2005 YAMAHA YZ250LC oil

9. Tighten:
9Base valve 1
NOTE:
Hold the damper assembly with the cap bolt
ring wrench
2and use the cap bolt wrench 3
to tighten the base valve with specified torque.
10. After filling, pump the damper assembly 1
slowly up and down more than 10 times to
distribute the fork oil.
5-34
CHASFRONT FORK
11. While protecting the damper assembly 1
with a rag and compressing fully, allow
excessive oil to overflow on the base valve
side.
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Take care not to damage the damper
assembly.
12. Allow the overflowing oil to escape at the
hole ain the damper assembly.
13. Check:
9Damper assembly smooth movement
Tightness/Binding/Rough spots  Repeat
the steps 2 to 12.
29 Nm (2.9 m•kg, 21 ft•lb)
Cap bolt wrench:
YM-01500/90890-01500
Cap bolt ring wrench:
YM-01501/90890-01501
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5-35
CHASFRONT FORK
14. Install:
9Dust seal 1
9Stopper ring 2
9Oil seal 3
9Oil seal washer 4
9Slide metal 5
To inner tube 6.
NOTE:
9Apply the fork oil on the inner tube.
9When installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
9Install the oil seal with its manufacture's marks
or number facing the axle holder side.
9Install the oil seal washer with its projections b
facing upward.
15. Install:
9Piston metal 1
NOTE:
Install the piston metal onto the slot on inner
tube.
16. Install:
9Outer tube 1
To inner tube 2.
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5-36
CHASFRONT FORK
17. Install:
9Slide metal 1
9Oil seal washer 2
To outer tube slot.
NOTE:
Press the slide metal into the outer tube with
fork seal driver 3.
18. Install:
9Oil seal 1
NOTE:
Press the oil seal into the outer tube with fork
seal driver 2.
19. Install:
9Stopper ring 1
NOTE:
Fit the stopper ring correctly in the groove in the
outer tube.
20. Install:
9Dust seal 1
NOTE:
Apply the lithium soap base grease on the inner
tube.
Fork seal driver:
YM-01442/90890-01442
Fork seal driver:
YM-01442/90890-01442
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5-38
CHASFRONT FORK
26. Install:
9Push rod 1
9Copper washer 2
9Adjuster 3
To damper assembly 4.
NOTE:
9While compressing the inner tube 5, set the
cap bolt ring wrench 7between the inner tube
and locknut 6.
9Fully finger tighten the adjuster onto the
damper assembly.
27. Inspect:
9Gap abetween adjuster 1and locknut 2.
Out of specificationRetighten and read-
just the locknut.
NOTE:
If the adjuster is installed out of specification,
proper damping force cannot be obtained.
28. Tighten:
9Adjuster (locknut) 1
NOTE:
Hold the locknut 2and tighten the adjuster with
specified torque.
29. Install:
9Adjuster 1
To inner tube.
30. Fill:
9Front fork oil 1
From outer tube top.
29 Nm (2.9 m•kg, 21 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
Gap a abetween adjuster and locknut
0.5~1.0mm (0.02~0.04 in)
Recommended oil:
Suspension oil "S1"
Standard oil amount:
245 cm
3(8.62 Imp oz, 8.28 US oz)
Extent of adjustment:
200
~300 cm3(7.04~10.6 Imp oz,
6.76~10.1 US oz)
Cap bolt ring wrench:
YM-01501/90890-01501
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5-39
CHASFRONT FORK
31. Install:
9Damper assembly 1
To outer tube.
NOTE:
Temporarily tighten the damper assembly.
32. Install:
9Protector guide 1
EC5552A1
Installation
1. Install:
9Front fork 1
NOTE:
9Temporarily tighten the pinch bolts (under
bracket).
9Do not tighten the pinch bolts (handle crown)
yet.
2. Tighten:
9Damper assembly 1
NOTE:
Use the cap bolt ring wrench 2to tighten the
damper assembly with specified torque.
w
Never fail to make the oil amount adjustment
between the maximum and minimum
amount and always adjust each front fork to
the same setting. Uneven adjustment can
cause poor handling and loss of stability.
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9Be sure to use recommended fork oil. If
other oils are used, they may have an ex-
cessively adverse effect on the front fork
performance.
9Never allow foreign materials to enter the
front fork.
30 Nm (3.0 m•kg, 22 ft•lb)
Cap bolt ring wrench:
YM-01501/90890-01501
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5-43
CHASHANDLEBAR
EC5B3000
REMOVAL POINTS
EC5B3100Master cylinder
1. Remove:
9Master cylinder bracket 1
9Master cylinder 2
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9Do not let the master cylinder hang on the
brake hose.
9Keep the master cylinder cap side horizontal
to prevent air from coming in.
EC5B3200
Grip
1. Remove:
9Grip 1
NOTE:
Blow in air between the handlebar or tube guide
and the grip. Then remove the grip which has
become loose.
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:
9Handlebar 1
Bends/Cracks /DamageReplace.
w
Do not attempt to straighten a bent handlebar
as this may dangerously weaken the handlebar.
EC5B5000
ASSEMBLY AND INSTALLATION
EC5B5100
Throttle assembly
1. Install
9Grip (right) 1
Apply the adhesive on the tube guide 2.
NOTE:
9Before applying the adhesive, wipe off grease
or oil on the tube guide surface awith a lac-
quer thinner.
9Align the mating mark bon the grip (right) with
the slot cin the tube guide.
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5-44
CHASHANDLEBAR
2. Install:
9Grip cap (upper) 1
9Grip cap (lower) 2
9Bolt (grip cap) 3
NOTE:
Temporarily tighten the bolts (grip cap).
EC5B5210
Handlebar
1. Install:
9Handlebar 1
9Handlebar holder 2
9Bolt (handlebar holder) 3
NOTE:
9The upper handlebar holder should be installed
with the punched mark aforward.
9Install the handlebar so that the marks bare in
place on both sides.
9First tighten the bolts on the front side of the
handlebar holder, and then tighten the bolts on
the rear side.
2. Install:
9Grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
9Before applying the adhesive, wipe off grease
or oil on the handlebar surface awith a lac-
quer thinner.
9Install the grip (left) to the handlebar so that the
line bbetween the two arrow marks faces
straight upward.
28 Nm (2.8 m•kg, 20 ft•lb)
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5-54
CHASSWINGARM
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1Cap 2 Refer to “REMOVAL POINTS”.
2Relay arm 1
3Connecting rod 1
4Collar 2
5Oil seal 2
6Thrust bearing 2
7Bush 2
8Oil seal 8
9Bearing 10 Refer to “REMOVAL POINTS”.
EC578000
SWINGARM DISASSEMBLY
Extent of removal:1Swingarm disassembly 2Connecting rod removal and disassembly
3Relay arm removal and disassembly
1
2
3
23
80 Nm (8.0 m•kg, 58 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
80 Nm (8.0 m•kg, 58 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
1P8-9-30-5D 11/5/04 11:07 AM Page 4