Yamaha Wr250r 2008 Manual
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TRANSMISSION 5-67 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. Shift fork cam follower “1” 2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends → Replace. WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar. 3. Check: Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. Shift drum segment “1” Damage/wear → Replace the shift drum as- sembly. Shift drum bearing Damage/pitting → Replace the shift drum as- sembly. EAS26290 CHECKING THE TRANSMISSION 1. Measure: Main axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 1
TRANSMISSION 5-68 2. Measure: Drive axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the drive axle. 3. Check: Transmission gears Blue discoloration/pitting/wear → Replace the defective gear (s). Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear (s). 4. Check: Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: When reassembling the main axle, press the 2nd pinion gear “1” onto it “2” as shown. 5. Check: Transmission gear movement Rough movement → Replace the defective part (s). EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: Shift fork guide bar “1” Shift fork-R “2” Shift fork-C “3” Shift fork-L “4” NOTE: The embossed marks on the shift forks should face towards the clutch side of the engine and be in the following sequence: “R”, “C”, “L”. Drive axle runout limit 0.08 mm (0.0032 in) a. 107.4 – 107.6 mm (4.228 – 4.236 in) a 21 1 2 34
TRANSMISSION 5-69 EAS26340 INSTALLING THE TRANSMISSION 1. Install: Transmission 2. Check: Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
1 2 3 4 5 6 7 8 9 COOLING SYSTEM RADIATOR .....................................................................................................6-1 CHECKING THE RADIATOR...................................................................6-2 INSTALLING THE RADIATOR.................................................................6-2 THERMOSTAT ...............................................................................................6-4 CHECKING THE THERMOSTAT ............................................................6-5 INSTALLING THE THERMOSTAT ASSEMBLY ......................................6-5 WATER PUMP ...............................................................................................6-6 CHECKING THE WATER PUMP .............................................................6-7 ASSEMBLING THE WATER PUMP ........................................................6-7
RADIATOR 6-1 EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Seat/Air scoop (left/right) Refer to“GENERAL CHASSIS” on page 4-1. Fuel tank Refer to“FUEL TANK” on page 7-1. CoolantDrain. Refer to“CHANGING THE COOLANT” on page 3-18. 1 Radiator fan motor coupler 1 Disconnect. 2 Radiator inlet hose 1 Disconnect. 3 Coolant reservoir hose 1 Disconnect. 4 Radiator outlet hose 1 Disconnect. 5 FID Hose (radiator side) 1 6 Radiator cover 1 7 Breather hose 1 Disconnect. 8 Recovery tank 1 9 Radiator 1 10 Radiator fan 1 For installation, reverse the removal proce- dure. 1 23 4 56 7 8 9 10 T R..7 Nm (0.7 m • kg, 5.1 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..8 Nm (0.8 m • kg, 5.8 ft • Ib) T R..2 Nm (0.2 m • kg, 1.4 ft • Ib)
RADIATOR 6-2 EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins “1” Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: Radiator hoses (IN/OUT) Radiator pipes Cracks/damage → Replace. 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. a. Install the radiator cap tester “1” and radiator cap tester adapter “2” to the radiator cap “3”.b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. 4. Check: Radiator fan Damage → Replace. Malfunction → Check and repair. Refer to “COOLING SYSTEM” on page 8-25. EAS26400 INSTALLING THE RADIATOR 1. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-18. 2. Check: Cooling system Leakage → Collect or replace. a. Attach the radiator cap tester “1” to the radia- tor. Radiator cap opening pressure 108.0 – 137.4 kPa (15.7 – 19.9 psi) (1.08 – 1.37 kgf/cm 2 ) Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984
RADIATOR 6-3 b. Apply the 100 kPa (14.22 psi) (1.0 kg/cm 2 ) pressure. c. Measure the indicated pressure with the gauge. 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. 1
THERMOSTAT 6-4 EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Seat/Air panel (left/right) Refer to“GENERAL CHASSIS” on page 4-1. Fuel tank Refer to“FUEL TANK” on page 7-1. Drains the coolant.Refer to“CHANGING THE COOLANT” on page 3-18. 1 Radiator inlet hose 1 Disconnect. 2 FID hose (thermostat side) 1 Disconnect. 3 Thermostat cover 1 4 Thermostat 1 For installation, reverse the removal proce- dure. 1 2 3 4 T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..2 Nm (0.2 m • kg, 1.4 ft • Ib)
THERMOSTAT 6-5 EAS26450 CHECKING THE THERMOSTAT 1. Check: Thermostat “1” Does not open at 70.5 – 73.5 ° C (158.9 – 164.3 ° F) → Replace. a. Suspend the thermostat “1” in a container “2” filled with water. b. Slowly heat the water. c. Place a thermometer “3” in the water “4”. d. While stirring the water, observe the thermo- stat and thermometer’s indicated tempera- ture. NOTE: If the accuracy of the thermostat is in doubt, re- place it. A faulty thermostat could cause serious overheating or overcooling. 2. Check: Thermostat housing cover Cracks/damage → Replace. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: Thermostat “1” Thermostat cover “2” NOTE: Install the thermostat by facing breather hole up- ward. 2. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-18. 3. Check: Cooling system Leaks → Repair or replace any faulty part. 4. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. A. Fully closed Thermostat cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) TR.. 12