brake YAMAHA WR 250R 2008 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Multi-function display .......................3-3
Handlebar switches .........................3-8
Clutch lever ......................................3-9
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-10
Fuel tank cap .................................3-11
Fuel ................................................3-11
Catalytic converter .........................3-12
Seat ...............................................3-12
Helmet holder ................................3-13
Adjusting the front fork ...................3-13
Front fork bleeding .........................3-15
Adjusting the shock absorber
assembly ....................................3-15
EXUP system ................................3-17
Sidestand .......................................3-18
Ignition circuit cut-off system .........3-18
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Removing and installing panels ...... 6-6
Checking the spark plug .................. 6-8
Engine oil and oil filter element ....... 6-9
Coolant .......................................... 6-12
Cleaning the air filter element and
check hose ................................. 6-15
Adjusting the engine idling
speed ......................................... 6-17
Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................. 6-18
Tires .............................................. 6-18
Spoke wheels ................................ 6-20Adjusting the clutch lever free
play ............................................ 6-21
Adjusting the brake lever free
play ............................................ 6-22
Adjusting the rear brake light
switch ......................................... 6-22
Checking the front and rear brake
pads ........................................... 6-23
Checking the brake fluid level ....... 6-23
Changing the brake fluid ............... 6-24
Drive chain slack ........................... 6-25
Cleaning and lubricating the drive
chain .......................................... 6-26
Checking and lubricating the
cables ........................................ 6-27
Checking and lubricating the throttle
grip and cable ............................ 6-27
Checking and lubricating the brake
and shift pedals ......................... 6-27
Checking and lubricating the brake
and clutch levers ........................ 6-28
Checking and lubricating the
sidestand ................................... 6-29
Lubricating the rear suspension .... 6-29
Checking the front fork .................. 6-29
Checking the steering ................... 6-30
Checking the wheel bearings ........ 6-31
Battery ........................................... 6-31
Replacing the fuses ...................... 6-32
Replacing the headlight bulb ........ 6-33
Tail/brake light ............................... 6-35

DESCRIPTION
2-2
2
3
4
5
6
7
8
9

EAU10420
Right view
3
1
2
5
4
6

1. Rear brake fluid reservoir (page 6-23)
2. Air filter element (page 6-15)
3. Rear brake light switch (page 6-22)
4. Engine oil filler cap (page 6-9)
5. Engine oil level check window (page 6-9)
6. Shock absorber assembly rebound damping force adjusting dial
(page 3-15)

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
12 34 5 6
8
7

1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Main switch/steering lock (page 3-1)
4. Multi-function display (page 3-3)
5. Right handlebar switches (page 3-8)
6. Brake lever (page 3-10)
7. Throttle grip (page 6-18)
8. Fuel tank cap (page 3-11)

INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9

EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1

1. Brake lever
1

1. Brake pedal
1

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-11
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-9
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-12
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check lever free play.

Adjust if necessary.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-22, 6-23
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-23
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-21

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-18, 6-27
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-27
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-25, 6-26
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-18, 6-20
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-27
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-28
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-29
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-18
ITEM CHECKS PAGE

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
1
2
3
4
5
6
7
8
9

EAU1770A
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*
Fuel line

Check fuel hoses for cracks or
damage.
√√√√√
2*
Spark plug

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km (24000 mi)
4
Air filter element

Clean.
√√

Replace.
√√
5
Clutch

Check operation.

Adjust.
√√√√√
6*
Front brake

Check operation, fluid level
and vehicle for fluid leakage.

Adjust brake lever free play.
√√√√√√

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level
and vehicle for fluid leakage.
√√√√√√

Replace brake pads. Whenever worn to the limit

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9

8*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years
9*
Wheels

Check runout, spoke tightness
and for damage.

Tighten spokes if necessary.
√√√√
10

*
Tires

Check tread depth and for
damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√√
11

*
Wheel bearings

Check bearing for looseness or
damage.
√√√√
12

*
Swingarm

Check operation and for exces-
sive play.
√√√√
13

Drive chain

Check chain slack, alignment
and condition.

Adjust and lubricate chain with
a special O-ring chain lubricant
thoroughly.Every 500 km (300 mi) and after washing the motorcycle or riding in the rain
14

*
Steering bearings

Check bearing play and steer-
ing for roughness.
√√√√√

Lubricate with lith-
ium-soap-based grease.Every 50000 km (30000 mi)
15

*
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly tight-
ened.
√√√√√
16

Brake lever pivot
shaft

Lubricate with silicone grease.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9

17

Brake pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
18

Clutch lever pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
19

Shift pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
20

Sidestand

Check operation.

Lubricate.
√√√√√
21

*
Sidestand switch

Check operation.
√√√√√√
22

*
Front fork

Check operation and for oil
leakage.
√√√√
23

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
24

*
Rear suspension
relay arm and con-
necting arm pivoting
points

Check operation.
√√√√
25

Engine oil

Change.

Check oil level and vehicle for
oil leakage.
√
Every 5000 km (3000 mi)
√
26

Engine oil filter ele-
ment

Replace.
√√√√√
27

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
28

*
Front and rear brake
switches

Check operation.
√√√√√√
29

Moving parts and
cables

Lubricate.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
8
9

EAU18670
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

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.
30

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
31

*
Air induction system

Check the air cut-off valve,
reed valve, and hose for dam-
age.

Replace any damaged parts if
necessary.
√√√√√
32

*
EXUP system

Check operation, cable free
play and pulley position.
√√√
33

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)