2009 YAMAHA YZ250F Owners Manual

4-35
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE IMPELLER
SHAFT
1. Remove:
•Impeller "1"
• Washer "2"
• Impeller shaft "3"
Hold the impeller shaft on its width
across the flats "a" with spanners,
etc. and remove the impeller.
REMOVING THE OIL SEAL
It is not necessary to disassemble the
water pump, unless there is an abnor-
mality such as excessive change in
coolant level, discoloration of coolant,
or milky transmission oil.
1. Remove:
• Bearing "1"
2. Remove:
•Oil seal "1"
CHECKING THE OIL DELIVERY
PIPE
1. Inspect:
• Oil delivery pipe "1"
Bend/damage→Replace.
Clogged→Blow.CHECKING THE IMPELLER SHAFT
1. Inspect:
• Impeller shaft "1"
Bend/wear/damage→Replace.
Fur deposits→Clean.
CHECKING THE IMPELLER SHAFT
GEAR
1. Inspect:
• Gear teeth "a"
Wear/damage→Replace.
CHECKING THE BEARING
1. Inspect:
• Bearing
Rotate inner race with a finger.
Rough spot/seizure→Replace.
CHECKING THE OIL SEAL
1. Inspect:
• Oil seal "1"
Wear/damage→Replace.INSTALLING THE OIL SEAL
1. Install:
•Oil seal "1"
• 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".
2. Install:
• Bearing "1"
Install the bearing by pressing its out-
er race parallel.
INSTALLING THE IMPELLER
SHAFT
1. Install:
• Impeller shaft "1"
• Washer "2"
• Impeller "3"
• Take care so that the oil seal lip is
not damaged or the spring does not
slip off its position.
• When installing the impeller shaft,
apply the lithium soap base grease
on the oil seal lip and impeller shaft.
And install the shaft while turning it.
• Hold the impeller shaft on its width
across the flats "a" with spanners,
etc. and install the impeller.
Impeller:
14 Nm (1.4 m•kg, 10
ft•lb)

4-36
OIL FILTER ELEMENT AND WATER PUMP
INSTALLING THE RIGHT
CRANKCASE COVER
1. Install:
• Dowel pin "1"
• O-ring "2"
•Collar "3"
•Gasket "4"
Apply the lithium soap base grease
on the O-ring.
2. Install:
• Right crankcase cover "1"
• Bolt (right crankcase cover) "2"
• Apply the engine oil on the impeller
shaft end.
• Mesh the impeller shaft gear "3"
with primary drive gear "4".
• Tighten the bolts in stage, using a
crisscross pattern.
INSTALLING THE KICKSTARTER
CRANK
1. Install:
• Kickstarter crank "1"
•Washer
• Bolt (kickstarter crank)
Install so that there is a clearance "a"
of 5 mm (0.20 in) or more between
the kickstarter and frame and that the
kickstarter does not contact the
crankcase cover when it is pulled.
2. Install:
• Oil hose "1"
• Bolt (oil hose) "2"
3. Install:
• Copper washer "1"
• Oil delivery pipe "2"
• Union bolt (M8) "3"
• Union bolt (M10) "4"INSTALLING THE WATER PUMP
HOUSING
1. Install:
• Dowel pin "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.
2. Install:
• Water pump housing "1"
• Bolt (water pump housing) "2"
INSTALLING THE OIL FILTER
ELEMENT
1. Install:
• Oil filter element "1"
• O-ring "2"
• Oil filter element cover "3"
• Bolt (oil filter element cover)
Apply the lithium soap base grease
on the O-ring.
Bolt (right crankcase
cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (kickstarter crank):
33 Nm (3.3 m•kg, 24
ft•lb)
Bolt (oil hose):
8 Nm (0.8 m•kg, 5.8
ft•lb)
Union bolt (M8):
18 Nm (1.8 m•kg, 13
ft•lb)
Union bolt (M10):
20 Nm (2.0 m•kg, 14
ft•lb)
Bolt (water pump hous-
ing):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (oil filter element
cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-37
BALANCER
BALANCER
REMOVING THE BALANCER
Order Part name Q'ty Remarks
Primary driven gear Refer to "CLUTCH" section.
Right crankcase cover Refer to "OIL FILTER ELEMENT AND WA-
TER PUMP" section.
Stator Refer to "CDI MAGNETO" section.
1 Nut (primary drive gear) 1 Refer to removal section.
2 Nut (balancer shaft driven gear) 1 Refer to removal section.
3 Lock washer 1
4 Primary drive gear 1
5 Balancer shaft drive gear 1
6 Lock washer 1
7 Balancer shaft driven gear 1
8 Balancer shaft 1 Refer to removal section.

4-38
BALANCER
REMOVING THE BALANCER
1. Straighten the lock washer tab.
2. Loosen:
• Nut (primary drive gear) "1"
• Nut (balancer shaft driven gear)
"2"
Place an aluminum plate "a" between
the teeth of the balancer shaft drive
gear "3" and driven gear "4".
3. Remove:
• Balancer shaft "1"
When removing the balancer shaft,
align the center "a" of the balancer
shaft weight along the line connecting
the centers of the crankshaft and bal-
ancer shaft.
CHECKING THE PRIMARY DRIVE
GEAR, BALANCER SHAFT DRIVE
GEAR AND BALANCER SHAFT
DRIVEN GEAR
1. Inspect:
• Primary drive gear "1"
• Balancer shaft drive gear "2"
• Balancer shaft driven gear "3"
Wear/damage→Replace.CHECKING THE BALANCER
SHAFT
1. Inspect:
• Balancer shaft
Cracks/damage→Replace.
INSTALLING THE BALANCER
1. Install:
• Balancer shaft "1"
• Apply the engine oil on the bearing.
• When installing the balancer shaft,
align the center "a" of the balancer
shaft weight along the line connect-
ing the centers of the crankshaft
and balancer shaft.
2. Install:
• Balancer shaft driven gear "1"
Install the balancer shaft driven gear
onto the balancer shaft while aligning
the punch mark "a" on the balancer
shaft driven gear with the lower spline
"b" on the balancer shaft end.
3. Install:
• Balancer shaft drive gear "1"
• Align the punched mark "a" on the
balancer shaft drive gear with the
punched mark "b" on the balancer
shaft driven gear "2".
• Align the punched mark "c" on the
balancer shaft drive gear with the
lower spline "d" on the crankshaft
end.
4. Install:
• Lock washer "1"
• Nut (balancer shaft driven gear)
"2"
• Primary drive gear "3"
• Lock washer "4"
• Nut (primary drive gear) "5"
• Install the primary drive gear with its
stepped side "a" facing the engine.
• Place an aluminum plate "b" be-
tween the teeth of the balancer
shaft drive gear "6" and driven gear
"7".
5. Bend the lock washer tab.
Nut (balancer shaft driv-
en gear):
50 Nm (5.0 m•kg, 36
ft•lb)
Nut (primary drive gear):
75 Nm (7.5 m•kg, 54
ft•lb)

4-39
OIL PUMP
OIL PUMP
REMOVING THE OIL PUMP
Order Part name Q'ty Remarks
Primary driven gear Refer to "CLUTCH" section.
Right crankcase coverRefer to "OIL FILTER ELEMENT AND WA-
TER PUMP" section.
1 Circlip 1
2 Washer 1
3 Oil pump drive gear 1
4 Oil pump assembly 1
5 Outer rotor 2 1
6 Circlip 1
7 Inner rotor 2 1
8 Dowel pin 1
9 Oil pump cover 1
10 Outer rotor 1 1
11 Inner rotor 1 1
12 Dowel pin 1
13 Washer 1
14 Oil pump drive shaft 1
15 Rotor housing 1

4-40
OIL PUMP
REMOVING THE OIL TANK
Order Part name Q'ty Remarks
Drain the engine oil.Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
1Oil hose 2 1
2Oil hose 1 1
3 Dowel pin 2
4 Oil tank breather hose 1
5 Oil tank 1
6 Oil strainer 1

4-41
OIL PUMP
CHECKING THE OIL PUMP
1. Inspect:
• Oil pump drive gear "1"
• Oil pump drive shaft "2"
• Rotor housing "3"
• Oil pump cover "4"
Cracks/wear/damage→Replace.
2. Measure:
• Tip clearance "a"
(between the inner rotor "1" and
outer rotor "2")
• Side clearance "b"
(between the outer rotor "2" and
rotor housing "3")
• Housing and rotor clearance "c"
(between the rotor housing "3"
and rotors "1" "2")
Out of specification→Replace the
oil pump assembly.3. Check:
• Unsmooth→Repeat steps #1 and
#2 or replace the defective parts.
INSTALLING THE OIL PUMP
1. Install:
• Oil pump drive shaft "1"
•Washer "2"
• Dowel pin "3"
• Inner rotor 1 "4"
• Apply the engine oil on the oil pump
drive shaft and inner rotor 1.
• Fit the dowel pin into the groove in
the inner rotor 1.
2. Install:
• Outer rotor 1 "1"
Apply the engine oil on the outer rotor
1.
3. Install:
• Oil pump cover "1"
• Screw (oil pump cover) "2"
• Dowel pin "3"
• Inner rotor 2 "4"
•Circlip "5"
• Apply the engine oil on the inner ro-
tor 2.
• Fit the dowel pin into the groove in
the inner rotor 2.
4. Install:
• Outer rotor 2 "1"
• Dowel pin "2"
• Oil pump assembly "3"
• Bolt (oil pump assembly)
[L = 25 mm (0.94 in)] "4"
• Bolt (oil pump assembly)
[L = 30 mm (1.18 in)] "5"
Apply the engine oil on the outer rotor
2.
5. Install:
• Oil pump drive gear "1"
• Washer "2"
• Circlip "3"
Apply the engine oil on the oil pump
drive gear inner circumference.
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 clear-
ance "c":
0.03–0.10 mm (0.0012–
0.0039 in)
: 0.17 mm
(0.0067 in)
Screw (oil pump cover):
1.7 Nm (0.17 m•kg, 1.2
ft•lb)
Bolt (oil pump assem-
bly):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (oil pump assem-
bly):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-42
KICK SHAFT AND SHIFT SHAFT
KICK SHAFT AND SHIFT SHAFT
REMOVING THE KICK SHAFT AND SHIFT SHAFT
Order Part name Q'ty Remarks
Oil pump Refer to "OIL PUMP" section.
1 Kick idle gear 1
2 Kick shaft assembly 1 Refer to removal section.
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
11 Collar 1
12 Torsion spring 1
13 Roller 1
14 Shift guide 1 Refer to removal section.
15 Shift lever assembly 1 Refer to removal section.
16 Shift lever 1