2017 YAMAHA WR 250F clutch

CLUTCH
6-42
EAS2GBB265
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
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(6)78961011
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CLUTCH
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14 Cushion spring 1
15 Friction plate 2 5 Identification color (purple)
16 Clutch boss 1
17 Thrust washer 1
18 Primary driven gear 1
19 Spacer 1
20 Bearing 1
21 Washer 1
22 Push lever shaft 1
For installation, reverse the removal proce-
dure.
Removing the clutch
Order Part name Q’ty Remarks
New
New
New
2
3 45
(5)
(6)78961011
12
22
1
15
12
13
13
18
1920 17
16
14
13
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T.R.
T.R.
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LT
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72

CLUTCH
6-44
Removing the right crankcase cover
Order Part name Q’ty Remarks
Engine guard Refer to “ENGINE REMOVAL” on page 6-1.
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
CoolantDrain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
Clutch cover Refer to “CLUTCH” on page 6-42.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Kickstarter lever 1
5 Right crankcase cover 1
6 Gaskets 1
7 Dowel pin 2
8Collar 1
For installation, reverse the removal proce-
dure.
T.R.
LS
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7 8
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LS

CLUTCH
6-45
EAS2GBB266REMOVING THE CLUTCH
1. Remove:
• Clutch boss nut “1”
• Lock washer “2”
• Clutch boss “3”
TIP
• Straighten the lock washer tab.
• While holding the clutch boss with the clutch
holder “4”, loosen the clutch boss nut.
EAS2GBB267CHECKING THE FRICTION PLATES
1. Check:
• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
EAS2GBB268CHECKING THE CLUTCH PLATES
1. Check:
• Clutch plate
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge
“1”)
Out of specification  Replace the clutch
plates as a set.
EAS2GBB269CHECKING THE CLUTCH SPRINGS
1. Check:
• Clutch spring
Damage  Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
Out of specification  Replace the clutch
springs as a set. Universal clutch holder
90890-04086
Universal clutch holder
YM-91042
Friction plate thickness
2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.85 mm (0.112 in)
34
12
Warpage limit
0.10 mm (0.004 in)
Clutch spring free length
47.80 mm (1.88 in)
Limit
45.41 mm (1.79 in)

CLUTCH
6-46
EAS2GBB270CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dogs “a”
Damage/pitting/wear  Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
EAS2GBB271CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear  Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS2GBB272CHECKING THE PRESSURE PLATE
1. Check:
• Pressure plate
Crack/damage  Replace.
EAS2GBB273CHECKING THE PUSH LEVER SHAFT
1. Check:
• Push lever shaft
Wear/damage  Replace.
EAS2GBB274CHECKING THE CLUTCH PUSH RODS
1. Check:
• Push rod 1 “1”
• Bearing “2”
• Washer “3”
• Push rod 2 “4”
•Ball “5”
Cracks/damage/wear  Replace.
2. Measure:
• Push rod 2 bending limit
Out of specification  Replace.
EAS2GBB275CHECKING THE PRIMARY DRIVE GEAR
1. Check:
• Primary drive gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
2. Check:
• Primary-drive-gear-to-primary-driven-gear
free play
Free play exists  Replace the primary
drive and primary driven gears as a set.
a
Push rod bending limit
0.30 mm (0.012 in)

CLUTCH
6-47
EAS2GBB276CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• Primary driven gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
EAS2GBB277INSTALLING THE OIL SEAL
1. Install:
• Oil seal “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
EAS2GBB278INSTALLING THE RIGHT CRANKCASE
COVER
1. Install:
• Dowel pin “1”
• O-ring “2”
• Collar “3”
• Gasket “4”
TIP
Apply the lithium-soap-based grease on the O-
ring.2. Install:
• Right crankcase cover “1”
• Right crankcase cover bolt “2”
TIP
• Apply the engine oil on the impeller shaft end.
• Mesh the impeller shaft gear “3” with primary
drive gear “4”.
• Tighten the right crankcase cover bolts in
stages and in a crisscross pattern.
EAS2GBB279INSTALLING THE CLUTCH
1. Install:
• Push lever shaft “1”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
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Right crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
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2

CLUTCH
6-48
2. Install:
• Washer “1”
• Bearing “2”
• Collar “3”
• Primary driven gear “4”
• Thrust washer “5”
• Clutch boss “6”
TIP
Apply the engine oil on the primary driven gear
inner circumference.
3. Install:
• Lock washer “1”
• Clutch boss nut “2”
ECA
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
TIP
• Apply the engine oil to the threads and con-
tact surface of the clutch boss nut.
• Use the clutch holding tool “3” to hold the
clutch boss.4. Bend the lock washer “1” tab.
5. Install:
• Friction plate 1 “1”
• Clutch plate “2”
• Cushion spring “3”
• Friction plate 2 “4”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• Install the cushion spring “3” in the position as
shown.
• From the clutch boss side, install the friction
plates in order: friction plate 1  2, friction
plate 2 (identification color: purple)  5, and
friction plate 1  2.
• Apply the engine oil on the friction plates and
clutch plates. Clutch boss nut
100 Nm (10 m·kgf, 72 ft·lbf)
Universal clutch holder
90890-04086
Universal clutch holder
YM-91042
1
New
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a. Identification color
3
21
1
1
2
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a

CLUTCH
6-49
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.
New
Clutch 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)
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