2002 YAMAHA YZ250LC drain bolt

4-40
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
Extent of removal Order Part name Q’ty Remarks
RPIMARY DRIVE GEAR 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.
Radiator hose 4 Disconnect at water pump side.
Bolt (push rod)
Refer to “CYLINDER HEAD, CYLINDER
AND PISTON” section.
1 Kick starter 1
2 Crankcase cover (right) 1
3 Bolt (Primary drive gear) 1 Only loosening
Refer to “REMOVAL POINTS”.
4 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR”section.
5 Primary drive gear 1
6 Thrust plate 1
EC4C0000
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAREC4C8000
PRIMARY DRIVE GEAR
1
Extent of removal:1Primary drive gear removal
30 Nm (3.0 m•kg, 22 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
5NX-9-30-4B 6/7/01 1:56 PM Page 26

4-55
WATER PUMPENG
EC4G5220
Impeller shaft
1. Install:
9Impeller shaft 1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip and
impeller shaft. And install the shaft while turn-
ing it.
2. Install:
9Plain washer 1
9Impeller 2
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and install the
impeller.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
5NX-9-30-4C 6/5/01 4:25 PM Page 12

5-10
CHASFRONT BRAKE AND REAR BRAKE
Extent of removal Order Part name Q’ty Remarks
FRONT BRAKE REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Hose cover 1
2 Brake hose holder 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1
Remove when loosening the pad pin.
7 Pad pin 1Loosen when disassembling the caliper.
8 Caliper 1
9 Brake lever 1
10 Master cylinder bracket 1
11 Master cylinder 1
EC5A0000
FRONT BRAKE AND REAR BRAKEEC5A8000
FRONT BRAKE
Extent of removal:1Brake hose removal2Caliper removal3Master cyilinder removal
w
Support the machine securely so there is no dan-
ger of it falling over.
2
1
3
3
2
9 Nm (0.9 m•kg, 6.5 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
3 Nm (0.3 m•kg, 2.2 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)16 Nm (1.6 m•kg, 11 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
5NX-9-30-5A 6/7/01 2:00 PM Page 20

5-11
CHASFRONT BRAKE AND REAR BRAKE
EC5A8100
REAR BRAKE
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Rear wheel Refer to “FRONT WHEEL AND
REAR WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Pad pin pulg 1
Remove when loosening the pad pin.
2 Pad pin 1Loosen when disassembling the caliper.
3 Caliper 1
4 Brake hose holder 2
5 Union bolt 2
6 Brake hose 1
7 Brake pedal 1
8 Reservoir tank 1
9 Reservoir hose 1
10 Master cylinder 1
Extent of removal:1Caliper removal2Brake hose removal3Master cylinder removal
w
Support the machine securely so there is no dan-
ger of it falling over.
2
1
3
31
1 Nm (0.1 m•kg, 0.7 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
3 Nm (0.3 m•kg, 2.2 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
5NX-9-30-5A 6/7/01 2:00 PM Page 22

5-28
CHASFRONT FORK
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1Cap bolt 1 Refer to “REMOVAL POINTS”.
2Fork spring 1 Drain the folk oil.
3Dust seal 1
4Stopper ring 1 Refer to “REMOVAL POINTS”.
5Inner tube 1
6Outer tube 1
7Piston metal 1
8Slide metal 1
9Plain washer 1
0Oil seal 1
qSpring guide 1
wBase valve 1 Use special tool.
eDamper rod 1 Refer to “REMOVAL POINTS”.
EC558000
FRONT FORK DISASSEMBLY
1
Extent of removal:1Oil seal removal2Damper rod removal
2






29 Nm (2.9 m•kg, 21 ft•lb)1 Nm (0.1 m•kg, 0.7 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
5NX-9-30-5B 6/7/01 2:04 PM Page 4