2005 YAMAHA YZ250LC oil

4-30
CYLINDER HEAD, CYLINDER AND PISTONENG
EC475383
Cylinder head and cylinder
1. Apply:
9Engine oil
To piston 1piston ring 2and cylinder sur-
face.
2. Install:
9Cylinder 1
cC
Make sure the piston rings are properly
positioned. Install the cylinder with one
hand while compressing the piston rings
with the other hand.
NOTE:
After installing, check the smooth movement of
the piston.
3. Install:
9Nut (cylinder) 1
NOTE:
Tighten the nuts in stage, using a crisscross pat-
tern.
3. Install:
9Piston 1
9Piston pin 2
9Piston pin clip 3
NOTE:
9The arrow aon the piston dome must point to
exhaust side.
9Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the pis-
ton pin clip from falling into the crankcase cavi-
ty.
cC
Do not allow the clip open ends to meet the
piston pin slot b b
.
42 Nm (4.2 m•kg, 30 ft•lb)
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4-33
CLUTCH AND PRIMARY DRIVEN GEARENG
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND
FRICTION PLATE 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.
Rotor and stator Refer to
“CDI MAGNETO“section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Screw (clutch spring) 6
3 Clutch spring 6
4 Pressure plate 1
5 Friction plate 8
6 Clutch plate 7
Extent of removal:1Clutch plate and friction plate removal
EC490000
CLUTCH AND PRIMARY DRIVEN GEAREC498000
CLUTCH PLATE AND FRICTION PLATE
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-30-4B 11/5/04 10:59 AM Page 12

4-36
CLUTCH AND PRIMARY DRIVEN GEARENG
EC484500
Friction plate
1. Measure:
9Friction plate thickness
Out of specification Replace friction
plate as a set.
Measure at all four points.
EC484600
Clutch plate
1. Measure:
9Clutch plate warpage
Out of specification Replace clutch plate
as a set.
Use a surface plate 1and thickness
gauge 2.
EC484700
Push lever axle
1. Inspect:
9Push lever axle 1
Wear/Damage Replace.
EC484810
Push rod
1. Inspect:
9Push rod 1 1
9Bearing 2
9Plain washer 3
9Push rod 2 4
Wear/Damage/Bend Replace.
EC495000
ASSEMBLY AND INSTALLATION
EC485120
Push lever axle
1. Install:
9Push lever axle 1
9Copper washer 2
9Bolt (push lever axle) 3
NOTE:
Apply the lithium soap base grease on the oil
seal lip and push lever axle.
Friction plate thickness:
Standard
2.9~3.1 mm 2.8 mm
(0.114~0.122 in) (0.110 in)
Warp limit:
0.2 mm (0.008 in)
6 Nm (0.6 m•kg, 4.3ft•lb)
1P8-9-30-4B 11/5/04 10:59 AM Page 18

4-36
EMBRAYAGE ET PIGNON MENE PRIMAIRE
KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD
FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIOENG
Schubstange
1. Prüfen:
9Schubstange 1 1
9Lager 2
9Beilegescheibe 3
9Schubstange 2 4
Abnutzung/Beschädigung/
Biegung Erneuern.IC484810Asta di spinta
1. Ispezionare:
9Asta di spinta 1 1
9Cuscinetto 2
9Rosetta 3
9Asta di spinta 2 4
Usura/Danni/CurvaturaSosti-
tuirli.
MONTAGE UND EINBAU
Schubhebelachse
1. Einbauen:
9Schubhebelachse 1
9Kupferscheibe 2
9Schrauben (Schubhebelachse)
3
HINWEIS:
Lithiumfett auf die Öldichtungslippe
und Schubhebelachse auftragen.
IC495000
MONTAGGIO E
INSTALLAZIONE
IC485120
Asse leva di spinta
1. Installare:
9Asse leva di spinta 1
9Rondella in rame 2
9Bullone (asse leva di spinta) 3
NOTA:
Applicare il grasso a base di sapone al
litio sul bordo del paraolio e spingere
l’asse della leva di spinta.
Reibscheibe
1. Messen:
9Reibscheibendicke
Abweichung von Spezifikation
Die Reibscheiben als Satz
erneuern.
Die Reibscheiben an vier Stel-
len messen.
Kuplungsscheibe
1. Messen:
9Verzug der Kupplungsschei-
ben
Abweichung von Spezifikation
Kupplungsscheiben als Satz
erneuern.
Eine Richtplatte 1und eine
Fühlerlehre 2verwenden.
Schubhebelachse
1. Prüfen:
9Schubhebelachse 1
Abnutzung/Beschädigung
Erneuern.Disque de friction
1. Mesurer:
9Epaisseur de disque de friction
Hors-spécificationChanger
tous les disques de friction.
Mesurer chaque disque en
quatre endroits.
Disque d’embrayage
1. Mesurer:
9Voile de disque d’embrayage
Hors-spécificationChanger
tous les disques d’embrayage.
Utiliser une plaque à surfacer 1
et une jauge d’épaisseur 2.
Axe de levier de poussée
1. Examiner:
9Axe de levier de poussée 1
Usure/endommagementChan-
ger.
Tige de poussée
1. Examiner:
9Tige de poussée 1 1
9Roulement 2
9Rondelle ordinaire 3
9Tige de poussée 2 4
Usure/endommagement/défor-
mationChanger.
REMONTAGE ET
MONTAGE
Axe de levier de poussée
1. Monter:
9Axe de levier de poussée 1
9Rondelle en cuivre 2
9Boulon (axe de levier de pous-
sée) 3
N.B.:
Appliquer de la graisse à base de sapo-
nification de lithium sur le joint à lèvre
et l’axe de levier de poussoir.
IC484500Disco di innesto
1. Misurare:
9Spessore del disco di innesto
Fuori specificaSostituire il
disco di innesto come set.
Misurare su tutti e quattro i
punti.
IC484600
Disco della frizione
1. Misurare:
9Svergolamento del disco della
frizione
Fuori specificaSostituire il
disco della frizione come set.
Usare un piano di riscontro 1e
uno spessimetro 2.
IC484700
Asse della leva di spinta
1. Ispezionare:
9Asse della leva di spinta 1
Usura/DanniSostituirlo.
Standard
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Reibscheibendicke:
Verzungsgrenze:
0,2 mm (0,008 in)
Valore normale
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Spessore del disco di inne-
sto:
Limite di svergolamento:
0,2 mm (0,008 in)
Limite de déformation:
0,2 mm (0,008 in)
Standard
2,9~3,1 mm 2,8 mm
(0,114~0,122 in) (0,110 in)
Epaisseur de disque de
friction:
6 Nm (0,6m•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)
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4-37
CLUTCH AND PRIMARY DRIVEN GEARENG
EC495230
Clutch
1. Install:
9Thrust plate [D=ø 42 mm (1.65 in)] 1
9Spacer 2
9Bearing 3
9Primary driven gear 4
NOTE:
Apply the transmission oil on the bearing, spacer
and primary driven gear inner circumference.
2. Install:
9Thrust plate [D=ø 44 mm (1.73 in)] 1
9Clutch boss 2
3. Install:
9Lock washer 1
9Nut (clutch boss) 2
NOTE:
Use the clutch holding tool 3, 4to hold the
clutch boss.
åFor USA and CDN
∫Except for USA and CDN
4. Bend the lock washer 1tab.
75 Nm (7.5 m•kg, 54 ft•lb)
Clutch holding tool:
YM-91042 ..............................3 3
90890-04086 ..........................4 4
å
∫
1P8-9-30-4B 11/5/04 10:59 AM Page 20

4-38
CLUTCH AND PRIMARY DRIVEN GEARENG
5. Install:
9Friction plate 1
9Clutch plate 2
NOTE:
9Install the clutch plates and friction plates alter-
nately on the clutch boss, starting with a friction
plate and ending with a friction plate.
9Apply the transmission oil on the friction plates
and clutch plates.
6. Install:
9Bearing 1
9Plain washer 2
9Circlip 3
To push rod 1 4.
NOTE:
Apply the lithium soap base grease on the bear-
ing and plain washer.
7. Install:
9Push rod 2 1
9Push rod 1 2
NOTE:
9Apply the transmission oil on the ends of the
push rod 2.
9Install the push rod 2 with its smaller end a
toward you.
8. Install:
9Pressure plate 1
9. Install:
9Clutch spring 1
9Screw (clutch spring) 2
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-30-4B 11/5/04 10:59 AM Page 22

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

4-44
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
3. Install:
9Shift lever assembly 1
9Shift guide 2
NOTE:
9The shift lever assembly is installed at the
same time as the shift guide.
9Apply the transmission oil on the bolt (seg-
ment) shaft.
2. Install:
9Shift lever assembly 1
To shift guide 2.
EC4C5202
Shift guide and shift lever assembly
1. Install:
9Spring 1
9Pawl pin 2
9Pawl 3
To shift lever 4.
EC4C5000
ASSEMBLY AND INSTALLATION
EC4C5130
Stopper lever
1. Install:
9Tension spring 1
9Holder 2
9Bolt (holder) 3
9Plain washer 4
9Stopper lever 5
9Bolt (stopper lever) 6
NOTE:
Align the stopper lever roller with the slot on
segment.
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-30-4B 11/5/04 10:59 AM Page 34