Yamaha WR250F Owner's Service Manual

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Contents

5-30CLUTCHREMOVING THE CLUTCH BOSS1. Remove:• Nut "1"• Lock washer "2"• Clutch boss "3"Straighten the lock washer tab anduse the clutch holding tool "4" to holdthe clutch boss.A. For USA and CDNB. Except for USA and CDNCHECKING THE CLUTCHHOUSING AND BOSS1. Inspect:• Clutch housing "1"Cracks/wear/damage →Replace.• Clutch boss "2"Scoring/wear/damage → Re-place.CHECKING THE PRIMARY DRIVENGEAR1. Check:• Circumferential playFree play exists → Replace.• Gear teeth "a"Wear/damage → Replace.CHECKING THE CLUTCHSPRINGS1. Measure:• Clutch spring free length "a"Out of specification → Replacesprings as a set.CHECKING THE FRICTIONPLATES1. Measure:• Friction plate thicknessOut of specification → Replacefriction plate as a set.Measure at all four points.CHECKING THE CLUTCH PLATES1. Measure:• Clutch plate warpageOut of specification → Replaceclutch plate as a set.Use a surface plate "1" and thick-ness gauge "2".CHECKING THE PUSH LEVERSHAFT1. Inspect:• Push lever shaft "1"Wear/damage → Replace.CHECKING THE PUSH ROD1. Inspect:• Push rod 1 "1"• Bearing "2"• Washer "3"• Push rod 2 "4"• Ball "5"Wear/damage/bend → Replace.INSTALLING THE PUSH LEVERSHAFT1. Install:• Push lever shaft "1"• Bolt (push lever shaft) "2"• Apply the lithium soap base greaseon the oil seal lip.• Apply the engine oil on the push le-ver shaft.• Fit the seat plate "3" in the groove"a" of the push lever shaft and tight-en the bolt (seat plate).INSTALLING THE CLUTCH1. Install:• Primary driven gear "1"• Thrust washer "2"• Clutch boss "3"Apply the engine oil on the primarydriven gear inner circumference.Clutch holding tool:YM-91042/90890-04086Clutch spring freelength:37.0 mm (1.46 in): 36.0 mm (1.42in)Friction plate thickness:2.9–3.1 mm (0.114–0.122 in): 2.7 mm (0.106in)Warp limit:0.1 mm (0.004 in)Bolt (push lever shaft):10 Nm (1.0 m•kg, 7.2ft•lb)