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YZ250 Clutch Push Rod Lever Bearings

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I am rebuilding a 2002 yz250. I am replacing all the bearings and was wondering if anyone has pulled and re-installed the clutch push rod lever bearings. I do a have a bearing puller (TUSK --like the promotion but cheaper). Any guidance on removal and re-installation (ie. how far in doe the last bearing go) would be greatly appreciated. I have not tried yet -- was hoping for advice first (dont want to screw it up).

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Curious to know as well, my brothers 125 uses a bearing on the lever rod for the clutch on the clutch cover, had no idea how to remove it if it were bad..

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I assume you are talking about the shaft hooked to the clutch arm at the cable end. There is a small bearing just inside the case. It is probably a half inch tall roller bearing--at least is was on my 450 when I had to swap it to a new case. it should come out fairly easily. Gently thread a wood screw into it and pull.

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I believe (from looking at parts blow-ups) that there are two bearings separate by a small space. The space is for the screw that holds the shaft in place. Not sure if I actually need to replace these bearings but I am replacing everything else. The current shaft has a little play. I am goint to replace it because of wear but I due not know if any of the play is due to bearings, shaft or may even be normal.

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Are yours bad? These should last seven lifetimes unless somethign goes wrong. Or am I nuts? I just done see them doing much.

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I agee they should last. I just figured the whole thing is apart I hate to leave just those bearings. The bike is 8 years old and based on what I have seen has not been maintained well. I did have clutch issues would not start in gear with clutch disengaged. I think I have found the source of most of the trouble but there was also a slight amount of side to side play in the push lever. It may be normal???? but don't know. Biggest thing is I hate to let the engine beat me and not change them because I did not know how. I also don't want to get to a point of no return without being pretty confident that I can get them out and new ones back in and in the correct position. Hard to believe but there is not much info out there on replacing these beaings.

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I suppose if your doing a full bottom end and you just want to make sure, you replace every single bearing for good measure. I would if I was doing a bottom end, just so that I have that piece of mind that every bearing is new.

But yea your right, that bearing see's very little wear. The new engines have the bearing inside the stator cover so no dirt gets in. But the old models have the lever outside exposed on the case, if the seal goes the bearing will be exposed to dirt and could wear out, just like on the 125's with the lever on the clutch side without a push rod assembly.

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Ive never heard of them being changed to tell you the truth, it's a rare replacement, so is it that surprising that no one has any experience?

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I'm in a similar situation. I'm replacing the left engine case and see no easy method of installing these two bearings.

Heat the case, freeze the bearing. They should go in fairly easy. The first bearing should go in until it seats in the bottom of the hole. The second bearing is a little tricky as you have to put it in just far enough that you have just enough room for the seal.

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i have replaced, mine due to a broken chain issue and having to weld the left side case there is no easy way to do this i put case in oven at 400 degrees for about half hour and used a bent pic to pull out not easy but doable to put in i used a 11 mm deepwell socket and pressed in again not easy but doable

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i have a 1996 yz250, when i first bought the bike this exact bearing failed and a few rollers dropped into the transmission and was responsible for chipping some gears. To remove it, I bought an inside bearing puller but it didnt even work. I went to a few bike shops and they said to just kind of fold it in from the edges and then pull it out. I used a punch and folded it in and it came out.

good luck and they go in pretty easy.

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Bump. I just rebuilt the engine in my 2002 YZ250. I replaced almost all the bearings, but did not replace the two on the clutch push rod pivot shaft whatever-the-hell-it-is-called, because I didn't know how to remove them, and because their job looks easy. I guess I should have tried the oven method! I watched a friend do this to remove crank and trans bearings from another bike. They all fell out into a cookie tray after about 15 minutes in 400F

Edited by mellephants

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