engine YAMAHA WR 250R 2012 Owner's Manual

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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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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 JOB ODOMETER 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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20 *Rear suspension
relay arm and
connecting arm
pivoting points •
Check operation. 
21 Engine oil •
Change.
• Check oil level and vehicle for oil
leakage. 
Every 5000 km (3000 mi) 
22 Engine oil filter
element •
Replace. 
23 * Cooling system •
Check coolant level and vehicle
for coolant leakage. 
• Change with ethylene glycol
anti-freeze coolant. Every 3 years
24 * Front and rear
brake switches •
Check operation. 
25 Moving 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 JOB
ODOMETER 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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PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
Before installing a spark plug, the spark
plug gap should be measured with awire 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 turnpast 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, twistit back and forth while pushing it in.
Specified spark plug:
NGK/CR9EK
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
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EAU45143
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 level1. 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 theminimum and maximum level marks. 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 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 isnot 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
2. Gasket
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6. Remove the oil filter element and
O-rings.
7. Install a new oil filter element and new O-rings.
TIPMake sure that the O-rings are properlyseated.
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
1. Oil filter element cover
2. Oil filter element cover bolt
1. O-ring
2. Oil filter element
1
2
1
2
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)
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9it 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 thespecified 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.
EAU20254
To check the coolant level1. 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 theside can result in a false reading.
2. Check the coolant level in the cool- ant reservoir.
TIPThe coolant should be between theminimum and maximum level marks.
1. Bleed boltTightening torque:Bleed bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
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3. If the coolant is at or below the
minimum level mark, remove pan-
el C (See page 6-8.), remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the reservoir cap and
the panel. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the ra-
diator cap when the engine is
hot.
[EWA15161]
NOTICE: If coolant is
not available, use distilled water
or soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.
If water has been used instead of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10472]

EAU45155
To change the coolant
1. Place the vehicle on a level sur- face and let the engine cool if nec-
essary.
2. Remove panels A and C. (See page 6-8.)
3. Place a container under the engine to collect the used coolant.
4. Remove the radiator cap retaining bolt and radiator cap. WARNING!
Never attempt to remove the ra-
diator cap when the engine is
hot.
[EWA10381]

5. Remove the coolant reservoir by removing the bolts.
1. Maximum level mark
2. Minimum level mark
1
2
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt)
1
1. Radiator cap
2. Radiator cap retaining bolt
2
1
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96. Remove the coolant reservoir cap.
7. Drain the coolant from the coolant
reservoir by turning it upside down.
8. Install the coolant reservoir by placing it in the original position, and then installing the bolts.
9. Remove the coolant drain bolt and its gasket to drain the cooling sys-
tem.
10. After the coolant is completely drained, thoroughly flush the cool-
ing system with clean tap water.
11. Install the coolant drain bolt and its new gasket, and then tighten the
bolt to the specified torque.
12. Pour the specified amount of the recommended coolant into the ra- diator and reservoir.
13. Install the coolant reservoir cap.
14. Install the radiator cap.
15. Start the engine, let it idle for sev- eral minutes, and then turn it off.
16. Remove the radiator cap to check the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and its retaining bolt.
17. Check the coolant level in the res- ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
1. Bolt
2. Coolant reservoir
1. Coolant reservoir cap
1 2
1
1. Coolant drain bolt
2. GasketTightening torque:
Coolant drain bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
2
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibitors
for aluminum engines
Coolant quantity: Radiator capacity (including all
routes):0.90 L (0.95 US qt, 0.79 Imp.qt)
Coolant reservoir capacity (up to the
maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt)
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18. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
19. Install the panels.
EAU44323
Cleaning the air filter element
and check hose The air filter element should be cleaned
or replaced at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean or, if necessary, re-
place the air filter element more
frequently if you are riding in unusually
wet or dusty areas. In addition, the air
filter check hose must be frequently
checked and cleaned if necessary.
To clean the air filter element 1. Remove panel B. (See page 6-8.)
2. Open the air filter case cover by re- moving the screw and pulling the
case cover outward as shown. 3. Unhook the holding clip, and then
pull the air filter element out.
4. Remove the sponge material from the air filter element frame, clean it
1. Screw
2. Air filter case cover
1. Holding clip
2. Air filter element
2
11
2
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