abs YAMAHA WR 250R 2009 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 .........................3-13
Seat ...............................................3-13
Helmet holder ................................3-14
Adjusting the front fork ...................3-14
Front fork bleeding .........................3-16
Adjusting the shock absorber
assembly ....................................3-17
EXUP system ................................3-18
Sidestand .......................................3-19
Ignition circuit cut-off system .........3-19
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 4-1
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
ADJUSTMENT
.................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance chart for the
emission control system .............. 6-2
General maintenance and
lubrication chart ........................... 6-3
Removing and installing panels ...... 6-7
Checking the spark plug .................. 6-9
Engine oil and oil filter element ..... 6-10
Coolant .......................................... 6-13
Cleaning the air filter element
and check hose .......................... 6-16
Adjusting the engine idling
speed ......................................... 6-18
Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................. 6-19
Tires .............................................. 6-19Spoke wheels ............................... 6-21
Adjusting the clutch lever free
play ............................................ 6-21
Adjusting the brake lever free
play ............................................ 6-22
Adjusting the rear brake light
switch ......................................... 6-23
Checking the front and rear brake
pads ........................................... 6-23
Checking the brake fluid level ....... 6-24
Changing the brake fluid ............... 6-25
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 clutch levers .............. 6-28
Checking and lubricating the
brake pedal ................................ 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

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

DESCRIPTION
EAU10410
Left view
4
5
1
2
3
6
7
8
9

1. Front fork rebound damping force adjusting screw (page 3-14)
2. Fuse box (page 6-32)
3. Coolant reservoir (page 6-13)
4. Shock absorber assembly compression damping force adjusting
screw (page 3-17)
5. Battery (page 6-31)
6. Main fuse (page 6-32)
7. Owner’s tool kit (page 6-1)8. Helmet holder (page 3-14)
9. Front fork compression damping force adjusting screw (page 3-14)

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

EAU10420
Right view
3
1
2
6
5
4

1. Rear brake fluid reservoir (page 6-24)
2. Air filter element (page 6-16)
3. Rear brake light switch (page 6-23)
4. Engine oil filler cap (page 6-10)
5. Engine oil level check window (page 6-10)
6. Shock absorber assembly rebound damping force adjusting dial
(page 3-17)

INSTRUMENT AND CONTROL FUNCTIONS
3-17
2
34
5
6
7
8
9

EAU45262
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring, a rebound damping force ad-
justing dial and a compression
damping force adjusting screw.
NOTICE

ECA10101
To avoid damaging the mechanism,
do not attempt to turn beyond the
maximum or minimum settings.
Spring preload
Spring preload adjustment should be
made by a Yamaha dealer, since this
service requires special tools and tech-
nical skills. The specified settings are
listed below.
The spring preload setting is deter-
mined by measuring distance A, shown
in the illustration. The shorter the dis-
tance A is, the higher the spring pre-
load; the longer distance A is, the lower
the spring preload.
Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting dial in direction
(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting dial in di-
rection (b).
Compression damping force
To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting screw
in direction (a). To decrease the com-
pression damping force and thereby
soften the compression damping, turn

1. Distance A
Spring preload:
Minimum (soft):
Distance A = 216 mm (8.50 in)
Standard:
Distance A = 211.5 mm (8.33 in)
Maximum (hard):
Distance A = 206 mm (8.11 in)
1
1. Rebound damping force adjusting dial
Rebound damping setting:
Minimum (soft):
25 click(s) in direction (b)*
Standard:
12 click(s) in direction (b)*
Maximum (hard):
3 click(s) in direction (b)*
* With the adjusting dial fully turned in
direction (a)
(a) (b) 1

INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9
the adjusting screw in direction (b).
TIP

To obtain a precise adjustment, it is ad-
visable to check the actual total number
of clicks or turns of each damping force
adjusting mechanism. This adjustment
range may not exactly match the spec-ifications listed due to small differences
in production.
WARNING

EWA10221
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber assembly.

Do not tamper with or attempt to
open the cylinder assembly.

Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.

Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.

Do not dispose of a damaged or
worn-out shock absorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
EAU41940
EXUP system
This model is equipped with Yamaha’s
EXUP (EXhaust Ultimate Power valve)
system. This system boosts engine
power by means of a valve that regu-
lates the diameter of the exhaust pipe.
The EXUP system valve is constantly
adjusted in accordance with the engine
speed by a computer-controlled servo-
motor.
NOTICE

ECA15610
The EXUP system has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
1. Compression damping force adjusting
screw
Compression damping setting:
Minimum (soft):
12 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
1 (a)
(b)

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

10

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
11

*
Steering bearings

Check bearing play and steering
for roughness.
√√√√√

Lubricate with lithium-soap-based
grease.Every 50000 km (30000 mi)
12

*
Chassis fasteners

Make sure that all nuts, bolts and
screws are properly tightened.
√√√√√
13

Brake lever pivot
shaft

Lubricate with silicone grease.
√√√√√
14

Brake pedal pivot
shaft

Lubricate with lithium-soap-based
grease.
√√√√√
15

Clutch lever pivot
shaft

Lubricate with lithium-soap-based
grease.
√√√√√
16

Sidestand

Check operation.

Lubricate.
√√√√√
17

*
Sidestand switch

Check operation.
√√√√√√
18

*
Front fork

Check operation and for oil leak-
age.
√√√√
19

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
20

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

Check operation.
√√√√
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)

MOTORCYCLE CARE AND STORAGE
7-2
2
3
4
5
6
78
9 off any detergent residue using
plenty of water, as it is harmful
to plastic parts.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leavescratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
TIP

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
NOTICE:
Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]

2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)

SPECIFICATIONS
8-2
2
3
4
5
6
7
89 Gear ratio:

1st:
37/14 (2.642)
2nd:
29/16 (1.813)
3rd:
29/22 (1.318)
4th:
26/25 (1.040)
5th:
24/27 (0.888)
6th:
22/28 (0.786)
Chassis:
Frame type:
Semi double cradle
Caster angle:
26.67 °
Trail:
111.0 mm (4.37 in)
Front tire:
Type:
With tube
Size:
80/100-21M/C 51P
Manufacturer/model:
BRIDGESTONE/TW-301 F
Rear tire:
Type:
With tube
Size:
120/80-18M/C 62PManufacturer/model:
BRIDGESTONE/TW-302 F
Loading:
Maximum load:
185 kg (408 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
125 kPa (1.25 kgf/cm
2

, 18 psi)
Rear:
175 kPa (1.75 kgf/cm
2

, 25 psi)
Loading condition:
90–185 kg (198–408 lb)
Front:
150 kPa (1.50 kgf/cm
2

, 22 psi)
Rear:
200 kPa (2.00 kgf/cm
2

, 29 psi)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
21x1.60
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
18x2.15
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
270.0 mm (10.63 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
270.0 mm (10.63 in)
Electrical system:
Ignition system:
TCI (digital)
Charging system:
AC magneto

INDEX
A
Air filter element and check hose,
cleaning .................................................6-16
Auxiliary light bulb, replacing ...................6-36
B
Battery .....................................................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 pedal .............................................3-10
Brake pedal, checking and lubricating .....6-28
C
Cables, 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 .............3-2
D
Dimmer switch ...........................................3-9
Drive chain, cleaning and lubricating .......6-26
Drive chain slack .....................................6-25
E
Engine break-in .........................................5-3
Engine idling speed .................................6-18
Engine oil and oil filter element ................6-10
Engine stop switch.....................................3-9
Engine trouble warning light ......................3-3
EXUP system ..........................................3-18
F
Front and rear brake pads, checking....... 6-23
Front fork, adjusting................................. 3-14
Front fork, bleeding ................................. 3-16
Front fork, checking ................................. 6-29
Fuel ......................................................... 3-11
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning light .............................. 3-2
Fuel tank cap ........................................... 3-11
Fuses, replacing ...................................... 6-32
H
Handlebar switches ................................... 3-8
Headlight bulb, replacing ......................... 6-33
Helmet holder .......................................... 3-14
High beam indicator light ........................... 3-2
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-19
Indicator and warning lights....................... 3-2
K
Key identification number .......................... 9-1
L
License plate light bulb, replacing ........... 6-35
M
Main switch/steering lock .......................... 3-1
Maintenance and lubrication, periodic ....... 6-3
Maintenance, emission control system ..... 6-2
Matte color, caution ................................... 7-1
Model label ................................................ 9-2
Multi-function display ................................. 3-3
N
Neutral indicator light................................. 3-2
P
Panels, removing and installing ................ 6-7
Parking ...................................................... 5-4
Part locations ............................................ 2-1
R
Rear brake light switch, adjusting ........... 6-23
Rear suspension, lubricating ................... 6-29
S
Safety information ..................................... 1-1
Seat ......................................................... 3-13
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
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 ...................... 6-36
T
Tail/brake light ......................................... 6-34
Throttle cable free play, checking ........... 6-18
Throttle grip and cable, checking and
lubricating ............................................. 6-27
Tires ........................................................ 6-19
Tool kit....................................................... 6-1
Troubleshooting ...................................... 6-39
Troubleshooting charts............................ 6-41
Turn signal indicator light .......................... 3-2
Turn signal light bulb, replacing .............. 6-35
Turn signal switch ..................................... 3-9