2017 YAMAHA WR 250F wheel

KICKSTATER
6-52
EAS2GBB282REMOVING THE KICK SHAFT ASSEMBLY
1. Remove:
• Kick shaft assembly “1”
TIP
Unhook the torsion spring “2” from the hole “a”
in the crankcase.
EAS2GBB283CHECKING THE KICK SHAFT AND RATCH-
ET WHEEL
1. Check:
• Ratchet wheel “1” smooth movement
Unsmooth movement  Replace.
• Kick shaft “2”
Wear/damage  Replace the kick shaft as-
sembly.
• Spring “3”
Broken  Replace.
EAS2GBB284CHECKING THE KICK GEAR, KICK IDLE
GEAR AND RATCHET WHEEL
1. Check:
• Kick gear “1”
Wear/damage  Replace the kick shaft as-
sembly.
• Kick idle gear “2”
• Ratchet wheel “3”
• Gear teeth “a”
• Ratchet teeth “b”
Wear/damage  Replace.
EAS2GBB285INSTALLING THE KICK SHAFT ASSEMBLY
1. Install:
• Kick gear “1”
• Washer “2”
• Circlip “3”
• Ratchet wheel “4”
• Spring “5”
• Washer “6”
• Circlip “7”
(to the kick shaft “8”)
TIP
• Apply molybdenum disulfide oil to the inner
circumferences of the kick gear and ratchet
wheel.
• Align the punch mark “a” on the ratchet wheel
with the punch mark “b” on the kick shaft.
2. Install:
• Torsion spring “1”
(to the kick shaft “2”)
TIP
Make sure the stopper “a” of the torsion spring
fits into the hole “b” on the kick shaft.
31
2
a
b
3
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KICKSTATER
6-53
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.
EAS2GBB286INSTALLING 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
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TRANSMISSION
6-83
EAS2GBB326CHECKING 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).EAS2GBB327INSTALLING 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.
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 the collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the
O-ring. 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
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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.
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 shift fork 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.
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ELECTRICAL COMPONENTS
9-77
c. Start the engine and let it run at approxi-
mately 5000 r/min.
d. Measure the charging voltage.
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EAS2GBB395CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
Out of specification  Replace.
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a. Connect the test harness-speed sensor (3P)
to the speed sensor coupler and wire har-
ness.
b. Connect the pocket tester (DC20V) to the
test harness-speed sensor (3P).c. Push the start switch.
d. Elevate the front wheel and slowly turn it.
e. Measure the voltage (DC 5 V) of white and
black/white. With the front wheel slowly ro-
tating, voltage alternates between 0 V and 5
V.
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EAS2GBB396CHECKING THE FUEL SENDER
1. Drain the gasoline.
2. Disconnect:
• Fuel sender coupler
(from the fuel sender)
3. Remove:
• Fuel sender
(from the fuel tank)
4. Check:
• Fuel sender resistance
Out of specification  Replace the fuel
sender.
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a. Connect the pocket tester ( 1k) to the
fuel sender as shown.
b. Measure the resistance of the fuel sender.
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Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Test harness– speed sensor 5TJ
(3P)
90890-03228
Test harness– speed sensor 5TJ
(3P)
YU-03228
• Positive tester probe 
White “1”
• Negative tester probe 
Black “2”
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BRW
21
Sender unit resistance (thermis-
tor)
1350–1900 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe 
Green “1”
• Negative tester probe 
Black “2”
1
2

TROUBLESHOOTING
10-4
7. Wheel (s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
EAS2GBB421HEADLIGHT DOES NOT COME ON
Electrical system
1. Headlight
• Fuse open circuit
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (start switch)
• Burnt-out headlight bulb
EAS2GBB422HEADLIGHT BULB BURNT OUT
Electrical system
1. Headlight
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty start switch
• Headlight bulb life expired
EAS2GBB423TAILLIGHT DOES NOT COME ON
Electrical system
1. Taillight
• Wrong taillight LED
• Too many electrical accessories
• Incorrect connection
• Faulty battery

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
10-6
SENSOR OPERATION TABLE
Diag-
nostic
code
No.Item Display Procedure
01 Throttle position sensor sig-
nal
• Fully closed position
• Fully opened position• 11–14
• 109–116• Check with throttle valve
fully closed.
• Check with throttle valve
fully open.
03 Intake air pressure Displays the intake air pres-
sure.Operate the throttle while
pushing the start switch. (If
the display value changes,
the performance is OK.)
05 Intake air temperature Displays the intake air tem-
perature.Compare the actually mea-
sured intake air tempera-
ture with the Yamaha
diagnostic tool display val-
ue.
06 Coolant temperature When engine is cold: Dis-
plays temperature closer to
air temperature.
When engine is hot: Displays
current coolant temperature.Compare the actually mea-
sured coolant temperature
with the Yamaha diagnostic
tool display value.
07 Vehicle speed pulses Vehicle speed pulse
0–999Check that the number in-
creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle sensor
• Upright
• OverturnedDisplays the output voltage.
• 0.4–1.4
• 3.7–4.4Remove the lean angle
sensor, and incline it more
than 45 degrees.
09 Monitor voltage Displays the fuel system volt-
age.
• Approximately 12.0 (V)—
21 Neutral switch
• Gear in neutral
• Gear not in neutral•ON
•OFFOperate the shift pedal.
60 EEPROM fault code display
• No fault
• CO adjustment value
• Setting tool adjustment
values 0–8 for fuel injec-
tion amount or ignition tim-
ing•00
•01
•07—
61 Malfunction history ( )
code display *1
• There is no history.
• There is some history.•00
• Other: Displays the fault
code of ( ).—