2001 YAMAHA WR 250F oil

4 - 67
ENGOIL PUMP
Extent of removal Order Part name Q’ty Remarks
12 Dowel pin 1
13 Washer 1
14 Oil pump drive shaft 1
15 Rotor housing 1
2

4 - 68
ENGOIL PUMP
INSPECTION
Oil pump
1. Inspect:
lOil pump drive gear 1
lOil pump drive shaft 2
lRotor housing 3
lOil pump cover 4
Cracks/wear/damage ® Replace.
1
32
4
2. Measure:
lTip clearance a
(between the inner rotor 1 and outer
rotor 2)
lSide clearance b
(between the outer rotor 2 and rotor
housing 3)
lHousing and rotor clearance c
(between the rotor housing 3 and
rotors 1 2)
Out of specification ® Replace the oil
pump assembly.
Tip clearance a:
0.12 mm or less
(0.0047 in or less)
: 0.20 mm (0.008 in)
Side clearance b:
0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in)
: 0.24 mm (0.009 in)
Housing and rotor clearance c:
0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in)
: 0.17 mm (0.0067 in)
3. Check:
lUnsmooth ® Repeat steps #1 and #2
or replace the defective parts.

4 - 69
ENGOIL PUMP
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
lOil pump drive shaft 1
lWasher 2
lDowel pin 3
lInner rotor 1 4
NOTE:
lApply the engine oil on the oil pump drive
shaft and inner rotor 1.
lFit the dowel pin into the groove in the inner
rotor 1.
2. Install:
lOuter rotor 1 1
NOTE:
Apply the engine oil on the outer rotor 1.
3. Install:
lOil pump cover 1
lScrew (oil pump cover) 2
lDowel pin 3
lInner rotor 2 4
lCirclip 5
NOTE:
lApply the engine oil on the inner rotor 2.
lFit the dowel pin into the groove in the inner
rotor 2.
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

4 - 70
ENG
4. Install:
lOuter rotor 2 1
lDowel pin 2
lOil pump assembly 3
lBolt (oil pump assembly)
[L = 25 mm (0.94 in)] 4
lBolt (oil pump assembly)
[L = 30 mm (1.18 in)] 5
NOTE:
Apply the engine oil on the outer rotor 2.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
5. Install:
lOil pump drive gear 1
lWasher 2
lCirclip 3
NOTE:
Apply the engine oil on the oil pump drive gear
inner circumference.
OIL PUMP

4 - 71
ENGKICK SHAFT AND SHIFT SHAFT
KICK SHAFT AND SHIFT SHAFT
Extent of removal:1 Kick shaft removal2 Kick shaft disassembly
3 Shift shaft removal4 Segment removal
Extent of removal Order Part name Q’ty Remarks
KICK SHAFT AND SHIFT
SHAFT REMOVAL
Preparation for removal Oil pump Refer to “OIL PUMP” section.
1 Kick idle gear 1
2 Kick shaft assembly 1 Refer to “REMOVAL POINTS”.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
8 Washer 1
9 Shift pedal 1
10 Shift shaft 1
11Collar
1
3
2
1
4
1

4 - 75
ENGKICK SHAFT AND SHIFT SHAFT
EC4B5111
Stopper lever
1. Install:
lTorsion spring 1
lStopper lever 2
lBolt (stopper lever) 3
NOTE:
Align the stopper lever roller with the slot on
segment.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Shift guide and shift lever assembly
1. Install:
lSpring 1
lPawl pin 2
lPawl 3
To shift lever 4.
NOTE:
Apply the engine oil on the spring, pawl pin
and pawl.
2. Install:
lShift lever assembly 1
To shift guide 2.
3. Install:
lShift lever assembly 1
lShift guide 2
NOTE:
lThe shift lever assembly is installed at the
same time as the shift guide.
lApply the engine oil on the bolt (segment)
shaft.

4 - 76
ENGKICK SHAFT AND SHIFT SHAFT
4. Install:
lBolt (shift guide) 1
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Shift shaft
1. Install:
lRoller 1
lCollar 2
lTorsion spring 3
lShift shaft 4
NOTE:
Apply the engine oil on the roller and shift
shaft.
2. Install:
lShift pedal 1
lBolt (shift pedal) 2
NOTE:
When installing the shift pedal onto the shift
shaft, be sure that the center of the shift pedal
is about 2 mm a above the top of the footrest.
Kick shaft assembly
1. Install:
lKick gear 1
lWasher 2
lCirclip 3
lRatchet wheel 4
lSpring 5
lWasher 6
lCirclip 7
To kick shaft 8.
NOTE:
lApply the molybdenum disulfide oil on the
kick gear inner circumference.
lAlign the punch mark a on the ratchet wheel
with the punch mark b on the kick shaft.

4 - 77
ENGKICK SHAFT AND SHIFT SHAFT
2. Install:
lTorsion spring 1
To kick shaft 2.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick shaft.
3. Install:
lSpring guide 1
NOTE:
Slide the spring guide into the kick shaft, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
lKick shaft assembly 1
lWasher 2
NOTE:
lApply the engine oil on the kick shaft.
lSlide the kick shaft assembly into the crank-
case, make sure the kick shaft stopper a fit
into their home position 3.
5. Hook:
lTorsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
lKick idle gear 1
lWasher 2
lCirclip 3
NOTE:
lApply the engine oil on the kick idle gear
inner circumference.
lInstall the kick idle gear with its depressed
side a toward you.