How To Use This Manual - Yamaha XT250X Service Manual

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
•
4
(5)
6
5
5
Order
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
1
kg, 5.8 ft Ib)
•
14
3
4
12
8
2 18
7
17
16
1
13 New
15
75 Nm (7.5 m kg, 54 ft Ib)
• •
E
80 Nm (8.0 m
Job/Parts to remove Q'ty
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
CLUTCH
EAS25070
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Loosen:
Primary drive gear nut "1"
NOTE:
Insert aluminum plate "a" between primary drive
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
YM-91042
19
11
10 New
9
2
kg, 58 ft Ib)
• •
Remarks
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
Friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
Friction plate thickness
Out of specification
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.70— 2.90 mm (0.106— 0.114 in)
Wear limit
2.60 mm (0.1024 in)
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
3
1
1. Check:
Clutch plate
Damage Replace the clutch plates as a
set.
2. Measure:
Clutch plate warpage
(with a surface plate and thickness gauge "1")
Out of specification Replace the clutch
plates as a set.
Warpage limit
0.20 mm (0.0079 in)
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
Clutch spring
Damage Replace the clutch springs as a
Replace the friction
set.
2. Measure:
5-33
CLUTCH
7
2