YAMAHA WR 250R 2011 Service Manual

OPERATION AND IMPORTANT RIDING POINTS
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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
cartridge or element replaced.
[ECA11282]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above1/2 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 dealercheck the vehicle.
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OPERATION AND IMPORTANT RIDING POINTS
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EAU17213
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10311

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.

Do not park near grass or other
flammable materials whichmight catch fire.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17244
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer performservice.
WARNING
EWA15122
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-2 for more in-
formation about carbon monox-ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool beforetouching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU35011
Owner’s tool kit The owner’s tool kit is located inside the
tool box.
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.1. Tool box
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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 technicalskills.
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 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*Fuel injection• Adjust engine idling speed.
5*Muffler and
exhaust pipe• Check the screw clamp(s) for
looseness.
6*Air induction
system• Check 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
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EAU1770C
General maintenance and lubrication chart 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)
1Air filter element• Clean.
• Replace.
2Clutch• Check operation.
• Adjust.
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.
• Adjust brake lever free play.
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.
• Check for correct routing and
clamping.
• Replace. Every 4 years
6*Wheels• Check runout, spoke tightness
and for damage.
• Tighten spokes if necessary.
7*Tires• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for looseness or
damage.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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9*Swingarm• Check operation and for
excessive play.
• Lubricate with
lithium-soap-based grease.Every 50000 km (30000 mi)
10Drive 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, riding in the rain or
riding in wet areas
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.
13Brake lever pivot
shaft• Lubricate with silicone grease.
14Brake pedal pivot
shaft• Lubricate with
lithium-soap-based grease.
15Clutch lever pivot
shaft• Lubricate with
lithium-soap-based grease.
16Sidestand• Check operation.
• Lubricate with
lithium-soap-based grease.
17 *Sidestand switch• Check operation.
18 *Front fork• Check operation and for oil
leakage.
19 *Shock absorber
assembly• Check operation and shock
absorber for oil leakage. 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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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20 *Rear suspension
relay arm and
connecting arm
pivoting points• Check operation.
21Engine oil• Change.
• Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)
22Engine oil filter
element• Replace.
23 *Cooling system• Check coolant level and vehicle
for coolant leakage.
• Change. Every 3 years
24 *Front and rear
brake switches• Check operation.
25Moving parts and
cables• Lubricate.
26 *Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip
housing.
27 *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
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EAU18670
TIP
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU18771
Removing and installing
panels The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAU45131
Panel A
To remove the panel1. Remove the seat. (See
page 3-13.)
2. Remove the bolts and collars.
1. Panel A
2. Panel B
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2
1. Panel C
1. Panel D
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1
1. Bolt
2. Collar
2
1
2
1
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