suspension 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

SAFETY INFORMATION
1-3
1
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:


Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items asclose to the center of the vehicle as
possible and make sure to distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

Properly adjust the suspension
for your load, and check the con-
dition and pressure of your tires.

Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.

This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces-
sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you

Maximum load:
185 kg (408 lb)

SAFETY INFORMATION
1-4
1
or others. Installing aftermarket prod-
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be aslightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 6-19 for tire
specifications and more information on
replacing your tires.

INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the num-
ber of clicks of each damping force ad-
justing mechanism and to modify the

specifications as necessary.
EAU14791
Front fork bleeding
WARNING

EWA10200
Always bleed both fork legs, other-
wise poor handling and loss of sta-
bility may result.
When riding in extremely rough condi-
tions, the air temperature and pressure
in the front fork will rise. This will in-
crease the spring preload and harden
the front suspension. If this occurs,
bleed the front fork as follows.
1. Elevate the front wheel by placing
a suitable stand under the engine.
TIP

When bleeding the front fork, thereshould be no weight on the front end of
the vehicle.
2. Remove the bleed screws and al-
low all of the air to escape from
each fork leg.
3. Install the bleed screws.
1. Bleed screw
1

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)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
1
2
3
4
5
6
7
8
9

EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23272
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

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