Yamaha Wr250r 2008 Manual

 
OIL PUMP AND BALANCER GEAR 
5-47 
EAS24940 
REMOVING THE OIL PUMP 
1. Drain: 
 
Engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
2. Remove: 
 
Idle gear “1” 
 
Oil pump assembly“2”
3. Remove: 
 
Balancer weight gear “1” 
 
Balancer drive gear assembly “2” 
EAS24960 
CHECKING THE OIL PUMP 
1. Check: 
 
Oil pump drive gear 
 
Oil pump driven gear 
 
Oil pump housing 
 
Oil pump housing cover
Cracks/damage/wear  
→ 
 Replace the defec-
tive part (s).
2....

 
OIL PUMP AND BALANCER GEAR 
5-48 
2. Install: 
 
Oil pump housing “1” 
 
Relief valve assembly 
 
Driven gear “2” 
 
Dowel pin “3” 
 
Outer rotor “4” 
 
Inner rotor “5” 
 
Oil pump cover
3. Check: 
 
Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-47. 
EAS32D1008 
INSTALLING THE OIL PUMP AND 
BALANCER GEAR 
1. Install: 
 
Oil pump assembly
CAUTION:
 
 ECA13890 
After tightening the bolts, make sure the oil 
pump turns smoothly. 
2. Install: 
 
Drive gear “1” 
 
Buffer boss “2”...

 
OIL PUMP AND BALANCER GEAR 
5-49 
6. Install:
Be sure to bend the lock washer tab along to
the nut side face.
1 2
3
a 

 
GENERATOR AND STARTER CLUTCH 
5-50 
EAS24480 
GENERATOR AND STARTER CLUTCH 
Removing the generator
Order Job/Parts to remove Q 
’ 
ty Remarks  
Drain the engine oilRefer to  
“CHANGING THE ENGINE OIL” 
on page 3-11 
.
SeatRefer to  
“GENERAL CHASSIS” on page 
4-1 
.
Air scoop (left)Refer to  
“GENERAL CHASSIS” on page 
4-1 
.
1Crankshaft position sensor coupler/Stator 
assembly coupler1/1
2 Timing mark accessing screw 1
3 Crankshaft end cover 1
4 Crankcase cover (left) 1
5 Crankcase cover gascket...

 
GENERATOR AND STARTER CLUTCH 
5-51 
14 Bearing 1
15 Starter clutch side plate 1
16 Starter clutch assembly 1
For installation, reverse the removal proce-
dure.  
Removing the generator
Order Job/Parts to remove Q 
’ 
ty Remarks
1
2
3
4 5 678
9
10
11 12 13
1415
16
LT
LT
E
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) 
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..65 Nm (6.5 m • kg, 47 ft • Ib)  

 
GENERATOR AND STARTER CLUTCH 
5-52 
Disassembling the damper assembly
Order Job/Parts to remove Q 
’ 
ty Remarks  
1 Circlip 1
2 Limiter disc 1
3 Starter reduction gear 1
4 Limiter disc 1
5 Outer torque limiter 1
6 Circlip 1
For installation, reverse the removal proce-
dure.
1 2 3 4 5 6
M 

 
GENERATOR AND STARTER CLUTCH 
5-53 
EAS24490 
REMOVING THE GENERATOR 
1. Remove: 
 
Generator rotor nut “1” 
 
Washer
NOTE:
 
 
While holding the generator rotor “3” with the
sheave holder “2”, loosen the generator rotor
nut. 
 
Do not allow the sheave holder to touch the 
projection on the generator rotor.
2. Remove: 
 
Generator rotor “1”
(with the rotor puller “2”) 
 
Woodruff key 
EAS24570 
CHECKING THE STARTER CLUTCH 
1. Check: 
 
Starter clutch rollers
Damage/wear  
→ 
 Replace.2. Check:...

 
GENERATOR AND STARTER CLUTCH 
5-54

 
EAS24600 
INSTALLING THE STARTER CLUTCH 
1. Install: 
 
Starter clutch assembly “1”
Push the starter clutch assembly strongly un-
til bumping. (Turn the projection part “a” to
the interior side.)
2. Install: 
 
Starter clutch side plate “1”
Set the 4 tabs “a” of the starter clutch side
plate to the groove “b” of the generator rotor
“2” securely. 
EAS24500 
INSTALLING THE GENERATOR 
1. Install: 
 
Woodruff key 
 
Generator rotor...

 
GENERATOR AND STARTER CLUTCH 
5-55
1
2 

 
CRANKCASE 
5-56 
EAS25540 
CRANKCASE 
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks  
Engine Refer to“ENGINE REMOVAL” on page 5-1.
Cylinder head Refer to“CYLINDER HEAD” on page 5-14.
CylinderRefer to“CYLINDER AND PISTON” on page 
5-25.
Starter motor Refer to“STARTER MOTOR” on page 5-30.
Clutch Refer to“CLUTCH” on page 5-34.
Balancer drive gearRefer to“OIL PUMP AND BALANCER 
GEAR” on page 5-45.
Shift shaft Refer to“SHIFT SHAFT” on page 5-43.
Oil pump,Balancer gearRefer to“OIL PUMP AND...