Yamaha Wr250r 2008 Manual

 
CLUTCH 
5-37 
Removing the push lever shaft
Order Job/Parts to remove Q’ty Remarks  
Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-1.
Clutch Refer to “CLUTCH” on page 5-34.
1 Clutch cable 1
2 Clutch cable holder 1
3 Push lever shaft 1
4 Push lever spring 1
5 Oil seal 1
6 Bearing 1
For installation, reverse the removal proce-
dure.
1
2 3
4
5
6
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)  

 
CLUTCH 
5-38 
EAS25070 
REMOVING THE CLUTCH 
You need not drain the coolant and engine oil if
you do not service the primary drive gear.
You can reach the clutch housing removal step
by simply removing the cover and clutch cover.
1. Straighten the lock washer tab.
2. Loosen: 
 
Clutch boss nut “1”
NOTE:
 
While holding the clutch boss “3” with the univer- 
sal clutch holder “2”, loosen the clutch boss nut.
3. Straighten the lock washer tab.
4. Remove: 
 
Primary drive gear nut “1” 
 
Lock washer...

 
CLUTCH 
5-39 
EAS25140 
CHECKING THE CLUTCH SPRINGS 
The following procedure applies to all of 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. 
EAS25150 
CHECKING THE CLUTCH HOUSING 
1. Check: 
 
Clutch housing dogs “a”
Damage/pitting/wear  
→ 
 Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
 
Pitting on the clutch housing dogs...

 
CLUTCH 
5-40 
EAS25200 
CHECKING 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  
→ 
 Replace
the primary drive and primary driven gears as
a set. 
EAS25210 
CHECKING 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  
→ 
 Replace
the primary drive and primary...

 
CLUTCH 
5-41 
7. Install: 
 
Friction plates 
 
Clutch plates
NOTE:
 
First, install a friction plate and then alternate be- 
tween a clutch plate and a friction plate.
8. Install: 
 
Push plate 
 
Push rod 
(onto the clutch pressure plate.)
9. Install: 
 
Push rod 
 
Ball 
 
Pressure plate 
 
Clutch spring
10.Tighten: 
 
Push rod 
 
Clutch spring
NOTE:
 
Tighten the clutch spring bolts in two stages and 
in a crisscross pattern.
11.Check: 
 
Push lever position
Push lever mark “a” and...

 
CLUTCH 
5-42 
14.Install: 
 
Oil cleaner element
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
15.Install: 
 
Water pump housing cover
Refer to “WATER PUMP” on page 6-6.
16.Fill: 
 
Crankcase
(with the specified amount of the engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
17.Fill: 
 
Cooling system
(with the specified amount of the the coolant)
Refer to “CHANGING THE COOLANT” on
page 3-18.
18.Install: 
 
Brake spring
5
34
12
3
New
New 

 
SHIFT SHAFT 
5-43 
EAS25410 
SHIFT SHAFT 
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks  
Shift pedal Refer to “ENGINE REMOVAL” on page 5-1.
Clutch housing Refer to “CLUTCH” on page 5-34.
1 Shift shaft 1
2 Plate washer 1
3 Stopper lever spring 1
4 Circlip 1
5 Plate washer 1
6 Stopper lever 1
7 Spacer 1
8 Shift shaft spring 1
9 Stopper screw 1
For installation, reverse the removal proce-
dure.
12
3
4
5
6
7 8
E
E
E
9
LT
T R..22 Nm (2.2 m • kg, 16 ft • Ib)  

 
SHIFT SHAFT 
5-44 
EAS25420 
CHECKING THE SHIFT SHAFT 
1. Check: 
 
Shift shaft 
 
Shift lever
Bends/damage/wear  
→ 
 Replace. 
 
Shift lever spring
Damage/wear  
→ 
 Replace. 
EAS25430 
CHECKING THE STOPPER LEVER 
1. Check: 
 
Stopper lever
Bends/damage  
→ 
 Replace.
Roller turns roughly  
→ 
 Replace the stopper
lever. 
EAS25450 
INSTALLING THE SHIFT SHAFT 
1. Install: 
 
Shift shaft “1” 
 
Shift shaft spring “2” 
 
Stopper lever “3” 
 
Stopper lever spring
NOTE:
 
 
Hook the ends “4” of...

 
OIL PUMP AND BALANCER GEAR 
5-45 
EAS24911 
OIL PUMP AND BALANCER GEAR  
Removing the oil pump
Order Job/Parts to remove Q’ty Remarks  
Clutch/Primary drive gear Refer to“CLUTCH” on page 5-34.
Shift shaft Refer to“SHIFT SHAFT” on page 5-43.
1 Balancer weight gear nut 1
2 Lock washer 1
3 Balancer weight gear 1
4 Straight key 1
5 Absorber plate 1
6 Balancer drive gear 1
7 Straight key 1
8 Circlip 1
9 Plain washer 2
10 Idle gear 1
11 Gasket 1
12 Oil pump assembly 1
13 Dowel pin 2
For installation, reverse...

 
OIL PUMP AND BALANCER GEAR 
5-46 
Disassembling the oil pump 
Order Job/Parts to remove Q’ty Remarks  
1 Pump cover 1
2 Outer rotor 1
3 Inner rotor 1
4 Dowel pin 1
5 Plain washer 1
6 Driven gear 1
7 Circlip 1
8 Relief valve assembly 1
9 Oil pump housing 1
For installation, reverse the removal proce-
dure.
1
2
3
4
5
6
78 9
E
T R..2 Nm (0.2 m • kg, 1.4 ft • Ib)