2005 YAMAHA YZ250LC brake

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.
105 Nm (10.5 m•kg, 75 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
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5-7
CHASFRONT WHEEL AND REAR WHEEL
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.
EC5251A1
Rear wheel
1. Install:
9Bearing (right) 1
9Circlip 2
9Spacer 3
9Bearing (left) 4
9Oil seal 5
14 Nm (1.4 m•kg, 10 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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5-10
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)
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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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5-12
CHASFRONT BRAKE AND REAR BRAKE
Extent of removal Order Part name Q’ty Remarks
CALIPER DISASSEMBLYAB
1Pad pin 1 1
2Brake pad 2 2
3Pad support 1 1
4Caliper piston 2 1 Refer to “REMOVAL POINTS”.
5Dust seal 2 1
Refer to “REMOVAL POINTS”.
6Piston seal 2 1
EC5A8200
CALIPER DISASSEMBLY
A Front
B Rear
Extent of removal:1Front caliper disassembly2Rear caliper disassembly
21



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)
6 Nm (0.6 m•kg, 4.3 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
3 Nm (0.3 m•kg, 2.2 ft•lb)
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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 Nm (0.2 m•kg, 1.4 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
2
2
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5-14
CHASFRONT BRAKE AND REAR BRAKE
EC5A3000
REMOVAL POINTS
EC5A3101
Brake fluid
1. Remove:
[Front]
9Master cylinder cap 1
[Rear]
9Master cylinder cap 1
9Protector
NOTE:
Do not remove the diaphragm.
AFront
BRear
2. Connect the transparent hose 2to the
bleed screw 1and place a suitable contain-
er under its end.
AFront
BRear
3. Loosen the bleed screw and drain the brake
fluid while pulling the lever in or pushing
down on the pedal.
cC
9Do not reuse the drained brake fluid.
9Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
EC533301
Caliper piston
1. Remove:
9Caliper piston
Use compressed air and proceed carefully.
w
9Cover piston with rag and use extreme cau-
tion when expelling piston from cylinder.
9Never attempt to pry out piston.
AFront
BRear
Caliper piston removal steps:
9Insert a piece of rag into the caliper to lock
one caliper.
9Carefully force the piston out of the caliper
cylinder with compressed air.
1P8-9-30-5A 19/5/04 9:28 AM Page 28