2004 YAMAHA YZ250LC wheel

5-5
CHASFRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
EC595101
Front wheel
1. Install:
9Bearing (left) 1
9Spacer 2
9Bearing (right) 3
9Oil seal 4
NOTE:
9Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
9Use a socket that matches the outside diam-
eter of the race of the bearing.
9Left side of bearing shall be installed first.
9Install the oil seal with its manufacture’s
marks or numbers facing outward.
cC
Do not strike the inner race of the bearing.
Contact should be made only with the out-
er race.
2. Install:
9Brake disc 1
9Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
3. Install:
9Collar 1
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the collars with their projections afacing
the wheel.
4. Install:
9Wheel
NOTE:
Install the brake disc 1between the brake pads
2correctly.
12 Nm (1.2 m•kg, 8.7 ft•lb)
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5-6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
9Wheel axle 1
NOTE:
Apply the lithium soap base grease on the wheel
axle.
6. Install:
9Nut (wheel axle) 1
7. Tighten:
9Bolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork several
times with the front brake applied.
8. Install:
9Brake hose 1
To brake hose holder 2.
NOTE:
Before tightening the bolt (brake hose holder),
align the top aof the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose in front of the axle boss cand fit it
into the hose groove dso that the brake hose
does not contact the nut (wheel axle).
105 Nm (10.5 m•kg, 75 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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5-7
CHASFRONT WHEEL AND REAR WHEEL
EC5251A1
Rear wheel
1. Install:
9Bearing (right) 1
9Circlip 2
9Spacer 3
9Bearing (left) 4
9Oil seal 5
NOTE:
9Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
9Install the bearing with seal facing outward.
9Use a socket that matches the outside diam-
eter of the race of the bearing.
9Right side of bearing shall be installed first.
9Install the oil seal with its manufacture’s
marks or numbers facing outward.
cC
Do not strike the inner race of the bearing.
Contact should be made only with the out-
er race.
2. Install:
9Brake disc 1
9Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
9. Install:
9Hose cover 1
9Plain washer 2
9Bolt [hose cover (M8)] 3
9Bolt [hose cover (M6)] 4
16 Nm (1.6 m•kg, 11 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
14 Nm (1.4 m•kg, 1.0 ft•lb)
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5-8
CHASFRONT WHEEL AND REAR WHEEL
3. Install:
9Driven sprocket 1
9Bolt (driven sprocket) 2
9Plain washer (driven sprocket) 3
9Nut (driven sprocket) 4
NOTE:
Tighten the nuts in stage, using a crisscross pat-
tern.
4. Install:
9Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5. Install:
9Wheel
NOTE:
Install the brake disc 1between the brake pads
2correctly.
6. Install:
9Drive chain 1
NOTE:
Push the wheel 2forward and install the drive
chain.
7. Install:
9Chain puller (left) 1
9Wheel axle 2
NOTE:
9Install the chain puller (left), and insert the
wheel axle from left side.
9Apply the lithium soap base grease on the
wheel axle.
42 Nm (4.2 m•kg, 30 ft•lb)
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5-9
CHASFRONT WHEEL AND REAR WHEEL
8. Install:
9Chain puller (right) 1
9Plain washer 2
9Nut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.
9. Adjust:
9Drive chain slack a
Refer to “DRIVE CHAIN SLACK ADJUSTMENT”
section in the CHAPTER 3.
10. Tighten:
9Nut (wheel axle) 1
9Locknut 2
125 Nm (12.5 m•kg, 90 ft•lb)
Drive chain slack :
40~50 mm (1.6~2.0 in)
16 Nm (1.6 m•kg, 11 ft•lb)
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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 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
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
Extent of removal:1Master cylinder removal2Brake hose removal3Caliper removal
w
Support the machine securely so there is no dan-
ger of it falling over.
2
3
31
1
1 Nm (0.1 m•kg, 0.7 ft•lb)
30 Nm (3.0 m•kg, 22 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)
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5-19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Disc cover 1
9Bolt (disc cover) 2
7 Nm (0.7 m•kg, 5.1 ft•lb)
3. Install:
9Caliper 1
9Rear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
4. Tighten:
9Pad pin 3
5. Install:
9Pad pin plug 4
EC5A5220
Master cylinder kit
1. Clean:
9Master cylinder
9Master cylinder kit
Clean them with brake fluid.
2. Install:
9Master cylinder cup (primary) 1
9Master cylinder cup (secondary) 2
To master cylinder piston 3.
NOTE:
Apply the brake fluid on the master cylinder cup.
w
After installing, cylinder cup should be in-
stalled as shown direction. Wrong installa-
tion cause improper brake performance.
AFront
BRear
18 Nm (1.8 m•kg, 13 ft•lb)
3 Nm (0.3 m•kg, 2.2 ft•lb)
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3. Install:
9Spring 1
9Brake pedal 2
9O-ring 3
9Bolt (brake pedal) 4
9Clip 5
NOTE:
9Apply the lithium soap base grease on the
bolt, O-ring and brake pedal bracket.
9Install the clip with its stopper portion afac-
ing inward.
5-22
CHASFRONT BRAKE AND REAR BRAKE
26 Nm (2.6 m•kg, 19 ft•lb)
EC5A5911
Front brake hose
1. Install:
9Brake hose 1
To brake hose holder 2.
NOTE:
Before tightening the bolt (brake hose holder),
align the top aof the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose in front of the axle boss cand fit it
into the hose groove dso that the brake hose
does not contact the nut (wheel axle).
2. Install:
9Hose cover 1
9Plain washer 2
9Bolt [hose cover (M8)] 3
9Bolt [hose cover (M6)] 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
4. Install:
9Pin 1
9Plain washer 2
9Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” section
in the CHAPTER 3.
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