Front Fender; Front Brake Master Cylinder; Clutch Cable - Yamaha 2002 YZ250FR Assembly Manual

1 Front fender

1
Hexagon bolt with plain
2 4
washer
3 Collar 4
1 Collar 1
Front brake master
2 1
cylinder
3 Master cylinder bracket 1
4 Flange bolt 2

1 Clutch cable

1
2 Boot 1
3 Lever cover 1
S
V d=6 (0.24), l =20 (0.78)
V d=6 (0.24)
*
*
V
V d=6 (0.24), l=22 (0.87)
*
V
V
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EAA00109
6. FRONT FENDER
A: Install the collars.
B: Tighten the bolts to specifica-
tion.
Bolt:
7 Nm (0.7 mdkg, 5.1 ftdlb)
CAUTION:
Be careful not to scratch the
front fender with the front fork
outer tubes.
W
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to "CABLE ROUTING".
EAA00033
7. FRONT BRAKE MAS-
TER CYLINDER
A: Lubricate the pivoting part of
the brake lever.
Recommended lubricants:
Lithium-soap-based
grease
B: Make sure that the "UP" mark
on the bracket is pointed
upwards.
NOTE:
D First tighten the bolt on the
upper side of the master cylinder
bracket, and then tighten the bolt
on the lower side.
D Tighten the bolts to specification.
EAA00049
8. CLUTCH CABLE
A: Install the boot and lever
cover to the clutch cable.
B: Lubricate the pivoting part of
the clutch lever.
Recommended lubricants:
Yamaha cable lube
or motor oil
C: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjusting nut on
the lever holder until tight.
Next, align the slit in the
adjusting nut and cable sock-
et with the slit in the lever
holder.
Bolt:
9 Nm (0.9 mdkg, 6.5 ftdlb)
C: Check the brake lever for
smooth action.
W
Proper hose routing is essen-
tial to assure safe machine
operation. Refer to "CABLE
ROUTING".
b. Insert the cable end into the
lever hole. Next, while pulling
the outer cable in the direc-
tion opposite to the lever, seat
the outer cable into the cable
socket.
NOTE:
Check the clutch lever for
smooth action. Refer
"ADJUSTMENTS AND PREDE-
LIVERY SERVICE".
W
Proper cable routing is essen-
tial to assure safe machine
operation. Refer to "CABLE
ROUTING".
to