2017 YAMAHA WR 250F clutch

CLUTCH
6-50
EAS2GBB280INSTALLING THE KICKSTARTER LEVER
1. Install:
• Kickstarter lever “1”
• Washer
• Bolt (kickstarter lever)
TIP
Install so that there is a clearance “a” of 5 mm
(0.2 in) or more between the kickstarter lever
and the frame and that the kickstarter lever
does not contact the right crankcase cover
when it is pulled.Bolt (kickstarter lever)
33 Nm (3.3 m·kgf, 24 ft·lbf)
LOCTITE®
T R..
1
a

KICKSTATER
6-51
EAS2GBB281
KICKSTATER
Removing the kick shaft
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 6-42.
1 Kick idle gear 1
2 Kick shaft assembly 1
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
For installation, reverse the removal proce-
dure.

SHIFT SHAFT
6-54
EAS2GBB287
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 6-42.
1 Shift pedal 1
2 Shift shaft 1
3 Oil seal 1
4Collar 1
5 Shift shaft spring 1
6Roller 1
7 Shift guide 1
8 Shift lever assembly 1
9 Shift lever 1
10 Pawl 2
11 Pawl pin 2
12 Spring 2
13 Stopper lever 1
14 Stopper lever spring 1
15 Segment 1
LS
1 3
13
15 14
LT
610 11 12
118
1210
4
25
LT
7
LT
E
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ftT.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
Ibf)
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

OIL PUMP AND BALANCER GEAR
6-59
EAS2GBB298
OIL PUMP AND BALANCER GEAR
Removing the oil pump
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 6-42.
Right crankcase cover Refer to “CLUTCH” on page 6-42.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Oil pump housing 1
For installation, reverse the removal proce-
dure.
2.0 Nm (0.20 m•kgf, 1.4 ftIbf)T.R
.
5 Nm (0.5 mkgf, 3.6 ftIbf)T.R
.
LT
E
3
2
1
4
5
7
6

OIL PUMP AND BALANCER GEAR
6-60
Removing the balancer
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 6-42.
Right crankcase cover Refer to “CLUTCH” on page 6-42.
Generator rotorRefer to “GENERATOR AND STARTER
CLUTCH” on page 6-66.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer weight gear) 1
4 Conical washer 1
5Balancer 1
6 Conical washer 1
7 Primary drive gear 1
8Collar 1
9 Balancer drive gear 1
10 Conical washer 1
11 Balancer weight gear 1
12 Collar 1
13 Balancer weight 1
T
.R.
75 Nm (7.5 mkgf, 54 ftlbf)T.R.
50 Nm (5.0 mkgf, 36 ftIbf)T
.R.
New
6
12
7
8
11T.R.
LT
13

GENERATOR AND STARTER CLUTCH
6-66
EAS2GBB305
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 6-54.
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
6-67
11 Woodruff key 1
12 Starter clutch 1
13 Starter clutch drive gear 1
14 Crankshaft position sensor 1
15 Stator 1
For installation, reverse the removal proce-
dure.
Removing the generator
Order Job/Parts to remove Q’ty Remarks
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
6-68
EAS2GBB306REMOVING THE GENERATOR
1. Remove:
• Generator rotor nut “1”
• Washer
2. Remove:
• Generator rotor “1”
(with the rotor puller “2”)
• Woodruff key
EAS2GBB307CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers
Damage/wear  Replace.
2. Check:
• Starter clutch idle gear
• Starter clutch gear
Burrs/chips/roughness/wear  Replace the
defective part (s).3. Check:
• Starter clutch gear
Damage/pitting/wear  Replace the starter
clutch gear.
4. Check:
• Damper assembly
Damage/pitting/wear  Replace the damp-
er assembly.
Check the gear of the starter motor arma-
ture.
5. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto
the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise “A”, the starter clutch and the
starter clutch drive gear should engage, oth-
erwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear
counterclockwise “B”, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GBB308INSTALLING THE STARTER CLUTCH
1. Install:
• Stator “1”
• Stator bolt “2” Rotor puller
90890-04142
Rotor puller
YM-04142
1
1
2
1 A
B