steering YAMAHA YZ250F 2005 User Guide

3 - 43
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Apply the lithium soap base grease on the
thread of the steering stem.
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tightening):
38 Nm (3.8 m  kg, 27 ft  lb)
Loosen the steering ring nut one turn.
Retighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tightening):
7 Nm (0.7 m  kg, 5.1 ft  lb)
Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
Install the washer 5, upper bracket 6,
washer 7, steering stem nut 8, steering
stem cap 9, handlebar 0, handlebar
upper holder A and number plate B.
NOTE:
The upper handlebar holder should be
installed with the punched mark a forward.
Install the handlebar so that the marks b
are in place on both sides.
Insert the end of fuel breather hose C into
the hole in the steering stem cap.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.

3 - 44
INSP
ADJ
T R..
Steering stem nut:
145 Nm (14.5 m  kg, 105 ft  lb)
Handlebar upper holder:
28 Nm (2.8 m  kg, 20 ft  lb)
Pinch bolt (upper bracket):
23 Nm (2.3 m  kg, 17 ft  lb)
Number plate:
7 Nm (0.7 m  kg, 5.1 ft  lb)
STEERING HEAD INSPECTION AND ADJUSTMENT

5 - 47
CHASHANDLEBAR
9. Install:
• Engine stop switch 1
 Clutch lever holder 2
 Bolt (clutch lever holder) 3
 Hot starter lever holder 4
 Bolt (hot starter lever holder) 5
Clamp 6
NOTE:
 The engine stop switch, clutch lever holder
and clamp should be installed according to
the dimensions shown.
 Pass the engine stop switch lead in the mid-
dle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
10. Install:
 Clutch cable 1
 Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.
11. Adjust:
 Clutch lever free play
Refer to “CLUTCH ADJUSTMENT” sec-
tion in the CHAPTER 3.
 Hot starter lever free play
Refer to “HOT STARTER LEVER
ADJUSTMENT” section in the CHAPTER
3.
12. Clamp the clamp portion a of the number
plate to the handlebar.
13. Insert the end of the fuel tank breather
hose 1 into the hole in the steering stem
cap 2.
2 1a

5 - 48
CHAS
EC560000
STEERING
Extent of removal:
1 Lower bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Number plate
Handlebar
Front fenderRefer to “HANDLEBAR” section.
1 Steering stem cap 1
2 Steering stem nut 1
3 Front fork 2 Refer to “FRONT FORK” section.
4 Upper bracket 1
5 Steering ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
6 Lower bracket 1
7 Bearing race cover 1
8 Upper bearing 1
9 Lower bearing 1 Refer to “REMOVAL POINTS”.
10 Bearing race 2 Refer to “REMOVAL POINTS”.
2
1
STEERING

5 - 49
CHAS
EC563000
REMOVAL POINTS
Steering ring nut
1. Remove:
Steering ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering stem so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Lower bearing
1. Remove:
Lower bearing 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
EC564000
INSPECTION
Steering stem
1. Inspect:
Steering stem 1
Bend/damage → Replace.
STEERING

5 - 50
CHAS
Bearing and bearing race
1. Wash the bearings and bearing races with
a solvent.
2. Inspect:
Bearing 1
Bearing race
Pitting/damage → Replace bearings and
bearing races as a set.
Install the bearing in the bearing races.
Spin the bearings by hand. If the bearings
hang up or are not smooth in their opera-
tion in the bearing races, replace bear-
ings and bearing races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Lower bracket
1. Install:
Lower bearing 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Bearing race
Upper bearing 1
Bearing race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and bearing race cover lip.
3. Install:
Lower bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing, the portion a and thread of the steer-
ing stem.
STEERING

5 - 51
CHASSTEERING
4. Install:
Steering ring nut 1
Tighten the steering ring nut using the
steering nut wrench 2.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in the
CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
6. Install:
Washer 1
7. Install:
Front fork 1
Upper bracket 2
NOTE:
Temporarily tighten the pinch bolts (lower
bracket).
Do not tighten the pinch bolts (upper bracket)
yet.
8. Install:
Washer 1
Steering stem nut 2
T R..145 Nm (14.5 m · kg, 105 ft · lb)

5 - 52
CHAS
9. Install:
Steering stem cap 1
10. After tightening the nut, check the steering
for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
11. Adjust:
Front fork top end a
Front fork top end (standard) a:
5 mm (0.20 in)
12. Tighten:
Pinch bolt (upper bracket) 1
Pinch bolt (lower bracket) 2
CAUTION:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
STEERING