten the screw, otherwise the
lens may break.
[ECA11191]
1. Screw
2. Turn signal light lens
1
2
1. Turn signal light bulb
1
U32DE4E0.book Page 35 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6 2. Lift the front wheel off the ground
according to the procedure on
page 6-37.
3. Remove the axle nut.
4. Pull the wheel axle out, and then
remove the wheel. NOTICE: Do
not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]
EAU49340
To install the front wheel
1. Lift the wheel up between the fork
legs.
TIPMake sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc.2. Insert the wheel axle.
3. Install the axle nut.
4. Lower the front wheel so that it is
on the ground, and then put the
sidestand down.
5. Tighten the axle nut and the wheel
axle pinch bolts to their specified
torques, and then install the rubber
cap.
6. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU45182
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
3. Remove the axle nut and washer.
4. Loosen the locknut on each side of
the swingarm.
1. Front wheel axle pinch bolt
2. Wheel axle
1
2
Tightening torques:
Axle nut:
63 Nm (6.3 m·kgf, 46 ft·lbf)
Wheel axle pinch bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1. Axle nut
2. Washer
1
2
U32DE4E0.book Page 38 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
65. Turn the drive chain slack adjust-
ing bolts fully in direction (a).
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the rear wheel.7. While supporting the brake caliper,
pull the wheel axle out.8. Remove the wheel. NOTICE: Do
not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]
EAU45191
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.TIP

Make sure that the retainer on the
brake caliper bracket is inserted
into the slot in the swingarm.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Install the washer and the axle nut.
4. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
5. Adjust the drive chain slack. (See
page 6-25.)
6. Tighten the axle nut to the speci-
fied torque.
1. Drive chain slack adjusting bolt
2. Locknut
3. Brake caliper
12
3 (a)
1. Wheel axle
1
1. Brake caliper bracket
2. Retainer
3. Slot
1
2
3
U32DE4E0.book Page 39 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-42
6 Engine overheating
WARNING
EWA10400


Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U32DE4E0.book Page 42 Monday, December 14, 2009 2:24 PM

INDEXAAir filter element and check hose,
cleaning .............................................. 6-16
Auxiliary light bulb, replacing ................ 6-36BBattery................................................... 6-31
Brake and clutch levers, checking and
lubricating ........................................... 6-28
Brake fluid, changing ............................ 6-25
Brake fluid level, checking .................... 6-24
Brake lever ............................................ 3-10
Brake lever free play, adjusting............. 6-22
Brake light switches .............................. 6-23
Brake pedal ........................................... 3-10
Brake pedal, checking and
lubricating ........................................... 6-29CCables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converter ................................ 3-13
Clutch lever ............................................. 3-9
Clutch lever free play, adjusting ............ 6-21
Coolant.................................................. 6-13
Coolant temperature warning light .......... 3-2DDimmer switch ........................................ 3-9
Drive chain, cleaning and lubricating .... 6-27
Drive chain slack ................................... 6-25EEngine break-in ....................................... 5-3
Engine idling speed............................... 6-17
Engine oil and oil filter element ............. 6-10
Engine stop switch .................................. 3-9
Engine trouble warning light.................... 3-3EXUP system ....................................... 3-18
FFront and rear brake pads, checking .... 6-23
Front fork, adjusting .............................. 3-14
Front fork, bleeding............................... 3-16
Front fork, checking .............................. 6-30
Fuel....................................................... 3-11
Fuel consumption, tips for reducing........ 5-3
Fuel level warning light ........................... 3-2
Fuel tank cap ........................................ 3-11
Fuses, replacing ................................... 6-32HHandlebar switches ................................ 3-8
Headlight bulb, replacing ...................... 6-33
Helmet holder ....................................... 3-14
High beam indicator light ........................ 3-2
Horn switch ............................................. 3-9IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-19
Indicator and warning lights .................... 3-2LLicense plate light bulb, replacing ........ 6-36MMain switch/steering lock........................ 3-1
Maintenance and lubrication, periodic .... 6-3
Maintenance, emission control system... 6-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-1
Multi-function display .............................. 3-3NNeutral indicator light .............................. 3-2PPanels, removing and installing .............. 6-7Parking .................................................... 5-4
Part locations .......................................... 2-1
SSafety information ................................... 1-1
Seat ....................................................... 3-13
Shifting .................................................... 5-2
Shift pedal ............................................. 3-10
Shift pedal, checking ............................. 6-23
Shock absorber assembly, adjusting .... 3-17
Sidestand .............................................. 3-19
Sidestand, checking and lubricating...... 6-29
Spark plug, checking ............................... 6-9
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch.............................................. 3-9
Steering, checking................................. 6-30
Storage.................................................... 7-3
Supporting the motorcycle .................... 6-37
Swingarm pivots, lubricating ................. 6-29TTail/brake light ....................................... 6-35
Throttle cable free play, checking ......... 6-18
Throttle grip and cable, checking and
lubricating ........................................... 6-28
Tires ...................................................... 6-19
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-40
Troubleshooting charts.......................... 6-41
Turn signal indicator light ........................ 3-2
Turn signal light bulb, replacing ............ 6-35
Turn signal switch ................................... 3-9VValve clearance..................................... 6-18
Vehicle identification number .................. 9-1
U32DE4E0.book Page 1 Monday, December 14, 2009 2:24 PM