2002 YAMAHA YZ250LC steering

3-35
STEERING HEAD INSPECTION AND ADJUSTMENT
INSP
ADJ
2. Inspect:
9Bearing free play
Exist play Replace.
EC36U013
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suitable
stand under the engine.
2. Check:
9Steering shaft
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play Adjust steering head.
3. Check:
9Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action Adjust steering ring
nut.
4. Adjust:
9Steering ring nut
Steering ring nut adjustment steps:
9Remove the number plate.
9Remove the handlebar and handle crown.
9Loosen the ring nut 1using the ring nut
wrench 2.
9Tighten the ring nut 3using ring nut
wrench 4.
NOTE:
Set the torque wrench to the ring nut wrench
so that they form a right angle.
Ring nut wrench:
YU-33975/90890-01403
5NX-9-30-3B 6/5/01 4:06 PM Page 38

3-36
STEERING HEAD INSPECTION AND ADJUSTMENT
INSP
ADJ
9Loosen the ring nut one turn.
9Retighten the ring nut using the ring nut
wrench.
w
Avoid over-tightening.
9Check the steering shaft by turning it lock to
lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
9Install the handle crown 5, steering shaft
nut 6, handlebar 7, handlebar holder 8
and number plate 9.
NOTE:
9The upper handlebar holder should be
installed with the punched mark aforward.
9Insert the end of fuel breather hose 0into
the hole of the number plate.
cC
First tighten the bolts on the front side of
the handlebar holder, and then tighten the
bolts on the rear side.
Ring nut wrench:
YU-33975/90890-01403
Ring nut (initial tightening):
38 Nm (3.8 m•kg, 27ft•lb)
Steering shaft nut:
145 Nm (14.5 m•kg, 105 t•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20 ft•lb)
Pinch bolt (handle crown):
23 Nm (2.3 m•kg, 17 ft•lb)
Number plate:
7 Nm (0.7 m•kg, 5.1 ft•lb)
Ring nut (final tightening):
7 Nm (0.7 m•kg, 5.1 ft•lb)
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5-47
CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Number plate
Handlebar Refer to “HANDLEBAR” section.
Cable guide
Front fender
1 Steering shaft nut 1
2 Front fork 2 Refer to “FRONT FORK” section.
3 Handle crown 1
4 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
5 Under bracket 1
6 Ball race cover 1
7 Bearing (upper) 1
8 Bearing (lower) 1 Refer to “REMOVAL POINTS”.
9 Ball race 2 Refer to “REMOVAL POINTS”. Extent of removal:1Under bracket removal 2Bearing removal
2
1
w
Support the machine securely so there is no dan-
ger of it falling over.
23 Nm (2.3 m•kg, 17 ft•lb)
145 Nm (14.5 m•kg, 105 ft•lb)
9Tighten ring nut.
38 Nm (3.8 m•kg, 27 ft•lb)
9Loosen it one turn.
9Retighten it.
7 Nm (0.7 m•kg, 5.1 ft•lb)
TIGHTENING STEPS:
20 Nm (2.0 m•kg, 14 ft•lb)
EC560000
STEERING
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5-48
CHASSTEERING
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
9Ring nut 1
Use the ring nut wrench 2.
w
Support the steering shaft so that it may
not fall down.
EC563300
Bearing (lower)
1. Remove:
9Bearing (lower) 1
Use the floor chisel 2.
cC
Take care not to damage the steering shaft
thread.
EC563400
Ball race
1. Remove:
9Ball race 1
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
9Steering shaft 1
Bend/Damage Replace.
Ring nut wrench:
YU-33975/90890-01403
5NX-9-30-5C 6/5/01 4:37 PM Page 18

5-49
CHASSTEERING
EC564101
Bearing and ball race
1. Wash the bearings and ball races with a sol-
vent.
2. Inspect:
9Bearing 1
9Ball race
Pitting/Damage Replace bearings and
ball races as a set.
Install the bearing in the ball races. Spin the
bearings by hand. If the bearings hang up or
are not smooth in their operation in the ball
races, replace bearings and ball races as a
set.
EC565000
ASSEMBLY AND INSTALLATION
EC565113
Under bracket
1. Install:
9Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
9Ball race
9Bearing (upper) 1
9Ball race cover 2
NOTE:
Apply the lithium soap base grease on the bear-
ing and ball race cover lip.
3. Install:
9Under bracket 1
NOTE:
Apply the lithium soap base grease on the bear-
ing and the portion aof the steering shaft.a
1
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5-50
CHASSTEERING
4. Install:
9Plain washer 1
9Ring nut 2
Tighten the ring nut using the ring nut
wrench 3.
Refer to “STEERING HEAD INSPECTION
AND ADJUSTMENT” section in the CHAP-
TER 3.
5. Check the steering shaft by turning it lock to
lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
6. Install:
9Plain washer 1
7. Install:
9Front fork 1
9Handle crown 2
NOTE:
9Temporarily tighten the pinch bolts (under
bracket).
9Do not tighten the pinch bolts (handle crown) yet.
8. Install:
9Plain washer 1
9Steering shaft nut 2
7 Nm (0.7 m•kg, 5.1 ft•lb)
145 Nm (14.5 m•kg, 105 ft•lb)
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5-51
CHASSTEERING
9. After tightening the nut, check the steering for
smooth movement. If not, adjust the steering
by loosening the ring nut little by little.
10. Adjust:
9Front fork top end a
11. Tighten:
9Pinch bolt (handle crown) 1
9Pinch bolt (under bracket) 2
cC
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
Front fork top end (standard) a a
:
Zero mm (Zero in)
23 Nm (2.3 m•kg, 17 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
5NX-9-30-5C 6/5/01 4:37 PM Page 24