User manual YAMAHA TZ250-2001

[. . . ] OWNER'S SERVICE MANUAL TZ250N1/(N) LIT-11626-14-44 5KE-28199-11 EC010000 TZ250N1/(N) OWNER'S SERVICE MANUAL ©2000 by Yamaha Motor Corporation, U. S. A. 1st Edition, September 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U. S. A. LIT-11626-14-44 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha TZ series. [. . . ] Install: · O-ring 1N · Dowel pin 2 ENG NOTE: Apply the lithium soap base grease on the Orings. 5. Install: · Cylinder head 1 · Copper washer 2 · Bolt (cylinder head) 3 T11 Nm (1. 1 mdkg, 8. 0 ftdlb) NOTE: · Apply the lithium soap base grease on the thread and contact surface of the bolt (cylinder head). · Tighten the bolts (cylinder head) in stage, using a crisscross pattern. 6. Install: · YPVS cable 2, 4 (open side) 1 · YPVS cable 1, 3 (close side) 2 To cable stay 3. NOTE: Install the open side cables (sleeve a cables) to the "0" marked b side of the cable stay. 7. Connect: · YPVS cable 2, 4 (open side) 1 · YPVS cable 1, 3 (close side) 2 To valve pulley 3. NOTE: Connect thhe silver cables to the left side cylinder and the black cables to the right cylinder. Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2. 4-29 CYLINDER HEAD, CYLINDER AND PISTON ENG 8. Install: · Cable stay 1 · Bolt (cable stay) 2 T7 Nm (0. 7 mdkg, 5. 1 ftdlb) 9. Adjust: · YPVS cable Refer to "YPVS OPEN SIDE CABLE ADJUSTMENT" and "YPVS CLOSE SIDE CABLE ADJUSTMENT" section in the CHAPTER 3. 10. Install: · Spark plug 1 T19 Nm (1. 9 mdkg, 13 ftdlb) · Spark plug cap 2 · Radiator hose 3 3 T2 Nm (0. 2 mdkg, 1. 4 ftdlb) · Radiator hose 4 4 T2 Nm (0. 2 mdkg, 1. 4 ftdlb) 4-30 CLUTCH EC4A0000 ENG CLUTCH EC4A8000 CLUTCH PLATE AND FRICTION PLATE T 6 Nm (0. 6 mdkg, 4. 3 ftdlb) T 9 Nm (0. 9 mdkg, 6. 5 ftdlb) Extend of removal: Extend of removal 1 Clutch plate and friction plate removal Order Part name CLUTCH PLATE AND FRICTION PLATE REMOVAL Lower cowl 1 2 3 4 5 Screw (clutch spring) Clutch spring Pressure plate Friction plate Clutch plate 6 6 1 6 5 Q'ty Remarks Preparation for removal Refer to "COWLING, SEAT AND FUEL TANK" section. 1 4-31 CLUTCH EC4A8200 ENG CLUTCH HOUSING AND PUSH ROD T 75 Nm (7. 5 mdkg, 54 ftdlb) Extend of removal: Extend of removal 1 Clutch housing removal Order Part name CLUTCH HOUSING AND PUSH ROD REMOVAL Nut (clutch boss) Lock washer Clutch boss Plain washer Clutch housing O-ring Bearing Spacer 1 Ball Push rod 2 Push rod removal Q'ty Remarks 1 2 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 1 Use special tool. Refer to "REMOVAL POINTS". 4-32 CLUTCH EC4A3000 ENG REMOVAL POINTS EC483211 Clutch boss 1. Remove: · Nut 1 · Lock washer 2 · Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. B Clutch holding tool: YM-91042 . . 5 A For USA and CDN B Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: · Clutch housing 1 Cracks/Wear/Damage Replace. · Clutch boss 2 Scoring/Wear/Damage Replace. EC4A4100 Clutch housing 1. Check: · Circumferential play Free play exists Replace. · Gear teeth a Wear/Damage Replace. · O-ring 1 Damage Replace. EC484400 Clutch spring 1. Measure: · Clutch spring free length a Out of specification Replace springs as a set. { Clutch spring free length: Standard 30. 6 mm (1. 205 in) <Limit> 29. 6 mm (1. 165 in) 4-33 CLUTCH EC484500 ENG Friction plate 1. Measure: · Friction plate thickness Out of specification Replace friction plate as a set. Measure at all four points. ] Friction plate thickness: Standard 2. 9~3. 1 mm (0. 114~0. 122 in) <Limit> 2. 7 mm (0. 106 in) EC484600 Clutch plate 1. Measure: · Clutch plate warpage Out of specification Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. a Warp limit: 0. 1 mm (0. 004 in) EC4A4301 Push rod 1. [. . . ] · Decrease damping force for compression. · Down the oil level (for front fork only). · Check deformation (runout). Further in stroke Too stiff (poor stroke) Looseness in parts Tire/Rim Too stiff feeling Poor operation · Check the shock absorber. If bent, replace. ) · Check for any deviation from center after tightening front wheel axle. [. . . ]