Yamaha WR250F Maintenance Schedule (service parts Interval)

INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

No.		Item	Checks and maintenance jobs	Initial	Odometer readings
				600 mi (1000 km) or 1 month	1800 mi (3000 km) or 3 months	3000 mi (5000 km) or 6 months
1	*	Fuel line	Check fuel hoses for cracks or damage. Replace if necessary.	✓	✓	✓
2		Spark plug	Check condition. Adjust gap and clean.	✓	✓	✓
3	*	Valve clearance	Check and adjust valve clearance when engine is cold.	✓		✓
4	*	Air filter element	Clean with solvent and apply Yamaha foam air filter oil or other quality foam air filter oil. Replace if necessary.	✓	✓	✓
5	*	Breather system	Check ventilation hose for cracks or damage and drain any deposits.	✓	✓	✓
			Replace.	Every 2 years
6	*	Fuel injection	Adjust engine idling speed.	✓	✓	✓
7		Exhaust system	Check for leakage. Tighten if necessary. Replace gasket(s) if necessary.	✓	✓	✓
8		Engine oil	Change (warm engine before draining).	✓	✓	✓
9		Engine oil filter element	Replace.	✓	✓	✓
10		Engine oil strainer	Clean.	✓	✓	✓

GENERAL MAINTENANCE AND LUBRICATION CHART

No.		Item	Checks and maintenance jobs	Initial	Odometer readings
				600 mi (1000 km) or 1 month	1800 mi (3000 km) or 3 months	3000 mi (5000 km) or 6 months
1		Clutch	Check operation. Adjust or replace cable.	✓	✓	✓
2	*	Cooling system	Check hoses for cracks of damage. Replace if necessary.	✓	✓	✓
			Replace with ethylene glycol anti-freeze coolant every 1 year.	Every 1 year
3	*	Spark arrester	Clean.			✓
4	*	Front brake	Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary.	✓	✓	✓
			Replace brake fluid every 1 year.	Every 1 year
5	*	Rear brake	Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary.	✓	✓	✓
			Replace brake fluid every 1 year.	Every 1 year
6	*	Brake hoses	Check for cracks or damage.		✓	✓
			Replace.	Every 4 years
7	*	Wheels	Check runout, spoke tightness and for damage. Tighten spokes if necessary.	✓	✓	✓
8	*	Tires	Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.	✓	✓	✓
9	*	Wheel bearings	Check bearings for smooth operation. Replace if necessary.	✓	✓	✓
10	*	Swingarm pivot bearings	Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease.	✓	✓	✓
11		Drive chain	Check chain slack/alignment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.	Every ride
12	*	Steering bearings	Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease every 1200 mi (2000 km) or 12 months (whichever comes first).	✓	✓	✓
13		Brake and clutch lever pivot shafts	Apply lithium-soap-based grease (all-purpose grease) or silicone grease lightly.	✓	✓	✓
14		Brake pedal pivot shafts	Apply lithium-soap-based grease (all-purpose grease) lightly.	✓	✓	✓
15		Sidestand pivot	Check operation. Apply lithium-soap-based grease (all-purpose grease) lightly.	✓	✓	✓
16	*	Front fork	Check operation and for oil leakage. Replace if necessary.		✓	✓
17	*	Shock absorber assembly	Check operation and for oil leakage. Replace if necessary.		✓	✓
18	*	Rear suspension link pivots	Apply molybdenum disulfide grease lightly.		✓	✓
19	*	Control cables	Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.	✓	✓	✓
20	*	Throttle grip housing and cable	Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.	✓	✓	✓
21	*	Chassis fasteners	Check all chassis fitting and fasteners. Correct if necessary.	✓	✓	✓
22		Battery	Check terminal for looseness and corrosion.		✓	✓

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• Hydraulic brake service

  • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

  • 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.

MAINTENANCE INTERVALS FOR COMPETITION USE

• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

No.		Item	Routine	After break-in	Every race	Every third race (or 500 km)	Every fifth race (or 1000 km)	As required
1		Engine oil	Replace.	✓			✓
2	*	Valve	Check the valve clearances.	✓		✓
			Check the valve seats and the valve stems for wear.				✓
			Replace.					✓
3	*	Valve spring	Check the free length.				✓
			Replace.					✓
4	*	Valve lifter	Check for scratches and wear.				✓
			Replace.					✓
5	*	Camshaft	Inspect the camshaft surface. Inspect the decompression system.				✓
			Replace.					✓
6	*	Timing chain	Check for damage and sticking.					✓
			Replace.				✓	✓
7	*	Timing chain tensioner	Replace.				✓	✓
8	*	Camshaft sprocket	Check for wear on the teeth and for damage.				✓
			Replace.					✓
9	*	Piston	Inspect crack. Inspect carbon deposits and eliminate them.				✓	✓
			Clean.					✓
			Replace. (It is recommended that the piston pin and ring are also replaced at the same time.)					✓
10	*	Piston ring	Check the ring end gap.				✓
			Replace.				✓	✓
11	*	Piston pin	Inspect.				✓
			Replace.					✓
12	*	Cylinder head	Inspect carbon deposits and eliminate them. Change gasket.				✓
13	*	Cylinder	Inspect score marks. Inspect wear.				✓
			Replace.					✓
14	*	Clutch	Inspect housing, friction plate, clutch plate and spring.	✓	✓
			Replace.					✓
15	*	Transmission	Inspect.					✓
			Replace bearings.					✓
16	*	Shift fork, shift drum, guide bar	Inspect wear.					✓
17	*	Generator rotor nut	Retighten.	✓			✓
18	*	Muffler	Inspect and retighten.	✓	✓
			Clean.				✓
			Replace.					✓
19	*	Crank	Inspect and clean.				✓	✓
20	*	Throttle body	Inspect.					✓
21		Spark plug	Inspect and clean.	✓		✓
			Replace.					✓
22		Drive chain	Lubricate, slack, alignment.	✓	✓
			Replace.					✓
23	*	Cooling system	Check coolant level and leakage.	✓	✓
			Check radiator cap operation.					✓
			Replace coolant.	Every two years				✓
			Inspect hoses.		✓
24		Outside nuts and bolts	Retighten.	✓	✓
25		Air filter	Clean and lubricate.	✓	✓
			Replace.					✓
26		Oil filter	Replace.	✓			✓
27	*	Engine guard	Replace.					✓
28	*	Frame	Clean and inspect.	✓	✓
29	*	Fuel tank, fuel pump	Clean and inspect.	✓		✓
30	*	Fuel hose	Inspect.					✓
			Replace.	Every four years				✓
31	*	Brake(s)	Adjust lever position and pedal position.	✓	✓
			Lubricate pivot point.	✓	✓
			Check brake disc surface.	✓	✓
			Check fluid level and leakage.	✓	✓
			Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts.	✓	✓
			Replace pads.					✓
			Replace brake fluid.	Every one year				✓
32	*	Front fork(s)	Inspect and adjust.	✓	✓
			Replace oil.	✓			✓
			Replace oil seal.					✓
33	*	Front fork oil seal and dust seal	Clean and lubricate.	✓	✓
34		Protector guide	Replace.					✓
35	*	Rear shock absorber	Inspect and adjust.	✓	✓
			Lubricate. (After rain ride)			✓		✓
			Retighten.	✓	✓
36	*	Drive chain guard and roller	Inspect.	✓	✓
37	*	Drive chain stopper	Inspect.					✓
38	*	Swingarm	Inspect, lube and retighten.	✓	✓
39	*	Relay arm, connecting rod	Inspect, lube and retighten.	✓	✓
40		Sidestand	Lubricate.					✓
41	*	Steering head	Inspect free play and retighten.	✓	✓
			Clean and lubricate.				✓
			Replace bearings.					✓
42	*	Tire, wheels	Inspect air pressure, wheel run-out, tire wear and spoke looseness.	✓	✓
			Retighten sprocket bolt.	✓	✓
			Inspect bearings.			✓
			Replace bearings.					✓
			Lubricate.			✓
43		Throttle, control cable	Check routing and connection.	✓	✓
			Lubricate.	✓	✓

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