2005 YAMAHA YZ250LC engine

4-65
CRANKCASE AND CRANKSHAFTENG
Extent of removal Order Part name Q’ty Remarks
CRANKCASE AND CRANKSHAFT
REMOVAL
Preparation for Engine Refer to “ENGINE REMOVAL”section.
removal Piston Refer to “
CYLINDER HEAD, CYLINDER
AND PISTON
” section.
Primary drive gear
Kick idle gearRefer to “
KICK AXLE, SHIFT SHAFT AND
Stopper leverPRIMARY DRIVE GEAR”section.
Rotor and stator Refer to “CDI MAGNETO” section.
1 Segment 1
2 Bolt [L=50 mm (1.97 in)] 7
3 Bolt [L=60 mm (2.36 in)] 1
4 Bolt [L=70 mm (2.76 in)] 3
5 Holder 2
6 Crankcase (right) 1 Use special tool.
7 Crankcase (left) 1 Refer to “REMOVAL POINTS”.
8 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
9 Oil seal 2
10 Bearing 2 Refer to “REMOVAL POINTS”.




EC4N0000
CRANKCASE AND CRANKSHAFT
12
3
Extent of removal:1Crankcase separation2Crankshaft removal
3Crankshaft bearing removal



10 Nm (1.0 m•kg, 7.2 ft•lb)30 Nm (3.0 m•kg, 22 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-66
CRANKCASE AND CRANKSHAFTENG
NOTE:
9Make appropriate bolts 3as shown available
by yourself and attach the tool with them.
9Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
9As pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
cC
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw,
realign, and start over. If the cases do not
separate, check for a remaining case
screw or fitting. Do not force.
EC4N3000
REMOVAL POINTS
EC4N3212
Crankcase
1. Remove:
9Crankcase (right) 1
Use the crankcase separating tool 2.
Crankcase separating tool:
YU-1135-A/90890-01135
EC4N3302
Crankshaft
1. Remove:
9Crankshaft 1
Use the crankcase separating tool 2.
NOTE:
Make appropriate bolts 3as shown available by
yourself and attach the tool with them.
cC
Do not use a hammer to drive out the
crankshaft.
Crankcase separating tool:
YU-1135-A/90890-01135
1P8-9-30-4C 21/5/04 1:00 PM Page 34

4-67
CRANKCASE AND CRANKSHAFTENG
EC4N4000
INSPECTION
EC4N4101
Crankcase
1. Inspect:
9Contacting surface a
Scratches
Replace.
9Engine mounting boss b, crankcase
Cracks/Damage
Replace.
EC4N3401
Crankshaft bearing
1. Remove:
9Bearing 1
NOTE:
9Remove the bearing from the crankcase by
pressing its inner race as shown in å.
9If the bearing is removed together with the
crankshaft, remove the bearing using a general
bearing puller 2as shown in ∫.
9Do not use the removed bearing.
2. Inspect:
9Bearings 1
Rotate inner race with a finger.
Rough spot/Seizure
Replace.
3. Inspect:
9Oil seal 1
Damage
Replace.
1P8-9-30-4C 21/5/04 1:00 PM Page 36

4-71
CRANKCASE AND CRANKSHAFTENG
8. Tighten:
9Segment 1
9Bolt (segment) 2
NOTE:
9When installing the segment onto the shift cam
3, align the punch mark awith the dowel pin
b.
9Turn the segment clockwise until it stops and
tighten the bolt.
30 Nm (3.0 m•kg, 22 ft•lb)
7. Install:
9Tension spring 1
9Holder 2
9Bolt (holder) 3
NOTE:
Install the holder so that it contacts the projec-
tion aon the crankcase (right).
10 Nm (1.0 m•kg, 7.2 ft•lb)
9. Remove:
9Sealant
Forced out on the cylinder mating surface.
10. Apply:
9Engine oil
To the crank pin, bearing, oil delivery hole
and connecting rod big end washer.
11. Check:
9Crankshaft and transmission operation
Unsmooth operation
Repair.
14 Nm (1.4 m•kg, 10 ft•lb)
6. Install:
9Bolt (crankcase) 1
NOTE:
Tighten the crankcase tightening bolts in stage,
using a crisscross pattern.
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4-72
TRANSMISSION, SHIFT CAM AND SHIFT FORKENG
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFT CAM AND
SHIFT FORK REMOVAL
Preparation for EngineRefer to “ENGINE REMOVAL” section.
removal Separate the crankcase. Refer to“CRANKCASE AND CRANK
SHAFT
” section.
1 Main axle 1
2 Drive axle 1
3 Shift cam 1
4 Shift fork 3 1Refer to “REMOVAL POINTS”.
5 Shift fork 2 1
6 Shift fork 1 1
7 Spacer 1
EC4H0000
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1Main axle, drive axle, shift cam and shift fork removal
1









1P8-9-30-4C 21/5/04 1:00 PM Page 46

5-1
CHASFRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
7 Bearing 2 Refer to “REMOVAL POINTS”.
8 Brake disc 1
EC500000
CHASSISEC590000
FRONT WHEEL AND REAR WHEELEC598000
FRONT WHEEL
2
13
3
Extent of removal:1Front wheel removal2Wheel bearing removal3Brake disc removal
w
Support the machine securely so there is no dan-
ger of it falling over.
23 Nm (2.3 m•kg, 17 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
105 Nm (10.5 m•kg, 75 ft•lb)
12 Nm (1.2 m•kg, 8.7 ft•lb)
1P8-9-30-5A 19/5/04 9:28 AM Page 2

5-2
CHASFRONT WHEEL AND REAR WHEEL
EC598100
REAR WHEEL
Extent of removal:1Rear wheel removal2Wheel bearing removal3Brake disc removal
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10 Brake disc 1
2
13
3
w
Support the machine securely so there is no dan-
ger of it falling over.
125 Nm (12.5 m•kg, 90 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
42 Nm (4.2 m•kg, 30 ft•lb)
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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 Brake hose holder (protector) 2
2 Brake hose holder (caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1
Remove when loosening the pad pin.
6 Pad pin 1Loosen when disassembling the caliper.
7 Caliper 1
8 Brake lever 1
9 Master cylinder bracket 1
10 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
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)
23 Nm (2.3 m•kg, 17 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
2
10 Nm (1.0 m•kg, 7.2 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
1P8-9-30-5A 19/5/04 9:28 AM Page 20