clock YAMAHA WR 250F 2002 User Guide

4 - 74
ENGKICK SHAFT AND SHIFT SHAFT
REMOVAL POINTS
Kick shaft assembly
1. Remove:
Kick 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:
Bolt (shift guide)
Shift guide 1
Shift lever assembly 2
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
Bolt (segment) 1
Segment 2
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
Kick shaft and ratchet wheel
1. Check:
Ratchet wheel 1 smooth movement
Unsmooth movement → Replace.
Kick shaft 2
Wear/damage → Replace.
Spring 3
Broken → Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
Kick gear 1
Kick idle gear 2
Ratchet wheel 3
Gear teeth a
Ratchet teeth b
Wear/damage → Replace.

4 - 78
ENGKICK SHAFT AND SHIFT SHAFT
2. Install:
Torsion spring 1
To kick shaft 2.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick shaft.
3. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick shaft, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick shaft assembly 1
Washer 2
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick shaft stop-
per a and stopper plate 3.
Apply the engine oil on the kick shaft.
Slide the kick shaft assembly into the crank-
case and make sure the kick shaft stopper
fits into the stopper plate.
5. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1
Washer 2
Circlip 3
NOTE:
Apply the engine oil on the kick idle gear
inner circumference.
Install the kick idle gear with its depressed
side a toward you.

7 - 22
TUNSETTING
EC72H002
Suspension setting
Front fork
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Before any change, set the rear shock absorber sunken length to the standard figure 90 ~
100 mm (3.5 ~ 3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire range

Compression damping
Oil level (oil amount)
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with soft spring.
Unsmooth movement
over entire range

Outer tube
Inner tube
Under bracket tightening
torqueCheck for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Retighten to specified torque.
Poor initial
movement

Rebound damping
Oil sealTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Apply grease in oil seal wall.
Soft over entire range,
bottoming out

Compression damping
Oil level (oil amount)
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with stiff spring.
Stiff toward stroke end
Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke end,
bottoming out
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial movement
Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front posture

Compression damping
Rebound damping
Balance with rear end
Oil level (oil amount)Turn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when
one passenger is astride seat (lower rear posture).
Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front, tend-
ing to upper front pos-
ture

Compression damping
Balance with rear end
Spring
Oil lever (oil amount)Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when
one passenger is astride seat (upper rear posture).
Replace with soft spring.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

7 - 23
TUNSETTING
Rear shock absorber
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Adjust the rebound damping in 2-click increments or decrements.
Adjust the low compression damping in 1-click increments or decrements.
Adjust the high compression damping in 1/6 turn increments or decrements.
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff, tending to sink

Rebound damping
Spring set lengthTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when
one passenger is astride seat.
Spongy and unstable

Rebound damping
Low compression damping
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster clockwise (about 1 click) to increase
damping.
Replace with stiff spring.
Heavy and dragging

Rebound damping
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Replace with soft spring.
Poor road gripping

Rebound damping
Low compression damping
High compression damp-
ing
Spring set length
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Turn adjuster clockwise (about 1 clicks) to increase
damping.
Turn adjuster clockwise (about 1/6 clicks) to increase
damping.
Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when
one passenger is astride seat.
Replace with soft spring.
Bottoming out

High compression damp-
ing
Spring set length
SpringTurn adjuster clockwise (about 1/6 turn) to increase
damping.
Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when
one passenger in astride seat.
Replace with stiff spring.
Bouncing

Rebound damping
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Replace with soft spring.
Stiff travel

High compression damp-
ing
Spring set length
SpringTurn adjuster counterclockwise (about 1/6 turn) to
decrease damping.
Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when
one passenger is astride seat.
Replace with soft spring.