Yamaha WR250R Project – Stage 1

WR250R Index Page

wrs11First up for the WR, an 18-litre IMS fuel tank that’s wider than it is long. And at the 31kpl I got on the way back from Holland, that should mean well over 500km, though 400 may be more realistic.
On the forums you read various horror stories about the IMS tank: misalignment, poor fittings, plugs falling out and so on. I was expecting aggro but it all went without a hitch or too much head scratching. The fuel line unclips from the pump, the OE tank lifts off, once unscrewed the pump lifts out of that and the wrs1-8chunky Yamaha tank mounts swap onto the IMS just fine. At the back though, no amount of jiggling could line up the mounts (below right) with the frame if using the locating washers. Without washers it crammed in OK. I didn’t bother with the screw-in stud on the back of the tank to locate wrs1-6the seat front either. It stays on well enough with the seat tongue going under the frame tab.
The IMS comes with a small low-pressure lift pump inside (the grey metal unit, above) to get to the fuel at the bottom. It’s powered by vacuum off some intake hose which you cut and tee into. Once all was plumbed up and bolted down, the bike started first press and ran normally. Hallelujah.
The tank splays out quite widely and the outer edges will get knocked about on falls, but they also protect the radiator better than the OE shrouds so it’s a good use of volume. On the road full up, I can’t say I noticed any unbaffled sloshing as some sensitive riders have reported. Looks like a good, solid unit. The pic at the bottom of the page shows it with 3 litres in and room for 15 more at the servo.


yamaha3d71390710WR250Rs are known for having dodgy fuel pumps (more here) which can behave erratically in hot weather after a few thousand kms, failing to prime (no buzzing on key turn). They might recover once cooled down but eventually will pack up for good. No one really knows what the problem is. One suggestion is fuel varnish coating the inside seizes the turbine when hot.
Early 2008s were very prone, although later WRs pack up too after a few thousand kms. It seems not living in Phoenix, AZ helps, and you do wonder if ropey US fuel has something to do with it or if it’s a case of the squeaky hinge getting all the oil? Don’t know but in the Sahara WR bike will get hot for sure.

A complete Yamaha pump with housing goes discounted for about $300 on amazon, and although the part number changed (from 3D7-13907-00 for 2008-12, to 3D7-13907-10 from 2013-onwards) suggesting an updated pump, some people still report failures on the newer pumps. wrfuelpump
Being a popular bike in US and Au, there are various aftermarket pumps from just £20 cheapies on ebay to £105 for a California Cycleworks unit (left, also made in China). They all require carefully dismantling the white plastic housing as above, to replace the actual fuel pump unit. Not really a trailside job.  Aftermarket ones fail too, especially the cheaper ones, which makes you think it’s modern fuel or an over-pressurised system, as I also read somewhere. I’ve not heard of other efi bikes having hot weather fuel pump issues, but anyway I cracked and bought a Cycleworks. I’ll will get round to fitting it and carry the OE unit as a spare.

wr250-rax

wrs1-11Next job: pannier racks. Long story short, choosing from the above selection, at $170 from Rocky Mtn Adv the US-made Tusk racks (a Rocky Mtn sub-brand, afaik) looked by far the best value for money, and when they turned up I was even more impressed – nice to see chunky ¾”  and the all-important back brace to stop them folding in when heavily loaded on rough terrain. The unbraced Moto and Barrett may rely on heavier gauge tubing to not cave in. That looks neater but I found with the Rally Raid racks on the CB500X it didn’t really work out like that, to be bend-proof and light you need a back brace. Once I removed the unwanted bracketry for mounting Tusk hard boxes, the weight was < 4kg.
The wrs1-10fitting video on Rocky Mtn is especially helpful, but mounting the back underplate (right) could only be solved by cutting away with a red-hot knife. It’s possible my bike’s non-original plastic numberplate holder mount plate thing complicated things. That apart, the rack lined up just right elsewhere and will give something to grab when hauling the WR across a dune. There’s plenty of space behind the non-pipe side too, to stash stuff or mount a container.

wrs1-9I splashed out on some Rox bar risers which have a bit of fore and aft adjustment. Fat bar sized plus with adapters for ⅞s, they can carry over to later bikes, like my old Barkbuster Storms. Talking of which, they can stay in the  box as the handguards that came with the WR look OK. There’s just enough room left on the bars to add my xco-shieldSpitfire screen mounts (right).
I have a nice shiny Flatland bashplate waiting to clamp on, but the old hex bolts on the OE bashplate were not playing ball. Instead they wanted a game of rounders, and so rounded out they now are. One for the shop when they MoT it next week.

wrs1-18I put on my old round Double Take mirror; it helps where I park the bike. But a run to the Overland Event near Oxford proved it vibrates on the WR just like it blurred on other bikes I’ve tried them on. screen-shot-2016-09-18-at-14-37-06The new asymmetric Double Take Adventure model (right) has done away with the stalk to reduce vibration, but now means you have to buy a hefty 6-inch RAM arm for another 20 quid (plus a bar-ball mount for another tenner). As I have those bits I may give the new one a try as it is handy to have one bombproof mirror.
82-cassisPicture left: my original desert bike, the ally-tanked ’76 XT500 I rode to Algeria in 1982. The WR is bike #57. For the first time since the 80s I’ve again had more bikes than birthdays.

wrsi-drdOther jobs include re-fitting my Trail Tech Vapor to give accurate speeds because, according to my GPS the WR speedo reads 12% fast and odo some 4% over. But I’ve also just fitted a Speedo DRD chip (left) from Totally TTRs. I was hoping the WR’s OE kph digital speedo could be reset to show mph, like my XT660ZE from the same era. But annoyingly, it seems WRs sold in kmh markets can’t flip their speedos to mph, while Brit and American mph WRs can changed to kph. WTF WR?
wrs1-spdLike those nifty fuel controllers, the DRD is very easy to programme and can also flip to mph to make the bike UK legit, as well as correct the large speed error, even though the Vapor technically does that job too. As a reminder the Trail Tech Vapor can also display ambient and engine temps – the latter a vital reading on any bike, IMO – as well as a GPS compass and altitude, rpm and, yes even the time of day.

vizxAs for lighting, I’m assuming the standard little headlight will not wake the badgers. Some say you can fit a super-bright $60 HiD bulb and fry burgers with it; other find the cut off is unsuited for road riding. I must say on a travel bike I prefer the idea of a secondary light; a back up should the main one fail.
I’ve had a Vision X 5″ Xmitter narrow beam (left) sitting around for ages. They say this is the best model to get for travel bikes, so now will be a good opportunity it fit it to the WR.

wrs1-tyresWakey wakey! A mate gave me a rear Sava MC23 Rockrider which he reckons are the new black (and round). At 140-80 it didn’t fit his TTR250 and I don’t think oversized tyres work on a WR (120/80-18) any more than noisy pipes make more power. More weight; more drag and over-stiff tyres on light bikes can be counterproductive in deep, soft sand. They’re just too stiff to sag usefully, even at very low pressures, to give better traction, as amh-tread-chooser-dirt1I found years ago running a Mich Desert on a Tenere right down to 5psi. The MC23 is 4 plies tread and 3 in the sides – sounds stiff. I won’t be that loaded up nor riding hard, and the WR will lack a Tenere’s grunt to hook up, for sure.
In the US they all rate the Dunlop 606 on WRs, but they don’t sell it in the UK. Either way, something from the list on the right will do the job or here. The Mitas E09/10s I’ve been wanting to try don’t come in WR rear sizes. With Sava/Mitas it’s the MC23 or nothing and in the end I succumbed to online tyre fatigue and clicked on a 120/90 Rockrider for £56. It may not hook up in the sands of the Erg Amatlich, but it won’t puncture up on the plateau, either.
To keep it company I also bought a front MC23 Rockrider – £42 from Oponeo, so that’s £98 all shod. This came branded as a Czech Mitas as Mitas have lately bought out Slovenian Sava. Just as well because as tyre names go, ‘Sava’ is even worse than Golden Tyre. I hope to at least mount the rear tubelessly, doing a better job than I did last time on the Tenere. Enough tyre talk.

wrs1-papsUnfortunately, delays in receiving paperwork to complete UK registration (added by my own confusion in how to set about the task efficiently) mean it’s unlikely I’ll have a UK plate and logbook in time for my Morocco tours in a few weeks. I’ll have to rent something down there. Can’t say I’m bitterly disappointed at missing the chance to cross Spain and back in early winter on an untried 250. Last couple of years I’ve been lucky with the rain in Spain. It can’t last and it all gives me a chance to get the WR in good shape for the proper desert trip we have lined up in the new year. It also means those rally tyres won’t get wasted running mostly roads.
wrs1-12I do wonder if it has been worth the faff and expense of buying a bike from Holland just to get some top-grade Hyperpro suspension (this is the first WR250R to have HP). All I know is if it works as well as my HP X-Country, then the answer will eventually be yes. You just wonder how many trees have given up promising futures to certify the re-registering process of this motorcycle.

wrs1-17Have to say, after having a close look, so far I’m impressed by the WR. The easy disassembly and access to things, nifty hinged air filter door, minimal-sized components where possible and solid parts elsewhere, like triple clamp and subframe. It’s like a Jap KTM, and grails don’t come much holier than that.

One thing I’m pretty sure I won’t be doing is meddling with the airbox flap, EXUP valve, silencer or other stuff to squeeze 3% more power out of it and save a few ounces. Like most things, the WR-R already is what it is: lighter and more powerful than any other Jap trail bike, with a travel workable oil-change interval and excellent mpg. That should do nicely for the next desert ride or two I have in mind.

wrs1-hpaOn the way to the Overland Event I had a pile of heavy books I was hoping not to bring back. Once loaded up it was great to just crank up the Hyperpro Hydraulic Preload Adjuster knob which still fits nicely alongside the new rack. At a pinch you can almost do it on the move, though probably not while texting.
I haven’t yet had the heart to run the WR at the revs it’s supposed to handle. What’s probably a true 55-60mph seems fine for now, but unlike a CRF-L or KLX, you do have a bit of spare oomph when you need it. For the first time in years I’m very much looking forward to getting my latest project bike on the dirt.

wrs1-16

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