engine YAMAHA WR 250F 2007 Owner's Guide

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
NOTE:The following schedule is intended as a general guide to maintenance 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 maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks
ENGINE OIL
Replace
VALVES
Check the valve clearances The engine must be cold.
Check the valve seats and
valve stems for wear. Inspect
Replace
VALVE SPRINGS
InspectCheck the free length and
the tilt.
Replace
VALVE LIFTERS
InspectCheck for scratches and
wear.
Replace
CAMSHAFTSInspect the camshaft
surface.
Inspect the decompression
system. Inspect
Replace
CAMSHAFT SPROCKETS
InspectCheck for wear on the teeth
and for damage.
Replace
PISTON
InspectInspect crack
Inspect carbon deposits and
eliminate them. Clean
Replace
PISTON RING
InspectCheck ring end gap
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEADInspect carbon deposits and
eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect and adjust Inspect housing, friction
plate, clutch plate and spring
Replace
TRANSMISSION
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear

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INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-35 ~ 41
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-49
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-51 ~ 59
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-41 ~ 43
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-43 ~ 45
Brakes Check the play of front brake and effect of front and rear brake. P.3-77 ~ 89
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-91 ~ 95
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-111 ~ 113
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-113 ~ 117
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-97 ~ 109
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.P.3-27 ~ 31
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-89
Lubrication Check for smooth operation. Lubricate if necessary. P.3-119
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-59
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are
connected tightly.P.1-9
SettingsIs 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 ~ 40

INSP
ADJ
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EC350000
ENGINE
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:
1 Seat removal
2 Fuel tank removal
3 Side covers removal
4 Headlight removal
Extent of removal Order Part name Q’ty Remarks
SEAT, FUEL TANK AND SIDE COVERS
REMOVAL
Preparation for removal 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 POINTS”.
7 Headlight coupler 1
8 Headlight 1
2
13
4
3
ENGINE

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INSP
ADJ
REMOVAL POINTS
Side cover
1. Remove:
Bolt (side cover)
Right side cover
1
NOTE:Draw the side cover backward to
remove it because its claw
a is
inserted in the air filter case.
POINTS DE DEPOSE
Cache latéral
1. Déposer:
Boulon (cache latéral)
Cache latéral droit 1
N.B.:
Glisser le couvercle latéral en arrière
pour le déposer car ses pattes a sont
insérées dans le boîtier de filtre à air.
ENGINE
MOTEUR

INSP
ADJ
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EC4S0000EXHAUST PIPE AND SILENCER
Extent of removal:
1 Silencer removal
2 Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks
EXHAUST PIPE AND SILENCER
REMOVAL
Preparation for removal Right side cover Refer to “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
1
2
2
ENGINE

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INSP
ADJ
INSPECTION
Silencer and exhaust pipe
1. Inspect:
Gasket
1
Damage
→ Replace.
1
ASSEMBLY AND INSTALLATION
Silencer and exhaust pipe
1. Install:
Gasket
Exhaust pipe
1
Nut (exhaust pipe)
2
NOTE:First, temporarily install both nuts,
then tighten either of these nuts to
13 Nm (1.3 mkg, 9.4 ftlb) and the
other to 20 Nm (2.0 mkg, 14 ftlb)
and then come back to the first one
and retighten it to 20 Nm (2.0 mkg,
14 ftlb).
T R..20 Nm (2.0 m · kg, 14 ft · lb)
New
2. Install:
Silencer clamp 1
Gasket 2
Silencer
Washer 4
Bolt (silencer) 5
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..30 Nm (3.0 m · kg, 22 ft · lb)
New
CONTROLE
Silencieux et tube d’échappement
1. Contrôler:
Joint 1
Endommagement → Remplacer.
ASSEMBLAGE ET MONTAGE
Silencieux et tube d’échappement
1. Poser:
Joint
Tube d’échappement 1
Ecrou (tube d’échappement) 2
N.B.:
Installer temporairement les deux
écrous, puis serrer l’un de ces écrous à
13 Nm (1,3 mkg, 9,4 ftlb) et l’autre
à 20 Nm (2,0 mkg, 14 ftlb), revenir
ensuite au premier et le resserrer à
20 Nm (2,0 mkg, 14 ftlb).
T R..20 Nm (2,0 m · kg, 14 ft · lb)
New
2. Monter:
Collier du silencieux 1
Joint 2
Silencieux
Rondelle 4
Boulon (silencieux) 5
T R..16 Nm (1,6 m · kg, 11 ft · lb)
T R..30 Nm (3,0 m · kg, 22 ft · lb)
New
ENGINE
MOTEUR

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INSP
ADJ
COOLANT LEVEL INSPECTION
WARNING
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 radia-
tor cap, slowly rotate the cap
counterclockwise to the detent.
This procedure allows any resid-
ual pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
CAUTION:
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
position.
2. Remove:
Radiator cap
3. Check:
Coolant level
a
Coolant level low
→ Add cool-
ant.
1Radiator
CONTROLE DU NIVEAU DU
LIQUIDE DE REFROIDISSEMENT
AVERTISSEMENT
Ne pas déposer le bouchon de radia-
teur 1, le boulon de vidange et les
durits quand le moteur et le radiateur
sont chauds. Du liquide chaud et de la
vapeur risquent de jaillir sous forte
pression et de provoquer des brûlures
graves.
Quand le moteur s’est refroidi, placer
un chiffon épais sur le bouchon du
radiateur et tourner lentement ce der-
nier dans le sens inverse des aiguilles
d’une montre jusqu’au point de
détente. Ceci permet à la pression rési-
duelle de s’échapper. Quand le siffle-
ment s’arrête, appuyer sur le bouchon
tout en le faisant tourner dans le sens
inverse des aiguilles d’une montre
puis l’enlever.
ATTENTION:
L’eau calcaire ou salée est nuisible
pour les pièces du moteur. En
l’absence d’eau non calcaire, il est pos-
sible d’utiliser de l’eau distillée.
1. Placer la moto sur un sol plan et la
maintenir à la verticale.
2. Déposer:
Bouchon de radiateur
3. Contrôler:
Niveau du liquide de refroidisse-
ment a
Niveau du liquide de refroidisse-
ment bas → Ajouter du liquide de
refroidissement.
1
Radiateur
ENGINE
MOTEUR

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INSP
ADJ
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap
when the engine is hot.
CAUTION:
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
engine.
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 cap
Drain the coolant completely.
6. Clean:
Cooling system
Thoroughly flush the cooling
system with clean tap water.
7. Install:
Copper washer
Coolant drain bolt
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
CHANGEMENT DU LIQUIDE DE
REFROIDISSEMENT
AVERTISSEMENT
Ne jamais enlever le bouchon de
radiateur quand le moteur est chaud.
ATTENTION:
Veiller à ne pas laisser échapper de
liquide de refroidissement sur les sur-
faces peintes. Si cela devait se pro-
duire, rincer à l’eau.
1. Placer un récipient sous le moteur.
2. Déposer:
Selle
Cache latéral gauche
3. Déposer la durit du réservoir de
récupération et vidanger le liquide
de refroidissement.
4. Déposer:
Boulon de vidange du liquide de
refroidissement 1
5. Déposer:
Bouchon du radiateur
Vidanger entièrement le liquide
de refroidissement.
6. Nettoyer:
Circuit de refroidissement
Rincer soigneusement le circuit
de refroidissement à l’eau claire.
7. Monter:
Rondelle en cuivre
Boulon de vidange du liquide de
refroidissement
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
New
ENGINE
MOTEUR

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INSP
ADJ
8. Fill:
Radiator
Engine
To specified level.
CAUTION:
Do not mix more than one type
of ethylene glycol antifreeze
containing corrosion inhibitors
for aluminum engine.
Do not use water containing
impurities or oil.
9. Install:
Radiator cap
Start the engine and warm it
up for a several minutes.
10. Check:
Coolant level
Coolant level low
→ Add cool-
ant.
Recommended coolant:
High quality ethylene
glycol anti-freeze con-
taining anti-corrosion
for aluminum engine
Coolant 1 and water
(soft water) 2 mixing
ratio:
50%/50%
Coolant capacity:
0.99 L
(0.87 Imp qt,
1.05 US qt)
Handling notes of coolant:
The coolant is harmful so it should
be handled with special care.
WARNING
When coolant splashes to
your eye.
Thoroughly wash your eye
with water and see your doc-
tor.
When coolant splashes to
your clothes.
Quickly wash it away with
water and then with soap.
When coolant is swallowed.
Quickly make him vomit and
take him to a doctor.
8. Remplir:
Radiateur
Moteur
Au niveau spécifié.
ATTENTION:
Ne pas mélanger différents types
d’antigel à l’éthylène glycol conte-
nant un agent anticorrosion pour
moteurs en aluminium.
Ne pas utiliser de l’eau contenant
des impuretés ou de l’huile.
9. Monter:
Bouchon du radiateur
Mettre le moteur en marche et le
laisser chauffer pendant quelques
minutes.
10. Contrôler:
Niveau du liquide de refroidisse-
ment
Niveau du liquide de refroidisse-
ment bas → Ajouter du liquide de
refroidissement.
Liquide de refroidissement
recommandé:
Antigel à l’éthylène gly-
col de haute qualité con-
tenant un agent anticor-
rosion pour moteurs en
aluminium
Rapport de mélange liquide
de refroidissement 1 et
eau (eau douce) 2:
50%/50%
Quantité de liquide de
refroidissement:
0,99 L
(0,87 Imp qt, 1,05 US qt)
Notes concernant la manipulation
du liquide de refroidissement:
Le liquide de refroidissement étant
dangereux, il doit être manipulé avec
une attention particulière.
AVERTISSEMENT
En cas de projection de liquide
de refroidissement dans les yeux:
rincer soigneusement les yeux à
l’eau et consulter un médecin.
En cas de projection de liquide
de refroidissement sur les vête-
ments:
rincer rapidement à l’eau claire
puis laver à l’eau savonneuse.
En cas d’ingestion de liquide de
refroidissement:
faire immédiatement vomir et
consulter un médecin dans les
plus brefs délais.
ENGINE
MOTEUR

3 - 39
INSP
ADJ
EC355000RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap)
1
Valve and valve seat
2
Crack/damage
→ Replace.
Exist fur deposits
3
→ Clean
or replace.
RADIATOR CAP OPENING
PRESSURE INSPECTION
1. Attach:
Radiator cap tester
1 and
adapter
2
NOTE:Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/
90890-01325
Radiator cap tester
adapter:
YU-33984/90890-01352
Radiator cap opening
pressure:
110 kPa
(1.1 kg/cm
2, 15.6 psi)
3. Inspect:
Pressure
Impossible to maintain the
specified pressure for 10 sec-
onds
→ Replace.CONTROLE DU BOUCHON DE
RADIATEUR
1. Contrôler:
Joint (bouchon de radiateur) 1
Soupape et siège de soupape 2
Craquelures/endommagement →
Remplacer.
Dépôts de tartre 3 → Nettoyer
ou remplacer.
CONTROLE DE LA PRESSION
D’OUVERTURE DU BOUCHON DE
RADIATEUR
1. Fixer:
Testeur de bouchon de radiateur
1 et adaptateur 2
N.B.:
Mouiller le joint du bouchon de radiateur
à l’aide d’eau.
3
Bouchon de radiateur
2. Appliquer la pression spécifiée.
Testeur de bouchon de
radiateur:
YU-24460-01/
90890-01325
Adaptateur du testeur de
bouchon de radiateur:
YU-33984/90890-01352
Pression d’ouverture du
bouchon de radiateur:
110 kPa
(1,1 kg/cm
2, 15,6 psi)
3. Contrôler:
Pression
Impossible de maintenir la pres-
sion spécifiée pendant 10 secon-
des → Remplacer.
ENGINE
MOTEUR