YAMAHA WR 250X 2009 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 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.

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 which
might catch fire.

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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
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 and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals 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 perform
service.
WARNING

EWA15121
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 1-1 for more in-
formation about carbon monox-
ide.
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.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Tool box
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46860
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 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*
Air induction sys-
tem

Check the air cut-off valve, reed
valve, and hose for damage.

Replace any damaged parts if
necessary.
√√√√√

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU1770B
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)
1
Air filter element

Clean.
√√

Replace.
√√
2
Clutch

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.
√√√√√

Replace. Every 4 years
6*
Wheels

Check runout, spoke tightness
and for damage.

Tighten spokes if necessary.
√√√√
7*
Tires

Check tread depth and for dam-
age.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√√
8*
Wheel bearings

Check bearing for looseness or
damage.
√√√√
9*
Swingarm

Check operation and for exces-
sive play.
√√√√

PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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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
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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.

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 panel
1. Remove the seat. (See
page 3-14.)2. Remove the bolts and collars.
3. Pull the front part of the panel out-
ward, and then remove the panel
by pulling it off.

1. Panel A
2. Panel B
1
2

1. Panel C
1. Panel D
1
1

1. Bolt
1. Bolt
2. Panel A
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2

PERIODIC MAINTENANCE AND ADJUSTMENT
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To install the panel
1. Place the panel in the original po-
sition, and then install the collars
and bolts.
2. Install the seat.
Panel B
To remove the panel1. Remove the seat. (See
page 3-14.)
2. Remove the bolt, and then remove
the panel as shown.To install the panel
1. Place the panel in the original po-
sition, and then install the bolt.
2. Install the seat.
Panel C
To remove the panel
1. Remove the bolts.
2. Lift the bottom of the panel slightly,
and then slide the panel forward.
To install the panelPlace the panel in the original position,
and then install the bolts.

1. Bolt
2. Panel B
12

1. Panel C
2. Bolt
12
2