Yamaha Wr250r 2008 Manual
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WATER PUMP 6-6 EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks Drains the coolant.Refer to“CHANGING THE COOLANT” on page 3-18. Drains the engine oilRefer to“CHANGING THE ENGINE OIL” on page 3-11. Water pump housing cover Refer to“CLUTCH” on page 5-34. Crank case cover light Refer to“CLUTCH” on page 5-34. 1 Circlips 1 2 Impeller shaft gear 1 3 Dowelpin 1 4 Plate 1 5 Impeller shaft 1 6 Mechanical seal 1 7 Bearing 1 For installation, reverse the removal proce- dure. LT 1 2 3 4 5 6 7 LT E T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
WATER PUMP 6-7 EAS26530 CHECKING THE WATER PUMP 1. Check: Water pump housing cover Impeller shaft Plate Cracks/damage/wear → Replace. 2. Check: Impeller shaft gear Cracks/damage/chips → Replace. EAS26560 ASSEMBLING THE WATER PUMP 1. Install: Bearing Mechanical “1” (to the right crankcase cover) NOTE: Install the mechanical seal by facing stamp world “WATER SIDE” to the impeller housing cover. Install the mechanical seal by using mechani- cal seal installer “2” and middle driven shaft bearing driver “3”. 2. Lubricate: Mechanical seal lip Impeller shaft 3. Install: Impeller shaft “1” Plate “2” NOTE: Tighten the plate bolt with appling the LOCTITE®.4. Lubricate: Engine oil (to the bearing) 5. Install: Plate washer Dowel pin Impeller shaft gear “1” Plate washer “2” Circlip “3” 6. Install: Crankcase cover right gascket Crankcase cover (right) Refer to “CLUTCH” on page 5-34. 7. Install: Water pump housing cover gascket Water pump housing cover “1” (Bolt “2” with new copper washer) 8. Fill: Mechanical seal installer 90890-04145 Middle driven shaft bearing driver 90890-04058 Plate bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) New New 3 2 1 TR.. Water pump housing cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 2 New 2 3 1 New New TR.. 2 1
WATER PUMP 6-8 Crankcase Refer to “CHANGING THE ENGINE OIL” on page 3-11. 9. Fill: Cooling system Refer to “CHANGING THE COOLANT” on page 3-18.
1 2 3 4 5 6 7 8 9 FUEL SYSTEM FUEL TANK ...................................................................................................7-1 REMOVING THE FUEL TANK .................................................................7-2 REMOVING THE FUEL PUMP ................................................................7-2 INSTALLING THE FUEL PUMP...............................................................7-2 INSTALLING THE FUEL TANK ...............................................................7-2 THROTTLE BODIES ......................................................................................7-4 CHECKING THE INJECTORS .................................................................7-6 CHECKING THE THROTTLE BODIES....................................................7-6 CHECKING THE PRESSURE REGULATOR ..........................................7-6 CHECKING THE PRESSURE REGULATOR OPERATION ....................7-6 ADJUSTING THE THROTTLE POSITION SENSOR ..............................7-7 AIR INDUCTION SYSTEM .............................................................................7-9 CHECKING THE AIR INDUCTION SYSTEM ..........................................7-12 CANISTER (FOR CALIFORNIA)..............................................................7-13
FUEL TANK 7-1 EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat Refer to“GENERAL CHASSIS” on page 4-1. Side cover (left/right) Air scoop (left/right) 1 Fuel tank 1 2 Fuel hose coupler 1 Disconnect. 3 Hose (fuel tank-roll over valve) 1 Disconnect (for California) 4 Fuel tank bracket (front/rear) 1/1 5 Fuel pump bracket 1 6 Fuel pump assembly 1 7 O-ring 1 For installation, reverse the removal proce- dure. 1 2 44 5 67 T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..4 Nm (0.4 m • kg, 2.9 ft • Ib) T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 3
FUEL TANK 7-2 EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: Fuel hose coupler CAUTION: ECA14700 Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it. NOTE: Slide the fuel hose connector cover “1” in the direction of the arrow mark, and press the but- tons “2” on both sides of the connector to re- move the fuel hose. Disconnecting the hose is done by hand. There is no need to use tools. Before removing the fuel hose, place a few rags in the area under where it will be re- moved. 3. Remove: Fuel tank NOTE: Do not set the fuel tank down so that the instal- lation surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an up- right position. EAS26640 REMOVING THE FUEL PUMP 1. Remove: Fuel pump CAUTION: ECA14720 Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender. EAS26700 INSTALLING THE FUEL PUMP 1. Install: Fuel pump NOTE: Do not damage the installation surfaces of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump as shown in the illustra- tion. Align the projection “a” on the fuel pump with the slot in the fuel pump bracket. Align the slot “b” on the fuel tank damper with the projection “a” on the fuel pump. Tighten the fuel pump bolts in stages in a criss- cross pattern. EAS32D1016 INSTALLING THE FUEL TANK 1. Install: Fuel hose Fuel return hose CAUTION: ECA14740 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, oth- erwise the fuel hose will not be properly in- stalled. NOTE: Insert the fuel hose on the fuel pipe until you hear a definite “click”. Slide the fuel hose connector cover “1” at the fuel hose end in the direction of the arrow. 1 2 Fuel pump bolts 4 Nm (0.4 m•kg, 2.9 ft•lb) TR.. a b
THROTTLE BODIES 7-4 EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks SeatRefer to “GENERAL CHASSIS” on page 4-1. Side cover (left/right) Air scoop (left/right) Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle cable Refer to “CAMSHAFT” on page 5-6. Clutch cable CoolantDrain. Refer to “CHANGING THE COOLANT” on page 3-18. Ignition coil lead Refer to “CAMSHAFT” on page 5-6. 1 Injector coupler 1 Disconnect. 2 Vacuum hose 1 3 ITS boost hose 1 4 FID hose (Thermostat side/radiator side) 2 5 Hose (canister-throttle body) 1 (for California) 6 Throttle bodies assembly 1 For installation, reverse the removal proce- dure. 6 1 2 5 3 4 4
THROTTLE BODIES 7-5 Disassembling the throttle body Order Job/Parts to remove Q’ty Remarks 1 Delivery pipe 1 2 Injector 1 3 Gasket 1 4 Throttle position sensor 1 For installation, reverse the removal proce- dure. 123 4 T R..5 Nm (0.5 m • kg, 3.6 ft • Ib) T R..3.5 Nm (0.4 m • kg, 2.5 ft • Ib)