2004 YAMAHA YZ250LC boot

EC040001
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY FOR
COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be
operated on any public street, road, or highway.
Off-road use on public lands may also be illegal.
Please check local regulations before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine
at maximum power until you are totally
familiar with its characteristics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE APPAR-
EL.
When operating this machine, always
wear an approved helmet with goggles
or a face shield. Also wear heavy
boots, gloves, and protective clothing.
Always wear proper fitting clothing
that will not be caught in any of the
moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE IN
PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks indi-
cated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
qSAFETY INFORMATION
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5-13
CHASFRONT BRAKE AND REAR BRAKE
Extent of removal Order Part name Q’ty Remarks
MASTER CYLINDER DISASSEMBLY
1Master cylinder cap 1
2Diaphragm 1
3Reservoir float 1
4Master cylinder boot 1
5Circlip 1 Use a long nose circlip pliers.
6Plain washer 1
7Push rod 1
8Master cylinder kit 1
EC5A8300
MASTER CYLINDER DISASSEMBLY
AFront
BRear
Extent of removal:1Front master cylinder disassembly2Rear master cylinder disassembly
1
12
2
2 Nm (0.2 m•kg, 1.4 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
2
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5-20
CHASFRONT BRAKE AND REAR BRAKE
3. Install:
9Spring 1
To master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
AFront
BRear
4. Install:
[Front]
9Master cylinder kit 1
9Plain washer 2
9Circlip 3
9Master cylinder boot 4
To master cylinder 5.
[Rear]
9Master cylinder kit 1
9Push rod 2
9Circlip 3
9Master cylinder boot 4
To master cylinder 5.
NOTE:
9Apply the brake fluid on the master cylinder
kit.
9Apply the lithium soap base grease on the tip
of the push rod.
9When installing the circlip, use a long nose
circlip pliers.
AFront
BRear
EC5A5310
Front master cylinder
1. Install:
9Master cylinder 1
9Master cylinder bracket 2
9Bolt (master cylinder bracket) 3
NOTE:
9Install the bracket so that the arrow mark a
face upward.
9First tighten the bolts on the upper side of the
master cylinder bracket, and then tighten the
bolts on the lower side.
9 Nm (0.9 m•kg, 6.5 ft•lb)
5XF-9-30-5A 4/21/03 9:58 PM Page 40