2007 YAMAHA YZ250LC lock

5-9
CHASFRONT WHEEL AND REAR WHEEL
8. Install:
9Chain puller (right) 1
9Plain washer 2
9Nut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.
9. Adjust:
9Drive chain slack a
Refer to “DRIVE CHAIN SLACK ADJUSTMENT”
section in the CHAPTER 3.
10. Tighten:
9Nut (wheel axle) 1
9Locknut 2
125 Nm (12.5 m•kg, 90 ft•lb)
Drive chain slack :
48~58 mm (1.9~2.3 in)
19 Nm (1.9 m•kg, 13 ft•lb)
1P8-9-32-5a 4/10/06 4:39 PM Page 18

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.
1P8-9-32-5a 4/10/06 4:40 PM Page 28

5-24
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Brake hose holder 1
9Screw (brake hose holder) 2
cC
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
EC5A5620
Brake fluid
1. Fill:
9Brake fluid
Until the fluid level reaches “LOWER” level
line a.
w
9Use only the designated quality brake fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
9Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemi-
cal reaction and lead to poor performance.
9Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
cC
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
AFront
BRear
Recommended brake fluid:
DOT #4
2 Nm (0.2 m•kg, 1.4 ft•lb)
1P8-9-32-5a 4/10/06 4:40 PM Page 48

5-24
CHAS
FREIN AVANT ET FREIN ARRIERE
VORDERRADBREMSE UND HINTERRADBREMSE
FRENO ANTERIORE E FRENO POSTERIORE
2. Einbauen:
9Bremsschlauchhalter 1
9Schraube (Bremsschlauchhal-
ter) 2
dD
Nachdem die Bremsschlauchhalter
eingebaut wurden, darauf achten,
dass der Bremsschlauch die Feder
(Hinterrad-Stoßdämpfer) nicht
berührt. Anderenfalls die Verdre-
hung berichtigen.
Bremsflüssigkeit
1. Füllen:
9Bremsflüssigkeit
Bis der Flüssigkeitsstand die
Standlinie „LOWER“ a
erreicht.
W
9Nur bezeichnete Qualitätsbrems-
flüssigkeit verwenden; anderen-
falls können die Gummidichtun-
gen angegriffen werden, wodurch
Undichtheiten und schlechte
Bremswirkung entstehen können.
9Zum Nachfüllen dieselbe Brems-
flüssigkeit verwenden; das
Mischen von Bremsflüssigkeiten
kann schädliche chemische Vor-
gänge hervorrufen und zu
schlechter Bremsleistung führen.
9Man achte darauf, dass beim
Nachfüllen kein Wasser in den
Steuerzylinder gelangt. Wasser
setzt den Siedepunkt erheblich
herab und kann Dampfblasenbil-
dung verursachen.
dD
Bremsflüssigkeit kann lackierte
Flächen oder Plastikteile angreifen.
Deshalb ist vergossene Bremsflüs-
sigkeit sofort abzuwischen.
AVorn
BHinten
2. Monter:
9Support de tuyau de frein 1
9
Vis (support de tuyau de frein) 2
fF
Après avoir installé les supports de
tuyau de frein, s’assurer que le tuyau
de frein ne touche pos le ressort
(amortisseur arrière) S’il le touche,
corriger le coude.
Liquide de frein
1. Remplir:
9Liquide de frein
Jusqu’à ce que le liquide
atteigne le niveau “LOWER”
a.
XG
9La qualité du liquide de frein utilisé
doit être conforme aux normes spé-
cifiées, sinon les joints en caout-
chouc risquent de se détériorer, ce
qui causera des fuites et un mauvais
fonctionnement du frein.
9Toujours utiliser la même marque
de liquide de frein. Le mélange de
liquides de marques différentes
risque de provoquer une réaction
chimique nuisible au fonctionne-
ment du frein.
9Lorsqu’on ajoute du liquide, faire
attention de ne pas laisser pénétrer
de l’eau dans le maître-cylindre.
L’eau risque d’abaisser fortement
le point d’ébullition et de provoquer
le phénomène appelé “VAPOR
LOCK”.
fF
Le liquide de frein attaque les sur-
faces peintes et le plastique. Si on en
renverse, il faut l’essuyer immédiate-
ment.
AAvant
BArrière2. Installare:
9Supporto del tubo flessibile del
freno 1
9Vite (supporto del tubo flessibi-
le del freno) 2
iI
Dopo avere installato i supporti del
tubo flessibile del freno, assicurarsi
che il tubo flessibile del freno non
tocchi la molla (ammortizzatore
posteriore). Se lo fa, correggerne la
torsione.
IC5A5620
Liquido per freni
1. Riempire:
9Liquido per freni
Finché il livello del liquido rag-
giunge la linea di livello
“LOWER” a.
T
9Usare soltanto il liquido per freni
della qualità indicata: altrimenti, le
tenute in gomma possono deterio-
rarsi, provocando perdite e uno
scarso rendimento frenante.
9Rabboccare con lo stesso tipo di
liquido per freni; miscelare liquidi
diversi può portare a una reazione
chimica nociva e comporta uno
scarso rendimento.
9Fare attenzione che, durante il rab-
bocco, non entri acqua nel cilindro
principale. L’acqua abbasserà note-
volmente il punto di ebollizione del
liquido e può comportare un tam-
pone di vapore.
iI
Il liquido per freni può erodere le
superfici verniciate o le parti in pla-
stica. Ripulire sempre immediata-
mente il liquido versato.
AAnteriore
BPosteriore
Liquide de frein recom-
mandé:
DOT #4Empfohlene Bremsflüs-
sigkeit:
DOT Nr. 4Liquido per freni racco-
mandato:
DOT No. 4
2 Nm (0,2 m•kg, 1,4ft•lb)
2 Nm (0,2 m•kg, 1,4 ft•lb)
2 Nm (0,2 m•kg, 1,4 ft•lb)
1P8-9-32-5a 4/10/06 4:40 PM Page 49

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 the damper
rod 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.
1P8-9-32-5b 4/5/06 4:23 PM Page 8

5-32
CHASFRONT FORK
EC554502
Inner tube
1. Inspect:
9Inner tube surface a
Score marksRepair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock pieceReplace.
9Inner tube bends
Out of specificationReplace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
Inner tube bending limit:
0.2 mm (0.008 in)
EC554600
Outer tube
1. Inspect:
9Outer tube 1
Score marks/Wear/DamageReplace.
Adjuster
1. Inspect:
9Adjuster 1
9O-ring 2
Wear/DamageReplace.
1P8-9-32-5b 4/5/06 4:23 PM Page 14

5-34
CHASFRONT FORK
5. Measure:
9Oil level (left and right) a
Out of specification  Adjust.
Standard oil level:
145~148 mm (5.71~5.83 in)
From top of fully stretched
damper assembly.
6. Tighten:
9Locknut 1
NOTE:
Fully finger tighten the locknut onto the
damper assembly.
7. Loosen:
9Compression damping adjuster 1
NOTE:
9Loosen the compression damping adjuster fin-
ger tight.
9Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
8. Install:
9Base valve 1
To damper assembly 2.
NOTE:
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
9. Check that the damper assembly is fully
stretched.
Not fully stretched  Repeat the steps 2 to 8.
1P8-9-32-5b 4/5/06 4:24 PM Page 18

5-38
CHASFRONT FORK
22. Check:
9Inner tube smooth movement
Tightness/Binding/Rough spots Repeat the
steps 15 to 21.
23. Measure:
9Distance a
Out of specificationTurn into the locknut.
Distance a a
:
19 mm (0.75 in) or more
Between damper assembly
1 1
bottom and locknut 2
2bottom.
24. Install:
9Collar 1
9Fork spring 2
To damper assembly 3.
NOTE:
Install the collar with its larger dia. end afacing
the fork spring.
25. Install:
9Damper assembly 1
To inner tube 2.
cC
To install the damper assembly into the
inner tube, hold the inner tube aslant. If the
inner tube is held vertically, the damper
assembly may fall into it, damaging the
valve inside.
26. Loosen:
9Rebound damping adjuster 1
NOTE:
9Loosen the rebound damping adjuster finger
tight.
9Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
1P8-9-32-5b 4/5/06 4:24 PM Page 26