2002 YAMAHA YZ250LC engine oil

INSP
ADJ
3-13
TRANSMISSION OIL REPLACEMENT
3. Check:
9Transmission oil level
EC35K002
TRANSMISSION OIL REPLACEMENT
1. Start the engine and warm it up for several
minutes and wait for five minute.
2. Place the machine on a level place and hold
it on upright position by placing the suitable
stand under the engine.
3. Place a suitable container under the engine.
Transmission oil level checking steps:
9Remove the oil check bolt 1.
9Inspect the oil level.
NOTE:
Be sure the machine is positioned straight
up when inspecting the oil level.
w
Never attempt to remove the oil check bolt
just after high speed operation. The heat-
ed oil could spout out, causing danger.
Wait until the oil cools down.
Oil flows outOil level is correct.
Oil does not flow outOil level is low.
Add transmission
oil until oil flows
out.
9Inspect the gasket (oil check bolt), replace if
damaged.
9Tighten the oil check bolt.
Recommended oil:
Yamalube 4 (10W-30) or SAE
10W-30 type SE motor oil
Oil check bolt:
10 Nm (1.0 m•kg, 7.2 ft•lb)
5NX-9-30-3A 6/5/01 3:59 PM Page 34

3-25
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
EC36A060
DRIVE CHAIN SLACK ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Check:
9Drive chain slack a
Above the seal guard installation bolt.
Out of specification Adjust
NOTE:
Before checking and/or adjusting, rotate the rear
wheel through several revolutions and check the
slack several times to find the tightest point. Check
and/or adjust chain slack with rear wheel in this
“tight chain” position.
Drive chain slack:
40~50 mm (1.6~2.0 in)
Drive chain lubricant:
SAE 10W-30 motor oil or suitable
chain lubricants
5. Install:
9Drive chain 1
9Joint 2
9Master link clip 3
cC
Be sure to install the master link clip to the
direction as shown.
aTurning direction
6. Lubricate:
9Drive chain
5NX-9-30-3B 6/5/01 4:06 PM Page 18

3-26
FRONT FORK INSPECTION
INSP
ADJ
3. Adjust:
9Drive chain slack
EC36C000
FRONT FORK INSPECTION
1. Inspect:
9Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage Repair or
replace.
Drive chain slack adjustment steps:
9Loosen the axle nut 1and locknuts 2.
9Adjust chain slack by turning the
adjusters 3.
To tighten Turn adjuster 3 3
counter-
clockwise.
To loosen Turn adjuster 3 3
clockwise
and push wheel forward.
9Turn each adjuster exactly the same amount
to maintain correct axle alignment. (There are
marks aon each side of chain puller align-
ment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
cC
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
9Tighten the axle nut while pushing down the
drive chain.
9Tighten the locknuts.
Axle nut:
125 Nm (12.5 m•kg, 90 ft•lb)
5NX-9-30-3B 6/5/01 4:06 PM Page 20

3-27
FRONT FORK OIL SEAL AND DUST SEAL CLEANING/
FRONT FORK INTERNAL PRESSURE RELIEVING/
FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT
INSP
ADJ
EC36D001
FRONT FORK OIL SEAL AND DUST SEAL
CLEANING
1. Remove:
9Protector
9Dust seal 1
NOTE:
Use a thin screw driver, and be careful not to
damage the inner fork tube and dust seal.
2. Clean:
9Dust seal a
9Oil seal b
NOTE:
9Clean the dust seal and oil seal after every
run.
9Apply the lithium soap base grease on the in-
ner tube.
EC36H002
FRONT FORK REBOUND DAMPING FORCE
ADJUSTMENT
1. Adjust:
9Rebound damping force
By turning the adjuster 1.
Stiffer a a
Increase the rebound damping
force. (Turn the adjuster 1 1
in.)
Softer b b
Decrease the rebound
damping force. (Turn the
adjuster 1 1
out.)
EC36f000
FRONT FORK INTERNAL PRESSURE
RELIEVING
NOTE:
If the front fork initial movement feels stiff during
a run, relieve the front fork internal pressure.
1. Elevate the front wheel by placing a suitable
stand under the engine.
2. Remove the air bleed screw 1and release
the internal pressure from the front fork.
3. Install:
9Air bleed screw
1 Nm (0.1 m•kg, 0.7 ft•lb)
5NX-9-30-3B 6/5/01 4:06 PM Page 22

3. Install:
9Pilot air screw 1
9Throttle stop screw 2
4. Install:
9Starter plunger 1
4-14
ENGCARBURETOR AND REED VALVE
Pilot air screw:
1 turn out
*1-3/8 turns out
(for reference only)
Note the following installation points:
9Turn in the pilot air screw until it is lightly
seated.
9Turn out the pilot air screw by the number
of turns recorded before removing.
5. Install:
9Pilot jet 1
9Main jet 2
2. Install:
9O-ring 1
9Solenoid valve 2
9Clamp 3
9Screw (clamp) 4
To carburetor 5.
cC
9
Before installing the solenoid valve, blow
air on the solenoid valve and its installing
location on the carburetor in order to
remove any foreign particles such as chips
etc.
9Apply the engine oil on the solenoid valve
thread.
*For EUROPE
5NX-9-30-4A 6/5/01 4:12 PM Page 28

4-29
CYLINDER HEAD, CYLINDER AND PISTONENG
7. Install:
9O-ring 1
9Side holder 2
9Screw (side holder) 3
9YPVS breather hose 4
NOTE:
9Apply the lithium soap base grease on the O-
rings.
9Install the side holder with its projection a
facing upward.
8. Install:
9Gasket (power valve cover) 1
9Power valve cover 2
9Screw (power valve cover) 3
NOTE:
9Install the gasket with its cut afacing down-
ward and the seal print side toward the power
valve cover.
9Install the power valve cover so that the arrow
mark bfaces upward.
EC475233
Piston ring and piston
1. Install:
9Piston ring 1
NOTE:
9Take care not to scratch the piston or damage
the piston ring.
9Align the piston ring gap with the pin 2.
9After installing the piston ring, check the
smooth movement of it.
2. Install:
9Gasket (cylinder) 1
9Small end bearing 2
9Dowel pin 3
NOTE:
9Apply the engine oil onto the bearing (crank-
shaft and connecting rod) and connecting rod
big end washers.
9Install the gasket with the seal print side
toward the crankcase.
4 Nm (0.4 m•kg, 2.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
5NX-9-30-4B 6/7/01 1:56 PM Page 4

4-30
CYLINDER HEAD, CYLINDER AND PISTONENG
EC475382
Cylinder head and cylinder
1. Apply:
9Engine oil
To piston 1piston ring 2and cylinder sur-
face.
2. Install:
9Cylinder 1
cC
Make sure the piston rings are properly
positioned. Install the cylinder with one
hand while compressing the piston rings
with the other hand.
NOTE:
After installing, check the smooth movement of
the piston.
3. Install:
9Nut (cylinder) 1
NOTE:
Tighten the nuts in stage, using a crisscross pat-
tern.
3. Install:
9Piston 1
9Piston pin 2
9Piston pin clip 3
NOTE:
9The arrow aon the piston dome must point to
exhaust side.
9Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the pis-
ton pin clip from falling into the crankcase cavi-
ty.
cC
Do not allow the clip open ends to meet the
piston pin slot b b
.
35 Nm (3.5 m•kg, 25 ft•lb)
5NX-9-30-4B 6/7/01 1:56 PM Page 6

4-33
CLUTCH AND PRIMARY DRIVEN GEARENG
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND
FRICTION PLATE REMOVAL
Preparation for Drain the transmission oil.
Refer to “TRANSMISSION OIL REPLACE-
removalMENT“ section in the CHAPTER 3.
Bolt (brake pedal) Shift the brake pedal downward.
Rotor and stator Refer to
“CDI MAGNETO“section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Screw (clutch spring) 6
3 Clutch spring 6
4 Pressure plate 1
5 Friction plate 8
6 Clutch plate 7
Extent of removal:1Clutch plate and friction plate removal
EC490000
CLUTCH AND PRIMARY DRIVEN GEAREC498000
CLUTCH PLATE AND FRICTION PLATE
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5NX-9-30-4B 6/7/01 1:56 PM Page 12