2016 YAMAHA WR 250F Owners Manual

TRANSMISSION
6-76
EAS2GB7322
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Part name Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 6-1.
CrankcaseSeparate.
Refer to “CRANKCASE” on page 6-68.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collar 1
For installation, reverse the removal proce-
dure.
2
10
1
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TRANSMISSION
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EAS2GB7323REMOVING THE TRANSMISSION
1. Remove:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed
to the crankcase.
• Make a note of the position of each part. Pay
particular attention to the location and direc-
tion of shift forks.
• Remove the main axle and the drive axle all
together by tapping the drive axle lightly with
a soft hammer.
EAS2GB7324CHECKING THE SHIFT FORKS
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear  Replace the
shift fork.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
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TRANSMISSION
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EAS2GB7325CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• Shift drum groove
Damage/scratches/wear  Replace the
shift drum assembly.
• Shift drum segment “1”
Damage/wear  Replace the shift drum as-
sembly.
EAS2GB7326CHECKING THE TRANSMISSION
1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”)
Out of specification  Replace the main ax-
le.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification  Replace the drive ax-
le.3. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace
the defective gear (s).
• Transmission gear dogs
Cracks/damage/rounded edges  Replace
the defective gear (s).
4. Check:
• Transmission gear movement
Rough movement  Replace the defective
gear (s).
EAS2GB7327INSTALLING THE TRANSMISSION
1. Install:
• 6th pinion gear (27T) “1”
• 3rd/4th pinion gear (18T/21T) “2”
• Collar “3”
• 5th pinion gear (23T) “4”
• 2nd pinion gear (16T) “5”
(to the main axle “6”)
TIP
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install. Main axle runout limit
0.08 mm (0.0032 in)
Drive axle runout limit
0.08 mm (0.0032 in)
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TRANSMISSION
6-79
2. Install:
• 2nd wheel gear (29T) “1”
• 5th wheel gear (22T) “2”
• 3rd wheel gear (26T) “3”
• 4th wheel gear (24T) “4”
• 6th wheel gear (22T) “5”
• Collar “6”
• 1st wheel gear (31T) “7”
• O-ring “8”
(to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-
fide oil to the inner and end surface of the idler
gear and to the inner surface of the sliding
gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install:
• Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests.4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5. Install:
• Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
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TRANSMISSION
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6. Install:
• Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift cam “4”
(to the main axle and the drive axle)
TIP
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 5th wheel
gear “5” and “3” (R) with the 6th wheel gear “7”
on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd/4th pin-
ion gear “6” on the main axle.7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar
lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.
8. Check:
• Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.
3
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6
2
4
5
3
7
1
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TRANSMISSION
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7
COOLING SYSTEM
RADIATOR....................................................................................................... 7-1
HANDLING NOTE ...................................................................................... 7-3
CHECKING THE RADIATOR ..................................................................... 7-3
WATER PUMP.................................................................................................. 7-4
REMOVING THE OIL SEAL ....................................................................... 7-6
CHECKING THE WATER PUMP ............................................................... 7-6
CHECKING THE BEARING....................................................................... 7-6
INSTALLING THE OIL SEAL..................................................................... 7-6
ASSEMBLING THE WATER PUMP........................................................... 7-6

RADIATOR
7-1
EAS2GB7328
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS2GB7329
RADIATOR
Removing the radiator
Order Part name Q’ty Remarks
CoolantDrain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
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.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Radiator fan 1
12
13
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3
458 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
6
7
89
10
112
2
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2 22 2
1 1