Yamaha Wr250r 2008 Manual
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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. Measure: Inner-rotor-to-outer-rotor-tip clearance “a” Outer-rotor-to-oil-pump-housing clearance “b” Oil-pump-housing-to-inner-rotor-and-out- er-rotor clearance “c” Out of specification → Replace the oil pump.3. Check: Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part (s). EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: Inner rotor Outer rotor Oil pump shaft (with the recommended lubricant) 2 1 21 Inner-rotor-to-outer-rotor-tip clearance Less than 0.120 mm (0.0047 in) Outer-rotor-to-oil-pump-housing clearance 0.090 – 0.160 mm (0.0004 – 0.0013 in) Limit 0.230 mm (0.0091 in) Oil-pump-housing-to-inner-ro- tor-and-outer-rotor clearance 0.030 – 0.100 mm (0.0012 – 0.0039 in) Limit 0.170 mm (0.0067 in) 1. Inner rotor 2. Outer rotor 3. Oil pump housing
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” Dowel pin “3” Spring “4” (to driven gear) NOTE: Align mark “a” of the drive gear with slot “b” of the buffer boss. Install the dowel pin on the spring as shown.3. Install: Drive gear “1” Balancer weight gear “2” Lock washer “3” Balancer weight gear nut “4” NOTE: Align mark “a” of the drive gear with mark “b” of the balancer shaft weight gear during assem- bling. 4. Tighten: Primary drive gear nut Refer to “CLUTCH” on page 5-34. 5. Tighten: Balancer weight gear nut “1” NOTE: Insert aluminum plate “a” between drive gear “2” and balancer weight gear “3”, and tighten the pri- mary drive gear nut. Recommended lubricant Engine oil Oil pump cover screw 2 Nm (0.2 m•kg, 1.4 ft•lb) Oil pump bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) TR.. 1 23 4 5 TR.. Blancer weight gear nut 50 Nm (5.0 m•kg, 36 ft•lb) 1 2 3 4 4 4 4 3 a b 3 3 New 2 b a1 3 4 TR..
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 (left) 1 6 Dowel pin 1 7 Stator assembly 1 8 Damper assembly 1 9 Starter idle gear shaft 1 10 Starter idle gear 1 11 Generator rotor 1 12 Woodruff key 1 13 Starter clutch gear 1 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 5-51 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: 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 damper assembly. Check the gear of the starter motor armature. 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 start- er clutch drive gear should engage, other- wise 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. Sheave holder 90890-01701 Primary clutch holder YS-01880-A Rotor puller 90890-04142 YM-04142 1 2 3 2 1
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 Washer Generator rotor bolt NOTE: Clean the tapered portion of the crankshaft and the generator rotor hub. When installing the generator rotor, make sure the woodruff key is properly sealed in the key- way of the crankshaft. 2. Tighten: Generator rotor nut “1” NOTE: While holding the generator rotor “3” with the sheave holder “2”, tighten the generator rotor bolt. Do not allow the sheave holder to touch the projection on the generator rotor. 3. Install: Starter idler gears 4. Install: Left crankcase cover “1” NOTE: Tighten bolts in a crisscross pattern. Use copper washer for part “2” only. 1 A B 1 a 1 b a 2 Generator rotor nut 65 Nm (6.5 m•kg, 47 ft•lb) Sheave holder 90890-01701 Primary clutch holder YS-01880-A Crankcase cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) TR.. 1 2 3 TR..
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 BALANCER GEAR” on page 5-45. Generator rotorRefer to“GENERATOR AND STARTER CLUTCH” on page 5-50. 1 Timing chain guide (intake side) 1 2 Stopper guide plate 1 3 Timing chain guide (exhaust side) 1 4 Timing chain 1 5 Speed sensor 1 6 Neutral switch 1 7 Delivery pipe 1 12 3 45 6 7 8 9 9 1011 12 LT LT LT LT 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..10 Nm (1.0 m • kg, 7.2 ft • Ib) 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..4 Nm (0.4 m • kg, 2.9 ft • Ib) LT