Checking The Clutch Plates; Checking The Clutch Springs; Checking The Clutch Housing; Checking The Clutch Boss - Yamaha XG250 Service Manual

Out of specification → Replace the friction
plate.
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.
1. Check:
Clutch plate
●
Damage → Replace the clutch plate.
2. Measure:
Clutch plate warpage
●
(with a surface plate and thickness gauge
"1")
Out of specification → Replace the clutch
plate.
Warpage limit
0.20 mm (0.0079 in)
EAS25140

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the
clutch springs.
1
1. Check:
Clutch spring
●
Damage → Replace the clutch spring.
2. Measure:
Clutch spring free length "a"
●
Out of specification → Replace the clutch
spring.
Clutch spring free length
40.10 mm (1.58 in)
Minimum length
38.10 mm (1.50 in)
a
EAS25150

CHECKING THE CLUTCH HOUSING

1. Check:
Clutch housing dogs "1"
●
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
EAS25160

CHECKING THE CLUTCH BOSS

1. Check:
Clutch boss splines
●
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
5-34
CLUTCH