Yamaha Wr250r 2008 Manual

							 
ENGINE 
3-19 
10.Fill: 
 
Cooling system
(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
 
EWA13040  
 
If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor. 
 
If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water. 
 
If coolant is swallowed, induce vomiting 
and get immediate medical attention.
CAUTION:
 
 ECA13480 
 
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant. 
 
Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used. 
 
If coolant comes into contact with painted
surfaces, immediately wash them with wa-ter. 
 
Do not mix different types of antifreeze.  
11.Install: 
 
Radiator cap
12.Fill: 
 
Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
13.Install: 
 
Coolant reservoir cap
14.Start the engine, warm it up for several min-
utes, and then stop it.
15.Check: 
 
Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-19.
NOTE:
 
Before checking the coolant level, wait a few 
minutes until the coolant has settled.
16.Install: 
 
Air scoop (left/right) 
 
Seat
Refer to “GENERAL CHASSIS” on page 4-1.  
Recommended antifreeze
High-quality ethylene glycol anti-
freeze containing corrosion inhib-
itors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
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)
a 
						

							 
CHASSIS 
3-21
WARNING
 
EWA13050  
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid- 
erably reduce braking performance.
CAUTION:
 
 ECA13510 
After adjusting the brake pedal position, 
make sure there is no brake drag.

 
3. Adjust: 
 
Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-24. 
EAS21240 
CHECKING THE BRAKE FLUID LEVEL 
1. Stand the vehicle on a level surface.
NOTE:
 
 
Place the vehicle on a suitable stand. 
 
Make sure the vehicle is upright. 
 
In order to ensure a correct reading of the
brake fluid level, make sure the top of the 
brake fluid reservoir is horizontal.
2. Check: 
 
Brake fluid level
Below the minimum level mark “a”  
→ 
 Add the
recommended brake fluid to the proper level.
WARNING
 
EWA13090  
 
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance. 
 
Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance. 
 
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock.
CAUTION:
 
 ECA13540 
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately. 
EAS21250 
CHECKING THE FRONT BRAKE PADS 
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check: 
 
Front brake pad
Wear indicator groove “1” almost disappeard  
→ 
 Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-11.  
Locknut
12 Nm (1.2 m•kg, 8.7 ft•lb)
Recommended fluid
DOT 4
TR..
A
a
 
A. Front brake
B. Rear brake
a
B
11 
						

							 
CHASSIS 
3-22 
EAS21260 
CHECKING THE REAR BRAKE PADS 
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check: 
 
Rear brake pad
Wear indicators “1” almost touch the brake
disc  
→ 
 Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-23. 
EAS21270 
CHECKING THE FRONT BRAKE HOSE 
1. Check: 
 
Brake hose “1”
Cracks/damage/wear  
→ 
 Replace.
2. Check: 
 
Brake hose clamp
Loose Connection  
→ 
 Tighten the clamp bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check: 
 
Brake hose “1”
Brake fluid leakage  
→ 
 Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-11. 
EAS21290 
CHECKING THE REAR BRAKE HOSE 
1. Check: 
 
Brake hose “1”
Cracks/damage/wear  
→ 
 Replace.2. Check: 
 
Brake hose clamp
Loose Connection  
→  
 Tighten the clamp bolt.
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check: 
 
Brake hose
Brake fluid leakage  
→  
 Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-23. 
EAS21330 
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
 
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
switch is properly adjusted when the brake light 
comes on just before the braking effect starts.
1. Check: 
 
Rear brake light operation timing
Incorrect  
→  
 Adjust.
2. Adjust: 
 
Rear brake light operation timing

 
a. Hold the main body “1” of the rear brake light
switch so that it does not turn the adjusting
nut “2” in direction “a” or “b” until the rear
brake light comes on at the proper time.
1
1
 
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
1 
						

							 
CHASSIS 
3-23

 
EAS21350 
BLEEDING THE HYDRAULIC BRAKE 
SYSTEM
WARNING
 
EWA13100  
Bleed the hydraulic brake system whenever: 
 
the system is disassembled. 
 
a brake hose is loosened, disconnected or
replaced. 
 
the brake fluid level is very low. 
 
brake operation is faulty. 
1. Remove: 
 
Brake master cylinder reservoir cap
NOTE:
 
 
Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow. 
 
When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure. 
 
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles 
in the hose have disappeared.
2. Bleed: 
 
Hydraulic brake system

 
a. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”, and place an oil pan under
the vinyl hose end on one side.d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
 
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake fluid reservoir to the proper level
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-23.
WARNING
 
EWA13110  
After bleeding the hydraulic brake system, 
check the brake operation. 
A. Front
B. Rear 
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
1 2
A
2
1B
TR.. 
						

							 
CHASSIS 
3-24

 
EAS21420 
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
 
The drive chain slack must be checked at the 
tightest point on the chain.
CAUTION:
 
 ECA13550 
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim- 
its. 
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
 
Place the vehicle on a suitable stand so that the 
rear wheel is elevated.
2. Spin the rear wheel several times and find the
tightest position of drive chain.
3. Check: 
 
Drive chain slack “a”
Out of specification  
→ 
 Adjust.
NOTE:
 
Measure the drive chain slack in an intermediate
position between the chain tensioner and the 
chain support bolt.
4. Adjust: 
 
Drive chain slack

 
a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn the drive chain puller “3” in direction “a”
or “b” until the specified drive chain slack is
obtained.
NOTE:
 
 
To maintain the proper wheel alignment, adjust
both sides evenly. 
 
Push the rear wheel forward to make sure
there is no clearance between the swingarm 
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.

 
EAS21440 
LUBRICATING THE DRIVE CHAIN 
The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the 
Drive chain slack
WR250R
38.0 
– 
48.0 mm
WR250X
40.0 
– 
50.0 mm
a
 
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
Locknut
16 Nm (1.6 m•kg, 12 ft•lb)
Wheel axle nut
125 Nm (12.5 m•kg, 90 ft•lb)
1
32
a b
TR..
TR.. 
						

							 
CHASSIS 
3-25 
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosene to
clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that could
damage the O-rings. 
EAS21510 
CHECKING AND ADJUSTING THE 
STEERING HEAD 
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
 
Place the vehicle on a suitable stand so that the 
front wheel is elevated.
2. Check: 
 
Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  
→ 
 Adjust the steering
head.
3. Remove: 
 
Handlebar
Refer to “HANDLEBAR” on page 4-34. 
 
Upper bracket
Refer to “STEERING HEAD” on page 4-49.
4. Adjust: 
 
Steering head

 
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.b. Tighten the lower ring nut “4” with a steering
nut wrench “5”.
c. Turn the front fork to the right and left a few
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and inspect the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-49.
d. Loosen the lower ring nut “4” fully turn and
then tighten it to specification with a steering
nut wrench.
WARNING
 
EWA13140  
Do not overtighten the lower ring nut. 
e. Install the rubber washer.
f. Install the upper ring nut.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,  
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains 
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Lower ring nut (initial tightening
torque)
38 Nm (3.8 m•kg, 27 ft•lb)
Lower ring nut (final tightening
torque)
7 Nm (0.7 m•kg, 5.1 ft•lb)
5
4
TR..
TR.. 
						

							 
CHASSIS 
3-26 
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
NOTE:
 
Make sure the special washer tabs “a” sit cor- 
rectly in the ring nut slots “b”.

 
5. Install: 
 
Upper bracket
Refer to “STEERING HEAD” on page 4-49. 
 
Handlebar
Refer to “HANDLEBAR” on page 4-34. 
EAS21530 
CHECKING THE FRONT FORK 
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over. 
2. Check: 
 
Inner tube
Damage/scratches  
→ 
 Replace. 
 
Oil seal
Oil leakage  
→ 
 Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check: 
 
Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement  
→ 
 Repair.
Refer to “FRONT FORK” on page 4-39. 
EAS21580 
ADJUSTING THE FRONT FORK LEGS 
The following procedure applies to both of the
front fork legs.
WARNING
 
EWA32D1006  
 
Always adjust the left and right front forks
evenly. If this is not done, the vehicle will
have poor stability. 
 
Securely support the vehicle so that there 
is no danger of it falling over.
Rebound damping
CAUTION:
 
 ECA13590 
Never go beyond the maximum or minimum 
adjustment positions. 
1. Adjust: 
 
Rebound damping

 
a. Turn the adjusting screw “1” in direction “a” or
“b”. 
Direction “a”
Rebound damping is increased (suspen-
sion is harder).
Direction “b”
Rebound damping is decreased (suspen-
sion is softer).
Rebound damping
Maximum (hard)
1click(s) out*
Standard
10 click(s) out*
Minimum (soft)
12 click(s) out* 
* With the adjusting screw fully turned in 
						

							 
CHASSIS 
3-27

 
Compression damping
CAUTION:
 
 ECA13590 
Never go beyond the maximum or minimum 
adjustment positions. 
1. Adjust: 
 
Compression damping

 
a. Turn the adjusting screw “1” in direction “a” or
“b”.

 
EAS32D1020 
AIR BLEEDING FROM FRONT FORK 
When the temperature increases in the front forkduring touring, the air pressure increases in the
fork and the suspension will become less flexi-
ble.
Bleed following procedure.
1. Stand the vehicle on a level surface.
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
 
Stand the vehicle vertically using an appropriate 
stand, and bleed the air from the front fork.
2. Bleed the air from the front fork.
Bleed the air from the front fork by removing
bleed screw “1”.
CAUTION:
 
 ECA32D1001  
 
Always bleed the left and right front fork
evenly. 
 
If this is not done, the vehicle will have poor 
stability. 
3. Install: 
 
Bleed screw 
EAS21610 
ADJUSTING THE REAR SHOCK ABSORBER 
ASSEMBLY
WARNING
 
EWA13120  
Securely support the vehicle so that there is 
no danger of it falling over.
Spring preload
CAUTION:
 
 ECA13590 
Never go beyond the maximum or minimum 
adjustment positions. 
1. Adjust: 
 
Spring preload
NOTE:
 
Remove the rear shock absorber from the vehi- 
Direction “a”
Compression damping is increased (sus-
pension is harder).
Direction “b”
Compression damping is decreased (sus-
pension is softer).
Compression damping
Maximum (hard)
1 click(s) out*
Standard
10 click(s) out*
Minimum (soft)
19 click(s) out* 
* With the adjusting screw fully turned in
1
ba
1a b
 
Bleed screw
1.5 Nm (0.15 m•kg, 1.1 ft•lb)
1
TR.. 
						

							 
CHASSIS 
3-28 
cle before this adjustment.
Refer to “REAR SHOCK ABSORBER ASSEM- 
BLY” on page 4-53.

 
a. Adjust the spring preload with a ring nut
wrench.
b. Loosen the locknut “1”.
c. Turn the adjusting nut “2” in direction “a” or
“b”.
d. Tighten the locknut.

 
Rebound damping
CAUTION:
 
 ECA13590 
Never go beyond the maximum or minimum 
adjustment positions.  
1. Adjust: 
 
Rebound damping

 
a. Turn the adjusting knob “1” in direction “a” or
“b”.

 
Compression damping
CAUTION:
 
 ECA13590 
Never go beyond the maximum or minimum 
adjustment positions.  
1. Adjust: 
 
Compression damping  
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Direction “a”
Spring preload is increased (suspension
is harder).
Direction “b”
Spring preload is decreased (suspension
is softer).
Spring length “c”
Standard
211.5 mm (8.33 in)
Minimum (hard)
206 mm (8.11 in)
Maximum (soft)
216 mm (8.50 in)
1
ab2
c
 
Locknut
42 Nm (4.2 m•kg, 30 ft•lb)
Direction “a”
Rebound damping is increased (suspen-
sion is harder).
Direction “b”
Rebound damping is decreased (suspen-
sion is softer).
Rebound damping
Maximum (hard)
3 click(s) out*
Standard
12 click(s) out* (WR250R)
13 click(s) out* (WR250X)
Minimum (soft)
25 click(s) out* 
* With the adjusting knob fully turned in
TR..
a b 1