2005 YAMAHA YZ250LC drain bolt

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)
1P8-9-30-4B 11/5/04 10:59 AM Page 26

4-55
WATER PUMPENG
EC4G5220
Impeller shaft
1. Install:
9Impeller shaft 1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip and
impeller shaft. And install the shaft while turn-
ing it.
2. Install:
9Plain washer 1
9Impeller 2
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and install the
impeller.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
1P8-9-30-4C 21/5/04 12:59 PM Page 12

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

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)
1P8-9-30-5A 19/5/04 9:28 AM Page 22

5-29
CHASFRONT FORK
Adjuster
1. Drain the outer tube of its front fork oil at its
top.
2. Loosen:
9Adjuster 1
3. Remove:
9Adjuster 1
NOTE:
9While compressing the inner tube 2, set the
cap bolt ring wrench 4between the inner tube
and locknut 3.
9Hold the locknut and remove the adjuster.
cC
Do not remove the locknut as it may go
into the damper assembly and not be taken
out.
Cap bolt ring wrench:
YM-01501/90890-01501
EC553201
Inner tube
1. Remove:
9Dust seal 1
9Stopper ring 2
Using slotted-head screwdriver.
cC
Take care not to scratch the inner tube.
2. Remove:
9Inner tube 1
Oil seal removal steps:
9Push in slowly athe inner tube just be-
fore it bottoms out and then pull it back
quickly b.
9Repeat this step until the inner tube can
be pulled out from the outer tube.
1P8-9-30-5B 20/5/04 2:11 PM Page 8