Yamaha XT250X - Checking the Clutch Housing; Checking the Clutch Boss; Checking the Pressure Plate; Checking the Clutch Push Rods

CLUTCH
5-34
● Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
● Clutch housing dogs
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.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
● Pressure plate
Cracks/damage → Replace.
EAS25190
CHECKING THE CLUTCH PUSH RODS
1. Check:
● Clutch push rod
● Adjusting screw
● Ball
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
● Push rod bending limit
Out of specification → Replace.
EAS25200
CHECKING THE PRIMARY DRIVE GEAR
1. Check:
● Primary drive gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
● Primary driven gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
EAS25260
INSTALLING THE CLUTCH
1. Install:
● Primary drive gear “1”
Clutch spring free length
40.10 mm (1.58 in)
Limit
38.10 mm (1.50 in)
Push rod bending limit
0.500 mm (0.0197 in)