2007 YAMAHA WR 250F water pump

CHAPTER 4
TUNING
ENGINE...................................... 4-1
CHASSIS.................................. 4-21
CHAPTER 5
ENGINE
RADIATOR................................. 5-1
CARBURETOR.......................... 5-9
AIR INDUCTION SYSTEM....... 5-39
CAMSHAFTS........................... 5-45
CYLINDER HEAD.................... 5-67
VALVES AND VALVE
SPRINGS.................................. 5-75
CYLINDER AND PISTON........ 5-95
CLUTCH................................. 5-111
OIL FILTER ELEMENT,
WATER PUMP AND RIGHT
CRANKCASE COVER........... 5-129
BALANCER............................ 5-145
OIL PUMP.............................. 5-153
OIL TANK............................... 5-157
KICK SHAFT AND SHIFT
SHAFT.................................... 5-167
AC MAGNETO AND
STARTER CLUTCH............... 5-185
ENGINE REMOVAL............... 5-207
CRANKCASE AND
CRANKSHAFT....................... 5-221
TRANSMISSION, SHIFT CAM
AND SHIFT FORK................. 5-245
CHAPTER 6
CHASSIS
FRONT WHEEL
AND REAR WHEEL................... 6-1
FRONT BRAKE AND
REAR BRAKE.......................... 6-23
FRONT FORK.......................... 6-61
HANDLEBAR........................... 6-91
STEERING............................. 6-105
SWINGARM........................... 6-121
REAR SHOCK
ABSORBER........................... 6-141
CHAPITRE 4
MISE AU POINT
MOTEUR......................................... 4-1
CHÂSSIS........................................ 4-21
CHAPITRE 5
MOTEUR
RADIATEUR................................... 5-2
CARBURATEUR.......................... 5-10
SYSTEME D’INDUCTION
D’AIR.............................................. 5-40
ARBRES A CAMES...................... 5-46
CULASSE....................................... 5-68
SOUPAPES ET RESSORTS
DE SOUPAPES.............................. 5-76
CYLINDRE ET PISTON.............. 5-96
EMBRAYAGE............................. 5-112
ELEMENT DE FILTRE
A HUILE, POMPE A EAU
ET DEMI-CARTER DROIT...... 5-130
BALANCIER............................... 5-146
POMPE A HUILE....................... 5-154
RÉSERVOIR D’HUILE.............. 5-158
ARBRE DE KICK ET AXE
DE SELECTEUR......................... 5-168
ALTERNATEUR AVEC
ROTOR A ALIMENTATION
PERMANENTE ET
EMBRAYAGE DU
DEMARREUR............................. 5-186
DEPOSE DU MOTEUR.............. 5-208
CARTER MOTEUR ET
VILEBREQUIN........................... 5-222
BOITE DE VITESSES, TAMBOUR
ET FOURCHETTES DE
SELECTION................................ 5-246
CHAPITRE 6
CHÂSSIS
ROUE AVANT ET
ROUE ARRIERE............................ 6-2
FREIN AVANT ET FREIN
ARRIERE....................................... 6-24
FOURCHE..................................... 6-62
GUIDON......................................... 6-92
DIRECTION................................ 6-106
BRAS OSCILLANT.................... 6-122
AMORTISSEUR ARRIERE...... 6-142

1 - 5
GEN
INFOIMPORTANT INFORMATION
EC130000
IMPORTANT
INFORMATION
EC131010PREPARATION FOR REMOVAL
AND DISASSEMBLY
1. Remove all dirt, mud, dust, and
foreign material before removal
and disassembly.
When washing the machine with
high pressured water, cover the
parts follows.
Silencer exhaust port
Side cover air intake port
Water pump housing hole at
the bottom
Drain hole on the cylinder
head
(right side)
All electrical components
2. Use proper tools and cleaning
equipment. Refer to “SPECIAL
TOOLS” section.
3. When disassembling the
machine, keep mated parts
together. They include gears,
cylinders, pistons, and other
mated parts that have been
“mated” through normal wear.
Mated parts must be reused as
an assembly or replaced.
4. During the machine disassem-
bly, clean all parts and place
them in trays in the order of dis-
assembly. This will speed up
assembly time and help assure
that all parts are correctly rein-
stalled.
5. Keep away from fire.
EC132000ALL REPLACEMENT PARTS
1. We recommend to use Yamaha
genuine parts for all replace-
ments. Use oil and/or grease
recommended by Yamaha for
assembly and adjustment.
INFORMATIONS
IMPORTANTES
PREPARATION A LA DEPOSE ET
AU DEMONTAGE
1. Eliminer soigneusement saletés,
boue, poussière et corps étrangers
avant la dépose et le démontage.
Avant de laver la moto à l’eau sous
pression, recouvrir les parties sui-
vantes.
Orifice d’échappement du silen-
cieux
Prise d’admission d’air du cache
latéral
Orifice situé dans le fond du car-
ter de la pompe à eau
Orifice de vidange de la culasse
(côté droit)
Tous les composants électriques
2. Utiliser les outils et le matériel de
nettoyage appropriés. Se reporter à
la section “OUTILS SPECIAUX”.
3. Lors du démontage de la moto, gar-
der ensemble les pièces appariées. Il
s’agit des engrenages, des cylindres,
pistons et autres pièces qui ont été
“façonnées l’une à l’autre” par
l’usure normale. Ces pièces doivent
être réutilisées ensemble ou rempla-
cées.
4. Lors du démontage de la moto, net-
toyer toutes les pièces et les dispo-
ser dans des plateaux dans l’ordre
du démontage. Ceci diminuera le
temps de remontage et permettra de
s’assurer que toutes les pièces ont
été correctement remontées.
5. Travailler à l’écart de toute flamme.
PIECES DE RECHANGE
1. Nous recommandons d’utiliser des
pièces Yamaha d’origine pour tous
les remplacements. Utiliser les
graisses et/ou huiles recommandées
par Yamaha lors des remontages et
réglages.
INFORMATIONS IMPORTANTES

MAINTENANCE SPECIFICATIONS
2 - 9
SPEC
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 120.2 mm (4.73 in) ----
Height 240 mm (9.45 in) ----
Thickness 22 mm (0.87 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.54 L (0.48 Imp qt, 0.57 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

MAINTENANCE SPECIFICATIONS
2 - 10
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 10 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator stay M6 × 1.0 6 10 1.0 7.2
Radiator M6 × 1.0 4 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer (crankcase) M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil hose clamp—220.21.4
Oil strainer (oil tank) M6 × 1.0 1 9 0.9 6.5
Oil tank drain bolt M8 × 1.25 1 18 1.8 13
Oil tank (upper) M6 × 1.0 1 7 0.7 5.1
Oil tank and frame M6 × 1.0 3 9 0.9 6.5
Oil pressure check bolt M6 × 1.0 1 10 1.0 7.2
Carburetor joint M6 × 1.0 2 10 1.0 7.2
Carburetor joint clamp M4 × 0.7 1 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4

5 - 129
ENGOIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
Extent of removal:
1 Oil filter element removal
2 Water pump removal
3 Right crankcase cover removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER
REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in
the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the
CHAPTER 3.
Radiator hose 3 Disconnect at water pump side.
Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section
in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Engine guard
1 Oil filter element cover 1
2 Oil filter element 1
13

5 - 133
ENGOIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
Extent of removal Order Part name Q’ty Remarks
3 Water pump housing 1
4 Oil delivery pipe 1
5 Bolt (oil hose) 1
6 Kickstarter crank 1
7 Right crankcase cover 1
8 Impeller 1
Refer to “REMOVAL POINTS”. 9 Washer 1
10 Impeller shaft 1
11 Oil seal 2
12 Bearing 1
2
3

5 - 137
ENGOIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
REMOVAL POINTS
Impeller shaft
1. Remove:
Impeller
1
Washer
2
Impeller shaft
3
NOTE:Hold the impeller shaft on its width
across the flats
a with spanners,
etc. and remove the impeller.
EC4G3210Oil seal
NOTE:It is not necessary to disassemble
the water pump, unless there is an
abnormality such as excessive
change in coolant level, discoloration
of coolant, or milky transmission oil.
1. Remove:
Bearing
1
2. Remove:
Oil seal
1
INSPECTION
Oil delivery pipe
1. Inspect:
Oil delivery pipe
1
Bend/damage
→ Replace.
Clogged
→ Blow.
EC444200Impeller shaft
1. Inspect:
Impeller shaft
1
Bend/wear/damage
→
Replace.
Fur deposits
→ Clean.
POINTS DE DEPOSE
Arbre d’entraînement
1. Déposer:
Rotor 1
Rondelle 2
Arbre d’entraînement 3
N.B.:
Maintenir l’arbre d’entraînement en le
saisissant par les côtés plats a à l’aide
d’une clé, etc., et déposer le rotor.
Bague d’étanchéité
N.B.:
Il n’est pas nécessaire de démonter la
pompe à eau sauf en cas d’anomalies tel-
les qu’une modification importante du
niveau de liquide de refroidissement, une
décoloration du liquide de refroidisse-
ment ou un aspect laiteux de l’huile de
boîte de vitesses.
1. Déposer:
Roulement 1
2. Déposer:
Bague d’étanchéité 1
CONTROLE
Tuyau d’huile
1. Contrôler:
Tuyau d’huile 1
Déformation/endommagement →
Remplacer.
Obstrué → Souffler.
Arbre d’entraînement
1. Contrôler:
Arbre d’entraînement 1
Déformation/usure/endommage-
ment → Remplacer.
Dépôts de tartre → Nettoyer.
ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT

5 - 139
ENGOIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER
EC444300Impeller shaft gear
1. Inspect:
Gear teeth
a
Wear/damage
→ Replace.
EC4H4600Bearing
1. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure
→
Replace.
EC444400Oil seal
1. Inspect:
Oil seal
1
Wear/damage
→ Replace.
ASSEMBLY AND INSTALLATION
Oil seal
1. Install:
Oil seal
1
NOTE:Apply the lithium soap base grease
on the oil seal lip.
Install the oil seal with its manufac-
ture’s marks or numbers facing the
right crankcase cover
2.
New
2. Install:
Bearing
1
NOTE:Install the bearing by pressing its
outer race parallel.
Pignon d’arbre d’entraînement
1. Contrôler:
Dents de pignon a
Usure/endommagement → Rem-
placer.
Roulement
1. Contrôler:
Roulement
Faire tourner la bague intérieure
avec le doigt.
Rugosité/grippage → Remplacer.
Bague d’étanchéité
1. Contrôler:
Bague d’étanchéité 1
Usure/endommagement → Rem-
placer.
ASSEMBLAGE ET MONTAGE
Bague d’étanchéité
1. Monter:
Bague d’étanchéité 1
N.B.:
Appliquer de la graisse à savon de
lithium sur la lèvre de la bague d’étan-
chéité.
Monter la bague d’étanchéité en orien-
tant vers le demi-carter droit la mar-
que ou le numéro du fabricant 2.
New
2. Monter:
Roulement 1
N.B.:
Monter le roulement en appuyant paral-
lèlement sur sa cage externe.
ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT