wheel YAMAHA WR 250F 2001 Owner's Manual

3 - 44
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
lBearing free play
Exist play ® Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
lSteering shaft
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play ® Adjust steering head.
3. Check:
lSteering smooth action
Turn the handlebar lock to lock.
Unsmooth action ® Adjust steering ring
nut.
4. Adjust:
lSteering ring nut
Steering ring nut adjustment steps:
lRemove the headlight.
lRemove the handlebar and upper bracket.
lLoosen the steering ring nut 1 using the
steering nut wrench 2.
Steering nut wrench:
YU-33975/90890-01403

4 - 71
ENGKICK SHAFT AND SHIFT SHAFT
KICK SHAFT AND SHIFT SHAFT
Extent of removal:1 Kick shaft removal2 Kick shaft disassembly
3 Shift shaft removal4 Segment removal
Extent of removal Order Part name Q’ty Remarks
KICK SHAFT AND SHIFT
SHAFT REMOVAL
Preparation for removal Oil pump Refer to “OIL PUMP” section.
1 Kick idle gear 1
2 Kick shaft assembly 1 Refer to “REMOVAL POINTS”.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
8 Washer 1
9 Shift pedal 1
10 Shift shaft 1
11Collar
1
3
2
1
4
1

4 - 73
ENGKICK SHAFT AND SHIFT SHAFT
REMOVAL POINTS
Kick shaft assembly
1. Remove:
lKick shaft assembly 1
NOTE:
Unhook the torsion spring 2 from the hole a
in the crankcase.
EC4C3101
Shift guide and shift lever assembly
1. Remove:
lBolt (shift guide)
lShift guide 1
lShift lever assembly 2
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
lBolt (segment) 1
lSegment 2
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
Kick shaft and ratchet wheel
1. Check:
lRatchet wheel 1 smooth movement
Unsmooth movement ® Replace.
lKick shaft 2
Wear/damage ® Replace.
lSpring 3
Broken ® Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
lKick gear 1
lKick idle gear 2
lRatchet wheel 3
lGear teeth a
lRatchet teeth b
Wear/damage ® Replace.

4 - 76
ENGKICK SHAFT AND SHIFT SHAFT
4. Install:
lBolt (shift guide) 1
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Shift shaft
1. Install:
lRoller 1
lCollar 2
lTorsion spring 3
lShift shaft 4
NOTE:
Apply the engine oil on the roller and shift
shaft.
2. Install:
lShift pedal 1
lBolt (shift pedal) 2
NOTE:
When installing the shift pedal onto the shift
shaft, be sure that the center of the shift pedal
is about 2 mm a above the top of the footrest.
Kick shaft assembly
1. Install:
lKick gear 1
lWasher 2
lCirclip 3
lRatchet wheel 4
lSpring 5
lWasher 6
lCirclip 7
To kick shaft 8.
NOTE:
lApply the molybdenum disulfide oil on the
kick gear inner circumference.
lAlign the punch mark a on the ratchet wheel
with the punch mark b on the kick shaft.

4 - 79
ENGCDI MAGNETO
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:
lNut (rotor) 1
lWasher 2
Use the rotor holding tool 3.
2. Remove:
lRotor 1
Use the flywheel puller 2.
NOTE:
Install three bolts 3 of the proper size, as
shown in illustration.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YU-33270-B/90890-01362
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
lRotor inner surface a
lStator outer surface b
Damage ® Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magneto and/
or stator.
EC4L4200
Woodruff key
1. Inspect:
lWoodruff key 1
Damage ® Replace.

4 - 99
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
l2nd wheel gear (28T) 1
l4th wheel gear (25T) 2
l3rd wheel gear (28T) 3
l5th wheel gear (22T) 4
l1st wheel gear (31T) 5
lO-ring 6
To drive axle 7.
NOTE:
lApply the molybdenum disulfide oil on the
1st, 2nd and 3rd wheel gears inner circum-
ference and on the end surface.
lApply the molybdenum disulfide oil on the
4th and 5th wheel gears inner circumfer-
ence.
lApply the lithium soap base grease on the O-
ring.
3. Install:
lWasher 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the washer and
gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
4. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.

4 - 100
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
lShift fork 1 (L) 1
lShift fork 2 (C) 2
lShift fork 3 (R) 3
lShift cam 4
To main axle and drive axle.
NOTE:
lApply the molybdenum disulfide oil on the
shift fork grooves.
lMesh the shift fork #1 (L) with the 4th wheel
gear 5 and #3 (R) with the 5th wheel gear
7 on the drive axle.
lMesh the shift fork #2 (C) with the 3rd pinion
gear 6 on the main axle.
6. Install:
lTransmission assembly 1
To left crankcase 2.
NOTE:
Apply the engine oil on the bearings and guide
bars.
7. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Trip meter cable 1
2 Brake hose cover 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Bolt (axle holder) 4 Only loosening.
5 Nut (front wheel axle) 1
6 Front wheel axle 1
7 Front wheel 1
8 Trip meter gear unit 1
9 Collar 1
10 Oil seal 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
12 Brake disc 1
2
31
3





5

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
REAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS

FRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:
l
Wheel
1

NOTE:

Push the wheel forward and remove the drive
chain
2
.
EC513201
Wheel bearing (if necessary)
1. Remove:
l
Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
EC594000
INSPECTION
EC514100
Wheel
1. Measure:
l
Wheel runout
Out of limit
®
Repair/replace.
2. Inspect:
l
Bearing
Rotate inner race with a finger.
Rough spot/seizure
®
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)