2006 YAMAHA YZ250F clutch

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Repair.
Radiator 1
Radiator hose joint 2
Coolant leakage → Repair or replace.
Radiator hose 3
Swelling → Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Before adjustment, expose the adjuster by
moving the boot 3 and cap 4 away.
Make minute adjustment on the lever side
using the adjuster 5.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknuts 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknuts.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
(For USA and CDN)
CAUTION:
Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD
a or higher.
Do not use oils labeled “ENERGY CON-
SERVING II”
b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
4. Install:
Oil tank cap
5. Start the engine and let it warm up for sev-
eral minutes.
6. Turn off the engine and inspect the oil level
once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
Recommended oil:
At 5 °C (40 °F) or higher
È
Yamalube 4 (20W-40) or SAE
20W-40 type SG motor oil (Non-
Friction modified)
At 15 °C (60 °F) or lower
É
Yamalube 4 (10W-30) or SAE
10W-30 type SG motor oil (Non-
Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
Recommended oil:
Refer to the following chart for
selection of oils which are
suited to the atmospheric
temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SG” or higher grade
(Designed primarily for
motorcycles)-20
-4-10
140
3010
5020
6830
8640 50
104
122 ˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40
a
b

3 - 44
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Hot starter cable end
ÈUse Yamaha cable lube or equivalent on these
areas.
ÉUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÊLubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC

4 - 2
ENG
REMOVAL POINTS
Side cover
1. Remove:
Bolt (side cover)
Left side cover 1
Right side cover 2
NOTE:
Draw the side cover downward to remove it
because its claws a are inserted in the air fil-
ter case.
Number plate
1. Remove:
Bolt (number plate)
Number plate 1
NOTE:
The projection a is inserted into the band of
the number plate. Pull the band off the pro-
jection before removal.
Remove the hot starter cable 2 and clutch
cable 3 from the cable guide b on the num-
ber plate.
The projection c on the lower bracket is
inserted into the number plate. Remove the
number plate by pulling it off the projection.
ASSEMBLY AND INSTALLATION
Air scoop
1. Install:
Air scoop 1
Bolt (air scoop)
NOTE:
Put the portion a of the flap of the air filter
case on the inside of the air scoop.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SEAT, FUEL TANK AND SIDE COVERS

4 - 50
ENGCLUTCH
EC4A0000
CLUTCH
Extent of removal:
1 Push rod 1, 2 and push lever shaft removal
2 Push rod 1 disassembly
3 Friction plate and clutch plate removal
4 Primary driven gear removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8Ball 1
9 Push rod 2 1
1
4
1
3
2

4 - 51
ENGCLUTCH
Extent of removal Order Part name Q’ty Remarks
10 Friction plate 9
11 Clutch plate 8
12 Cushion spring 1
13 Seat plate 1
14 Nut (clutch boss) 1
Use special tool.
Refer to “REMOVAL POINTS”. 15 Lock washer 1
16 Clutch boss 1
17 Thrust washer 1
18 Primary driven gear 1
19 Push lever shaft 1
4
1
3

4 - 52
ENGCLUTCH
EC4A3000
REMOVAL POINTS
Clutch boss
1. Remove:
Nut 1
Lock washer 2
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4 to hold the clutch boss.
È
For USA and CDN
ÉExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
È
É
EC4A4000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
40.4 mm (1.59 in)
: 39.4 mm (1.55 in)

4 - 53
ENGCLUTCH
Friction plate
1. Measure:
Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate 1 and thickness
gauge 2.
Friction plate thickness:
2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
: 2.7 mm (0.106 in)
Warp limit:
0.1 mm (0.004 in)
Push lever shaft
1. Inspect:
Push lever shaft 1
Wear/damage → Replace.
Push rod
1. Inspect:
Push rod 1 1
Bearing 2
Washer 3
Push rod 2 4
Ball 5
Wear/damage/bend → Replace.