2016 YAMAHA WR 250F engine

CLUTCH
6-47
6. Install:
• Bearing “1”
• Washer “2”
• Circlip “3”
To push rod 1 “4”.
TIP
Apply the engine oil on the bearing and washer.
7. Install:
• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
8. Install:
• Pressure plate “1”9. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
10.Install:
• Gasket “1”
11.Install:
• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
NewClutch spring bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
1
2 3
45
New
T R..
1

KICKSTATER
6-51
3. Install:
• Spring guide “1”
TIP
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:
• Kick shaft assembly “1”
TIP
• Before installation, apply molybdenum disul-
fide grease to the contacting surfaces of the
kick shaft ratchet wheel guide “2” and the kick
shaft stopper “a”.
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crank-
case and make sure the kick shaft stopper “a”
fits into the kick shaft ratchet wheel guide.5. Install:
• Torsion spring “1”
TIP
Turn the torsion spring clockwise and hook into
the proper hole “a” in the crankcase.
EAS2GB7286INSTALLING THE KICK IDLE GEAR
1. Install:
• Kick idle gear “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the engine oil on the kick idle gear inner
circumference.
• Install the kick idle gear with its depressed
side “a” toward you.
1 2a b
New

SHIFT SHAFT
6-54
EAS2GB7293INSTALLING THE STOPPER LEVER
1. Install:
• Torsion spring “1”
• Collar “2”
• Stopper lever “3”
• Bolt (stopper lever) “4”
EAS2GB7294INSTALLING THE SEGMENT
1. Install:
• Segment “1”
• Segment bolt
TIP
• Align the notch “a” on the segment with the
pin “b” on the shift cam.
• With the stopper lever pushed down, install
the segment.
ECA
NOTICE
If the segment gets an impact, the stopper
lever may be damaged. Take care not to
give an impact to it when tightening the bolt.
EAS2GB7295INSTALLING THE SHIFT GUIDE AND SHIFT
LEVER ASSEMBLY
1. Install:
• Spring “1”
• Pawl pin “2”
•Pawl “3”
(to the shift lever “4”)
TIP
Apply the engine oil on the spring, pawl pin and
pawl.
2. Install:
• Shift lever assembly “1”
(to the shift guide “2”)
3. Install:
• Shift lever assembly “1”
• Shift guide “2”
TIP
• The shift lever assembly is installed at the
same time as the shift guide.
• Apply the engine oil on the segment bolt shaft. Bolt (stopper lever)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Segment bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T R..
2 1
3
4
LT
T R..1
2
1 2

SHIFT SHAFT
6-55
4. Tighten:
• Shift guide bolt “1”
EAS2GB7296INSTALLING THE SHIFT SHAFT
1. Install:
• Roller “1”
• Shift haft spring “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller, collar and
shift shaft.
2. Install:
• Oil seal
EAS2GB7297INSTALLING THE SHIFT PEDAL
1. Install:
• Shift pedal “1”
• Shift pedal bolt “2”
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.Shift guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Shift pedal bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T R..
1 1
LT
E
E
1
23
4
New
T R..
a
12b

OIL PUMP AND BALANCER GEAR
6-59
3. Check:
• Oil pump operation
Rough movement  Repeat steps (1) and
(2) or replace the defective part(s).
EAS2GB7303
ASSEMBLING THE OIL PUMP
1. Install:
• Oil pump drive shaft “1”
• Inner rotor “2”
• Dowel pin “3”
TIP
• Apply the engine oil on the oil pump drive
shaft and inner rotor.
• Fit the dowel pin into the groove in the inner
rotor.
2. Install:
• Outer rotor “1”
TIP
Apply the engine oil on the outer rotor.
3. Install:
• Oil pump cover “1”
• Oil pump cover screw “2” Inner-rotor-to-outer-rotor-tip
clearance
Less than
0.150 mm (0.0059 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit
0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-
outer-rotor
clearance
0.06–0.11 mm (0.0024–0.0043 in)
Limit
0.17 mm (0.0067 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
b
a 1
2
3
c
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
21
3
1
E
T R..
2
1

OIL PUMP AND BALANCER GEAR
6-60
EAS2GB7304INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:
• Collar “1”
• Balancer weight gear “2”
TIP
Install the balancer weight gear and balancer
shaft with their lower splines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
• Collar “2”
TIP
• Align the punched mark “a” on the balancer
drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other.4. Install:
• Conical washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
•Balancer “6”
• Conical washer “7”
• Balancer nut “8”
TIP
• Apply engine oil to the contact surface and
threaded portion of the primary drive gear nut.
• Place an aluminum plate “a” between the
teeth of the balancer drive gear “9” and bal-
ancer weight gear “10”.
• Install the conical washer with its convex sur-
face “b” outward.
• Align the balancer flat portion “c” with the flat
portion “d”.
• Apply the engine oil to the contact surface and
threaded portion of the balancer nut. Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
T R..
1
2
LT
21
Balancer weight gear nut
50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Balancer nut
38 Nm (3.8 m·kgf, 27 ft·lbf)
1
2
New
T R..
New
T R..
New
T R..

GENERATOR AND STARTER CLUTCH
6-62
EAS2GB7305
GENERATOR AND STARTER CLUTCH
Removing the generator
Order Job/Parts to remove Q’ty Remarks
Drain the engine oil.Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Seat and fuel tankRefer to “GENERAL CHASSIS” on page 5-1
and “FUEL TANK” on page 8-1.
Disconnect the AC magneto lead.
Clutch cable
Shift pedal Refer to “SHIFT SHAFT” on page 6-52.
1 Cover (Damper assembly) 1
2 Damper assembly 1
3 Breather hose 1
4 Left crankcase cover 1
5Gasket 1
6 Dowel pin 2
7 Starter idle gear 1
8 Bearing 1
9 Starter idle gear shaft 1
10 Generator rotor 1
T R..
T R..
6
611
9
8
7
2
3
1
14
4 5
12
10
13
T R..
T R..
T R..LTT R..
T R..
15

GENERATOR AND STARTER CLUTCH
6-65
EAS2GB7308INSTALLING THE STARTER CLUTCH
1. Install:
• Stator “1”
• Stator bolt “2”
• Crankshaft position sensor “3”
• Holder “4”
• Crankshaft position sensor bolt “5”
TIP
• Pass the AC magneto lead “6” and crankshaft
position sensor lead “7” under the holder as
shown.
• Tighten the stator bolt using the T25 bit.
• Apply the sealant to the grommet of the AC
magneto lead.
2. Install
• Starter clutch drive gear “1”
TIP
Apply the engine oil on the starter clutch drive
gear inner circumference.3. Install:
• Starter clutch “1”
To generator rotor “2”.
EAS2GB7309INSTALLING THE GENERATOR
1. Install:
• Woodruff key “1”
• Generator rotor “2”
TIP
• Clean the contact surfaces of the tapered por-
tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure
that its flat surface “a” is in parallel with the
crankshaft center line “b”.
• When installing the generator rotor, align the
keyway “c” of the generator rotor with the
woodruff key. Stator bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
Crankshaft position sensor bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
T R..
T R..
6
7
1
3
22
5
5
4LT
Starter clutch bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
LOCTITE®
21
LT
T R..
2 C1 1
1a b