2004 YAMAHA YZ250LC clutch

4-39
CLUTCH AND PRIMARY DRIVEN GEARENG
10. Install:
9O-ring 1
To clucth cover.
11. Install:
9Clutch cover 1
9Bolt (clutch cover) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
12. Install:
9O-ring 1
9Clutch cable 2
NOTE:
Apply the lithium soap base grease on the O-
ring.
10 Nm (1.0 m•kg, 7.2 ft•lb)
5XF-9-30-4B 4/22/03 9:00 AM Page 24

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)
5XF-9-30-4B 4/22/03 9:00 AM Page 26

4-47
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
5. Install:
9Crankcase cover (right) 1
NOTE:
Mesh the governor gear 2with the governor
drive gear 3and the impeller shaft gear 4with
the primary drive gear 5.
4. Install:
9Dowel pin 1
9Gasket [crankcase cover (right)] 2
3. Tighten:
9Bolt (primary drive gear) 1
NOTE:
Place an aluminum plate abetween the teeth of
the primary drive gear 2and driven gear 3.
EC4C5531
Primary drive gear
1. Install:
9Thrust plate 1
9Primary drive gear 2
9Governor drive gear 3
9Plain washer 4
9Bolt (primary drive gear) 5
NOTE:
9Install the plain washer with its chamfered side
atoward you.
9Temporarily tighten the bolt at this point.
2. Install:
9Primary driven gear
Refer to “CLUTCH AND PRIMARY DRI-
VEN GEAR” section.
55 Nm (5.5 m•kg, 40 ft•lb)
5XF-9-30-4B 4/22/03 9:00 AM Page 40

4-48
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
8. Install:
9Shift pedal 1
9Bolt (shift pedal) 2
NOTE:
Install the shift pedal so that the top of the shift
pedal outer diameter ais highest without
exceeding the line bconnecting the center of
the shift shaft and bottom of the screw
[crankcase cover (left)] 3.
7. Install:
9Kick starter 1
9Plain washer 2
9Bolt (kick starter) 3
NOTE:
Install the kick starter closest to but not contact-
ing the clutch cover mounting boss a.
6. Install:
9Bolt [crankcase cover (right)] 1
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
30 Nm (3.0 m•kg, 22 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5XF-9-30-4B 4/22/03 9:00 AM Page 42

4-60
ENGINE REMOVALENG
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Seat and fuel tankRefer to “SEAT, FUEL TANK AND
SIDE COVERS” section.
Carburetor and carburetor jointRefer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
Exhaust pipe stay (rear) SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator Refer to “RADIATOR” section.
Spark plug
Disconnect the CDI magneto lead.
CDI unit
Reservoir tank (rear brake) Refer to “FRONT BRAKE AND REAR
BRAKE” section in the CHAPTER 5.
EC4M0000
ENGINE REMOVAL
w
Support the machine securely so there is no dan-
ger of it falling over.



26 Nm (2.6 m•kg, 19 ft•lb)
64 Nm (6.4 m•kg, 46 ft•lb)
64 Nm (6.4 m•kg, 46 ft•lb)
75 Nm (7.5 m•kg, 54 ft•lb)
8 Nm (0.8 m•kg, 5.8 ft•lb)
85 Nm (8.5 m•kg, 61 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
5XF-9-30-4C 5/8/03 11:50 AM Page 22

5-39
CHASHANDLEBAR
Extent of removal Order Part name Q’ty Remarks
Preparation forHANDLEBAR REMOVAL
removal
Number plate Remove the clamp portion only.
1 Clutch cable 1 Disconnect at the lever side.
2 Clutch lever holder 1
3 “ENGINE STOP” button 1
4 Master cylinder 1 Refer to “REMOVAL POINTS”.
5 Throttle cable cap 1 Turn over the cap cover.
6 Throttle cable 1 Disconnect at the throttle side.
7 Throttle 1 Loosen the bolts.
8 Cap cover 1
9 Collar 1
10 Grip (left) 1 Refer to “REMOVAL POINTS”.
11 Handlebar holder (upper) 2
12 Handlebar 1
EC5B0000
HANDLEBAR
1
Extent of removal:1Handlebar removal
1 Nm (0.1 m•kg, 0.7 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
9 Nm (0.9 m•kg, 6.5 ft•lb)
28 Nm (2.8 m•kg, 20 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
5XF-9-30-5C 5/6/03 6:39 PM Page 2

5-44
CHASHANDLEBAR
10. Install:
9Bolt (grip cap) 1
w
9Install the grip cap so that the gaps a a
and
b b
between the bolt (grip cap) and brake
lever 2 2
are equal. If you make a mistake in
the grip cap installation position, the brake
lever may contact the grip cap, resulting in
poor brake performance.
9After tightening the bolts, check that the
throttle grip 3 3
moves smoothly. If it does
not, retighten the bolts for adjustment.
11. Install:
9“ENGINE STOP” button 1
9Clutch lever holder 2
9Bolt (clutch lever holder) 3
9Clamp 4
NOTE:
9The “ENGINE STOP” button, clutch lever hold-
er and clamp should be installed according to
the dimensions shown.
9Pass the “ENGINE STOP” button lead in the
middle of the clutch holder.
12. Install:
9Clutch cable 1
NOTE:
Apply the lithium soap base grease on the clutch
cable end.
13. Adjust:
9Clutch lever free play
Refer to “CLUTCH ADJUSTMENT” section in
the CHAPTER 3.
4 Nm (0.4 m•kg, 2.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
5XF-9-30-5C 5/6/03 6:39 PM Page 12