2012 YAMAHA YZ250F oil

4-44
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)

4-45
OIL PUMP
IINSTALLING THE OIL TANK
BREATHER HOSE
1. Install:
• Oil tank "1"
• Oil tank breather hose "2"
• Clamp "3"
Install the clamp so that it does not
contact the oil tank.
• Insert the oil tank breather hose so
that its end "a" comes where the oil
tank pipe begins to bend.
• Install the clamp 3 mm (0.12 in)
away from the oil tank breather
hose end "a".
Clamp:
2 Nm (0.2 m•kg, 1.4
ft•lb)

4-46
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

4-49
KICK SHAFT AND SHIFT SHAFT
INSTALLING THE STOPPER
LEVER
1. Install:
• Torsion spring "1"
• Stopper lever "2"
• Bolt (stopper lever) "3"
Align the stopper lever roller with the
slot on segment.
INSTALLING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Install:
• Spring "1"
• Pawl pin "2"
•Pawl "3"
To shift lever "4".
Apply the engine oil on the spring,
pawl pin and pawl.
2. Install:
• Shift lever assembly "1"
To shift guide "2".
3. Install:
• Shift lever assembly "1"
• Shift guide "2"
• The shift lever assembly is installed
at the same time as the shift guide.
• Apply the engine oil on the bolt
(segment) shaft.
4. Install:
• Bolt (shift guide) "1"
INSTALLING THE SHIFT SHAFT
1. Install:
• Roller "1"
• Collar "2"
• Torsion spring "3"
• Shift shaft "4"
Apply the engine oil on the roller and
shift shaft.
2. Install:
• Shift pedal "1"
• Bolt (shift pedal) "2"
Install with the punch mark "a" on the
shift pedal in alignment with the
punch mark "b" on the shift shaft.
INSTALLING THE KICK SHAFT
ASSEMBLY
1. Install:
• Kick gear "1"
• Washer "2"
• Circlip "3"
• Ratchet wheel "4"
• Spring "5"
• Washer "6"
• Circlip "7"
To kick shaft "8".
• Apply the molybdenum disulfide oil
on the inner circumferences of the
kick gear and ratchet wheel.
• Align the punch mark "a" on the
ratchet wheel with the punch mark
"b" on the kick shaft.
2. Install:
• Torsion spring "1"
To kick shaft "2".
Make sure the stopper "a" of the tor-
sion spring fits into the hole "b" on the
kick shaft.
3. Install:
• Spring guide "1"
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.
Bolt (stopper lever):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (shift guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (shift pedal):
12 Nm (1.2 m•kg, 8.7
ft•lb)

4-50
KICK SHAFT AND SHIFT SHAFT
4. Install:
• Kick shaft assembly "1"
• Washer "2"
• Apply the molybdenum disulfide
grease on the contacting surfaces
of the kick shaft stopper "a" and kick
shaft ratchet wheel guide "3".
• Apply the engine oil on the kick
shaft.
• Slide the kick shaft assembly into
the crankcase and make sure the
kick shaft stopper "a" fits into the
kick shaft ratchet wheel guide.
5. Hook:
• Torsion spring "1"
Turn the torsion spring clockwise and
hook into the proper hole "a" in the
crankcase.
INSTALLING THE KICK IDLE
GEAR
1. Install:
• Kick idle gear "1"
• Washer "2"
• Circlip "3"
• Apply the engine oil on the kick idle
gear inner circumference.
• Install the kick idle gear with its de-
pressed side "a" toward you.

4-53
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ENGINE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the frame.Refer to "HANDLING NOTE".
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Carburetor Refer to "CARBURETOR" section.
Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER"
section.
Clutch cable Disconnect at the engine side.
Radiator Refer to "RADIATOR" section.
Shift pedalRefer to "KICK SHAFT AND SHIFT SHAFT"
section.
Cylinder head breather hose Refer to "CAMSHAFTS" section.
Drain the engine oil.Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Oil hose and oil tank breather hose Refer to "OIL PUMP" section.
Ignition coil
Disconnect the CDI magneto lead.
1 Lower engine guard 1

4-57
CRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
REMOVING THE CRANKSHAFT
Order Part name Q'ty Remarks
Engine Refer to "ENGINE REMOVAL" section.
Piston Refer to "CYLINDER AND PISTON" section.
Kick shaft assemblyRefer to "KICK SHAFT AND SHIFT SHAFT"
section.
SegmentRefer to "KICK SHAFT AND SHIFT SHAFT"
section.
Stator Refer to "CDI MAGNETO" section.
Balancer shaft Refer to "BALANCER" section.
1 Timing chain guide (intake side) 1
2 Timing chain 1
3 Oil delivery pipe 2 1
4 Bolt [L = 45 mm (1.77 in)] 6 Refer to removal section.
5 Bolt [L = 55 mm (2.17 in)] 1 Refer to removal section.
6 Bolt [L = 70 mm (2.76 in)] 4 Refer to removal section.
7 Hose guide 1 Refer to removal section.
8 Clutch cable holder 1 Refer to removal section.
9 Right crankcase 1 Refer to removal section.

4-58
CRANKCASE AND CRANKSHAFT
10 Left crankcase 1 Refer to removal section.
11 Oil strainer 1
12 Crankshaft 1 Refer to removal section. Order Part name Q'ty Remarks