engine oil 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

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)

4-1
2
3
45
6
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
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.6-10
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-13
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, 6-24

OPERATION AND IMPORTANT RIDING POINTS
5-3
1
2
3
4
5
6
7
8
9

EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17023
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
NOTICE:
After 1000 km (600
mi) of operation, the engine oil must
be changed, and the oil filter car-
tridge or element replaced.

[ECA11282]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE

ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

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

21

Engine oil

Change.

Check oil level and vehicle for oil
leakage.
√
Every 5000 km (3000 mi)
√
22

Engine oil filter ele-
ment

Replace.
√√√√√
23

*
Cooling system

Check coolant level and vehicle
for coolant leakage.
√√√√√

Change. Every 3 years
24

*
EXUP system

Check operation, cable free play
and pulley position.
√√√
25

*
Front and rear brake
switches

Check operation.
√√√√√√
26

Moving parts and
cables

Lubricate.
√√√√√
27

*
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.
√√√√√
28

*
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)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
2
3
4
5
67
8
9
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimateof the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
EAU45141
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
TIP

The engine oil should be between the
minimum and maximum level marks.
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
11

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
1
2
3
4
5
6
7
8
9
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Place the vehicle on a level sur-
face.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engineto collect the used oil.
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
TIP

Check the washer for damage and re-
place it if necessary.
TIP

Skip steps 5–7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
4. Engine oil level check window
1
2
3
4

1. Engine oil drain bolt
1

1. Engine oil drain bolt
2. Washer
2
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
2
3
4
5
67
8
9
6. Remove and replace the oil filter
element and O-rings.
TIP

Make sure that the O-rings are properly
seated.7. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
9. Refill with the specified amount of
the recommended engine oil, andthen install and tighten the oil filler
cap.
TIP

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
NOTICE

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
1. Oil filter element cover
2. Oil filter element cover bolt
1
2

1. O-ring
2. Oil filter element
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
1
2

Recommended oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
1.30 L (1.37 US qt, 1.14 Imp.qt)
With oil filter element replacement:
1.40 L (1.48 US qt, 1.23 Imp.qt)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
1
2
3
4
5
6
7
8
9

rial enters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
NOTICE

ECA11230
After changing the engine oil, make
sure to check the oil pressure as de-
scribed below.

Remove the bleed bolt.

Start the engine and keep itidling until oil flows out. If no oil
comes out after one minute,
turn the engine off immediately
so it will not seize. If this occurs,
have a Yamaha dealer repair the
vehicle.

After checking the oil pressure,
tighten the bleed bolt to the
specified torque.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20253
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
TIP

The coolant should be between the
minimum and maximum level marks.
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2

1. Bleed bolt
Tightening torque:
Bleed bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
1
2
3
4
5
6
7
8
9
5. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
TIP

The sponge material should be wet but
not dripping.
6. Pull the sponge material over the
air filter element frame.
7. Insert the air filter element into the
air filter case.
NOTICE:
Make sure
that the air filter element is prop-
erly seated in the air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
[ECA10481]

8. Place the holding clip in the origi-
nal position.
9. Close the air filter case cover, and
then install the screw.
10. Install the panel.
To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
1. Sponge material
2. Air filter element frame
1
2
12
3
4

Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Air filter check hose
1