2015 YAMAHA WR 250F clutch

HANDLEBAR
5-33
EAS2GB2195
HANDLEBAR
Removing the handlebar
Order Part name Q’ty Remarks
1 Clutch cable 1 Disconnect.
2 Clutch switch 1
3 Clutch lever holder 1
4 Engine stop switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Handlebar upper holder 2
14 Handlebar 1

HANDLEBAR
5-35
EAS2GB2196REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
•Clutch switch “1”
TIP
Press the projection, and remove it from the
clutch lever assembly.
3. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
4. Remove:
• Throttle cable housings “1”
• Throttle grip “2”
TIP
While removing the throttle cable housing, pull
back the rubber cover “3”.
EAS2GB2197CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage  Replace.
EWA
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS2GB2198INSTALLING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Damper “1”
• Lower handlebar holders“2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handlebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that
right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d”
of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA
Upper handlebar holder bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..

HANDLEBAR
5-37
5. Install:
• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and
the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install:
• Right grip “1”
• Collar “2”
Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the
grip match mark “b” and tube guide slot “c”
form the angle as shown.7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:
• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
1b
c
3
T R..

HANDLEBAR
5-38
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
10.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install:
• Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Bolt (brake master cylinder holder) “4”
•Clamp “5”
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install:
• Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-12. Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
2
5
1
4
3
4
1LS

CLUTCH......................................................................................................... 6-40
REMOVING THE CLUTCH ...................................................................... 6-43
CHECKING THE FRICTION PLATES...................................................... 6-43
CHECKING THE CLUTCH PLATES ........................................................ 6-43
CHECKING THE CLUTCH SPRINGS...................................................... 6-43
CHECKING THE CLUTCH HOUSING ..................................................... 6-44
CHECKING THE CLUTCH BOSS ............................................................ 6-44
CHECKING THE PRESSURE PLATE ..................................................... 6-44
CHECKING THE PUSH LEVER SHAFT .................................................. 6-44
CHECKING THE CLUTCH PUSH RODS ................................................ 6-44
CHECKING THE PRIMARY DRIVE GEAR .............................................. 6-44
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 6-45
INSTALLING THE OIL SEAL................................................................... 6-45
INSTALLING THE RIGHT CRANKCASE COVER ................................... 6-45
INSTALLING THE CLUTCH ..................................................................... 6-45
INSTALLING THE KICKSTARTER LEVER ............................................. 6-48
KICKSTATER................................................................................................. 6-49
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 6-50
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-50
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 6-50
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 6-50
INSTALLING THE KICK IDLE GEAR ....................................................... 6-51
SHIFT SHAFT................................................................................................. 6-52
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-53
REMOVING THE SEGMENT ................................................................... 6-53
CHECKING THE SHIFT SHAFT .............................................................. 6-53
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-53
CHECKING THE STOPPER LEVER ....................................................... 6-53
INSTALLING THE STOPPER LEVER ..................................................... 6-54
INSTALLING THE SEGMENT.................................................................. 6-54
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 6-54
INSTALLING THE SHIFT SHAFT ............................................................ 6-55
INSTALLING THE SHIFT PEDAL ............................................................ 6-55
OIL PUMP AND BALANCER GEAR............................................................. 6-56
REMOVING THE BALANCER ................................................................. 6-58
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT DRIVE
GEAR, AND BALANCER WEIGHT GEAR .............................................. 6-58
CHECKING THE BALANCER .................................................................. 6-58
CHECKING THE OIL PUMP .................................................................... 6-58
ASSEMBLING THE OIL PUMP ................................................................ 6-59
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 6-59

GENERATOR AND STARTER CLUTCH....................................................... 6-62
REMOVING THE GENERATOR .............................................................. 6-64
CHECKING THE STARTER CLUTCH ..................................................... 6-64
INSTALLING THE STARTER CLUTCH ................................................... 6-65
INSTALLING THE GENERATOR............................................................. 6-65
CRANKCASE................................................................................................. 6-68
DISASSEMBLING THE CRANKCASE..................................................... 6-71
REMOVING THE CRANKCASE BEARING ............................................. 6-71
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE,
OIL STRAINER ........................................................................................ 6-71
CHECKING THE CRANKCASE ............................................................... 6-71
INSTALLING THE OIL SEAL................................................................... 6-72
ASSEMBLING THE CRANKCASE........................................................... 6-72
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT............................... 6-73
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 6-74
CHECKING THE CRANKSHAFT ASSEMBLY......................................... 6-74
INSTALLING THE CRANKSHAFT ASSEMBLY....................................... 6-75
INSTALLING THE BALANCER SHAFT ................................................... 6-75
TRANSMISSION............................................................................................. 6-76
REMOVING THE TRANSMISSION ......................................................... 6-77
CHECKING THE SHIFT FORKS.............................................................. 6-77
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 6-78
CHECKING THE TRANSMISSION .......................................................... 6-78
INSTALLING THE TRANSMISSION ........................................................ 6-78

ENGINE REMOVAL
6-4
Removing the engine
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 6-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
Throttle body Refer to “THROTTLE BODY” on page 8-7.
Clutch cable Refer to “CLUTCH” on page 6-40.
Shift pedal Refer to “SHIFT SHAFT” on page 6-52.
Starter motor 1Refer to “ELECTRIC STARTER” on page 6-
35.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
New
New
LS
M
8
8
7
6
13
45
New
1 12
3
2
1110
9
55 Nm (5.5 m kgf, 40 ft Ibf)T.R.

CLUTCH
6-40
EAS2GB2267
CLUTCH
Removing the clutch
Order Part name Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3Gasket 1
4 Clutch spring 5
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Friction plate 1 4
13 Clutch plate 8
New
New
New
2
3 45
(5)
(6)78961011
12
22
1
15
12
13
13
18
1920 17
16
14
13
T.R.
T.R.
T.R.
T.R.
LT
21