check engine YAMAHA WR 250R 2010 User Guide

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
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
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-11
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13
Front brakeCheck 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
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU46632
TIPThis model is equipped with:

a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the multi-function display in-
dicates error code 30, but this is
not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the
error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.


an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. In this case,
the multi-function display indicates
error code 70, but this is not a mal-
function. Push the start switch to
clear the error code and to restart
the engine.
EAU45125
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
See page 3-19 for more informa-
tion.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to“”.
The following warning lights
should come on for a few seconds,
then go off.

Fuel level warning light


Coolant temperature warning
light


Engine trouble warning light
NOTICE
ECA15484
If a warning light does not come on
initially when the key is turned to
“ON”, or if a warning light remains
on, see page 3-2 for the correspond-
ing warning light circuit check.
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OPERATION AND IMPORTANT RIDING POINTS
5-2
5 2. Shift the transmission into the neu-
tral position. (See page 5-2.) The
neutral indicator light should come
on. If not, ask a Yamaha dealer to
check the electrical circuit.
3. Start the engine by pushing the
start switch. NOTICE: For maxi-
mum engine life, never acceler-
ate hard when the engine is
cold!
[ECA11041]
If the engine fails to start, release
the start switch, wait a few sec-
onds, and then try again. Each
starting attempt should be as short
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10260


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
1. Shift pedal
2. Neutral position
1
1 2 3 4 5N26
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel con-
sumption 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU46861
TIP

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.
EAU46910
Periodic maintenance chart for the emission control system 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 lineCheck fuel hoses for cracks or
damage.√√√√√
2*Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km (24000 mi)
4*Fuel injectionAdjust engine idling speed.√√√√√√
5*Air induction sys-
temCheck the air cut-off valve, reed
valve, and hose for damage.
Replace any damaged parts if
necessary.√√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
19*Shock absorber as-
semblyCheck operation and shock ab-
sorber for oil leakage.√√√√
20*Rear suspension re-
lay arm and con-
necting arm
pivoting pointsCheck operation.√√√√
21 Engine oilChange.
Check oil level and vehicle for oil
leakage.√Every 5000 km (3000 mi)√
22Engine oil filter ele-
mentReplace.√√√√√
23*Cooling systemCheck coolant level and vehicle
for coolant leakage.√√√√√
Change. Every 3 years
24*Front and rear brake
switchesCheck operation.√√√√√√
25Moving parts and
cablesLubricate.√√√√√
26*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.√√√√√
27*Lights, signals and
switchesCheck 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)U32DE4E0.book Page 5 Monday, December 14, 2009 2:24 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
62. Lift the bottom of the panel slightly,
and then slide the panel forward.
To install the panel
Place the panel in the original position,
and then install the bolts.
Panel D
To remove the panel1. Remove the seat. (See page
3-13.)
2. Remove the bolt and washer, and
then remove the panel as shown.To install the panel
1. Place the panel in the original posi-
tion, and then install the washer
and bolt.
2. Install the seat.
EAU48340
Checking the spark plug The spark plug is an important engine
component, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode, it
should be removed and checked in ac-
cordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of the spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally). If
the spark plug shows a distinctly differ-
ent color, the engine could be operating
improperly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced.
1. Bolt
2. Washer
3. Panel D
3
2
1
Specified spark plug:
NGK/CR9EK
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6 Before installing a spark plug, the spark
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.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of 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.NOTICE
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.
EAU45143
Engine oil and oil filter ele-
ment 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.TIPThe engine oil should be between the
minimum and maximum level marks.
1. Spark plug gapSpark 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
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
64. 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 engine
to collect the used oil.4. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIPSkip steps 5–8 if the oil filter element is
not being replaced.5. Remove the oil filter element cover
by removing the bolts.6. Remove the oil filter element and
O-rings.
7. Install a new oil filter element and
new O-rings.
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
2. Gasket
12
1. Oil filter element cover
2. Oil filter element cover bolt
1. O-ring
2. Oil filter element
1
2
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
TIPMake sure that the O-rings are properly
seated.8. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
9. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
10. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe 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-
rial enters the crankcase.
11. 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.
12. Turn the engine off, wait a few min-
utes until the oil settles, and then
check the oil level and correct it if
necessary.NOTICE
ECA11231
After changing the engine oil, make
sure to check the oil pressure as de-
scribed below.

Loosen the bleed bolt.


Start the engine and keep it
idling 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.
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 ft·lbf)
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)
U32DE4E0.book Page 12 Monday, December 14, 2009 2:24 PM