Yamaha XT250X 2008 Service Manual page 5

EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
The manual is divided into chapters and each chapter is divided into sections. The current section title
G
is shown at the top of each page "1".
Sub-section titles appear in smaller print than the section title "2".
G
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
G
removal and disassembly section "3".
Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-
G
bly step "4".
Symbols indicate parts to be lubricated or replaced "5".
G
Refer to "SYMBOLS".
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
G
parts, notes in jobs, etc "6".
Jobs requiring more information (such as special tools and technical data) are described sequentially
G
"7".
Removing the clutch
3
8 Nm (0.8 m kg, 5.8 ft
•
4
1
(5)
6
5
5
Order Job/Parts to remove
1 Clutch spring
2 Pressure plate
3 Adjusting screw
4 Push plate
5 Friction plate
6 Clutch plate
7 Clutch damper spring
8 Clutch damper spring seat
9 Primary drive gear nut
6
10 Lock washer
11 Claw washer
12 Clutch boss nut
13 Lock washer
14 Clutch boss
15 Thrust washer
16 Clutch housing
17 Ball
18 Clutch push rod
19 Primary drive gear
All manuals and user guides at all-guides.com
1
CLUTCH
Ib)
•
14
3
4
12
8
2 18
7
17
16
13 New
15
19
11
10 New
9
75 Nm (7.5 m kg, 54 ft Ib)
• •
E
80 Nm (8.0 m kg, 58 ft Ib)
• •
Q'ty Remarks
5
1
1
1
6
5
1
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal proce-
dure.
5-31
EAS25070
NOTE:
REMOVING THE CLUTCH
Measure the friction plate at four places.
1. Straighten the lock washer tab.
2. Loosen:
Friction plate thickness
Primary drive gear nut "1"
2.70— 2.90 mm (0.106— 0.114 in)
NOTE:
Wear limit
Insert aluminum plate "a" between primary drive
2.60 mm (0.1024 in)
gear "2" and primary driven gear "3", and loosen
the primary drive gear nut.
3. Loosen:
Clutch boss nut "1"
NOTE:
While holding the clutch boss "1" with the univer-
sal clutch holder "2", loosen the clutch boss nut.
Universal clutch holder
90890-04086
EAS25110
CHECKING THE CLUTCH PLATES
YM-91042
The following procedure applies to all of the
clutch plates.
3
1
1. Check:
Clutch plate
Damage
2
set.
2. Measure:
Clutch plate warpage
(with a surface plate and thickness gauge "1")
Out of specification
plates as a set.
Warpage limit
EAS25100
CHECKING THE FRICTION PLATES 0.20 mm (0.0079 in)
The following procedure applies to all of the fric-
tion plates.
EAS25140
1. Check:
CHECKING THE CLUTCH SPRINGS
Friction plate
The following procedure applies to all of the
Damage/wear Replace the friction plates
clutch springs.
as a set.
1. Check:
2. Measure:
Clutch spring
Friction plate thickness
Damage
Out of specification Replace the friction
set.
plates as a set.
2. Measure:
5-33
CLUTCH
7
Replace the clutch plates as a
Replace the clutch
2
Replace the clutch springs as a