lock YAMAHA WR 250X 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
1
2
3
4
56
7
8
9
EAU21943
Spoke wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tireson this model.
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.
The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage, and the spokes for
looseness or damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU48373
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39– 0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows. 1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the clutch lever free play
adjusting bolt in direction (a). To
decrease the clutch lever free play,
turn the adjusting bolt in direction
(b).
TIPIf the specified clutch lever free play
could be obtained as described above,skip steps 4 –7.
4. Fully turn the adjusting bolt in di- rection (a) to loosen the clutch ca-
ble.
5. Slide the rubber cover back further down the clutch cable, and then
loosen the locknut.
6. To increase the clutch lever free play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,1. Clutch lever free play
2. Locknut (clutch lever)
3. Clutch lever free play adjusting bolt
4. Rubber cover
3
2
1
4
(a)(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
2
3
4
567
8
9
turn the adjusting nut in direction
(b).
7. Tighten the locknut at the clutch cable, and then slide the rubber
cover to its original position.
8. Tighten the locknut at the clutch le- ver, and then slide the rubber cov-
er to its original position.
EAU48442
Adjusting the brake lever free
play The brake lever free play should mea-
sure 5.0– 8.0 mm (0.20– 0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows. 1. Slide the rubber cover back at the brake lever.
2. Loosen the locknut.
3. To increase the brake lever free play, turn the brake lever free play
adjusting screw in direction (a). To
decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b). 4. Tighten the locknut, and then slide
the rubber cover back to its original
position.
WARNING
EWA10630

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
1. Locknut (clutch cable)
2. Clutch lever free play adjusting nut (clutch cable)
3. Rubber cover
1
2
3
(a)
(b)
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
4. Rubber cover
3
1 2
4
(b)
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
1
2
3
4
56
7
8
9Rear brake
WARNING
EWA15990
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.

Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.

Use only the specified brake flu-
id; otherwise, the rubber seals may deteriorate, causing leak-
age.

Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.

Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vaporlock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always cleanup spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.
Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
1. Minimum level markSpecified brake fluid:
DOT 41
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
2
3
4
567
8
9
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU47222
To check the drive chain slack1. Place the motorcycle on the side- stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu- tral position.
3. Push on the drive chain at the cen- ter point between the chain ten-
sioner and the chain support
mounting bolt with a force of 50 N
(5.0 kgf, 11 lbf).
4. Measure drive chain slack be- tween the swingarm and the top of
the chain link closest to the swing-
arm as shown. 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU34317
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.1. Loosen the axle nut and the lock- nut on each side of the swingarm.
2. To tighten the drive chain, turn the drive chain slack adjusting bolt on
each side of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt on each side
of the swingarm in direction (b),
and then push the rear wheel for- ward.
NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]

TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the sameposition for proper wheel alignment.
Drive chain slack: 8.0 –13.0 mm (0.31 –0.51 in)
1. Drive chain slack
2. Chain support mounting bolt
3. Chain tensioner
1
3
2
1. Axle nut
2. Locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
5. Drive chain puller
15
32
4
(b)
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
1
2
3
4
56
7
8
93. Tighten the axle nut, then the lock-
nuts to their specified torques.
4. Make sure that the drive chain pull- ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23025
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, ridingin the rain or riding in wet areas.
1. Clean the drive chain with kero- sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11121]

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they may contain substances that
could damage the O-rings.
[ECA11111]

Tightening torques:
Axle nut:125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
1
2
3
4
56
7
8
9sition, and then secure it with the
bulb holder.
5. Install the bulb cover, and then connect the coupler.
6. Install the headlight cowling (to- gether with the headlight unit) by
placing it in the original position,
and then installing the bolts.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
EAU24181
Tail/brake light This model is equipped with an
LED-type tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU24204
Replacing a turn signal light
bulb 1. Remove the turn signal light lensby removing the screw.
2. Remove the burnt-out bulb by pushing it in and turning it counter-
clockwise.1. Screw
2. Turn signal light lens
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
2
3
4
567
8
9
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screw. NOTICE: Do not over-
tighten the screw, otherwise the
lens may break.
[ECA11191]

EAU24313
Replacing the license plate
light bulb 1. Remove the license plate light unit
by removing the screws.
2. Remove the license plate light bulb socket (together with the bulb) by
pulling it out. 3. Remove the burnt-out bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the bulb) by pushing it in.
6. Install the license plate light unit by installing the screws.
1. Turn signal light bulb
1
1. Screw
1
1. License plate light unit
2. License plate light bulb socket
1 2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-40
1
2
3
4
56
7
8
9
EAU25080
Rear wheel
EAU45183
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of itfalling over.1. Loosen the axle nut.
2. Lift the rear wheel off the ground according to the procedure on
page 6-38.
3. Remove the axle nut and washer.
4. Loosen the locknut on each side of the swingarm. 5. Turn the drive chain slack adjust-
ing bolts fully in direction (a).
6. Push the wheel forward, and then remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove andinstall the rear wheel.
7. While supporting the brake caliper, pull the wheel axle out. 8. Remove the drive chain pullers,
spacers and the wheel. NOTICE:
Do not apply the brake after the
wheel has been removed to-
gether with the brake disc, oth-
erwise the brake pads will be
forced shut.
[ECA11071]

EAU45193
To install the rear wheel 1. Install the spacers into both sides of the wheel hub. NOTICE: When
installing the spacers, be sure
to install them on the correct
side.
[ECA17700]

2. Install the wheel, drive chain pull- ers and the brake caliper bracket
by inserting the wheel axle from
1. Axle nut
2. Washer1
2
1. Drive chain slack adjusting bolt
2. Locknut
3. Brake caliper
12
3
(a)
1. Wheel axle
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-41
2
3
4
567
8
9
the left-hand side.
TIP
Make sure that the retainer on the
brake caliper bracket is inserted
into the slot in the swingarm.

Make sure that there is enough
space between the brake pads be-fore installing the wheel.
3. Install the drive chain onto the rear sprocket.
4. Install the washer and the axle nut.
5. Lower the rear wheel so that it is on the ground, and then put the
sidestand down.
6. Adjust the drive chain slack. (See page 6-27.)
7. Tighten the axle nut, and then the locknuts to their specified torques.
EAU25871
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
1. Brake caliper bracket
2. Retainer
3. Slot
1
2
3
Tightening torques:Axle nut:125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-44
1
2
3
4
56
7
8
9Engine overheating
WARNING
EWA10400

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissingsound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIPIf coolant is not available, tap water can be temporarily us
ed instead, provided that it is changed to the recommended coolantas soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
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