2001 YAMAHA YZ250LC ignition

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM.....................................6-1
IGNITION SYSTEM.....................................6-2
SOLENOID VALVE SYSTEM......................6-6
TPS (THROTTLE POSITION SENSOR)
SYSTEM......................................................6-8
CHAPTER 7
TUNING
ENGINE.......................................................7-1
CHASSIS...................................................7-13
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1-7
SPECIAL TOOLS
GEN
INFO
EC140001
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and part number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.
NOTE:
9For U.S.A. and Canada, use part number starting with “YM-” or “YU-”.
9For others, use part number starting with “90890-”.
Part number Tool name / How to use IIIustration
YU-1135-A, 90890-01135Crankcase separating toolYU-1135-A 90890-01135
YM-1305, 90890-01305 Crankcase separating boltYM-1305 90890-01305
These tools are used to split the crankcase as well
as remove the crankshaft from either case.
YM-1189, 90890-01189 Flywheel puller
YM-1189 90890-01189
This tool is used to remove the flywheel magneto.
YU-1235, 90890-01235 Rotor holding tool
YU-1235 90890-01235
This tool is used when loosening or tightening the
flywheel magneto securing nut.
YU-3097, 90890-01252 Dial gauge and stand
YU-3097 90890-01252
YU-1256 StandYU-1256
These tools are used to set the ignition timing.
Crankcase installing tool
YU-90050 90890-01274
YU-90050, 90890-01274 PotYM-1277 90890-01275
YU-90050, 90890-01275 Bolt90890-01277
YM-1277, 90890-01277 Adapter
These tools are used to install the crankshaft.
YU-1304, 90890-01304 Piston pin puller
YU-1304 90890-01304
This tool is used to remove the piston pin.
YU-24460-01,90890-01325Radiator cap testerYU-24460-01 90890-01325
YU-33984, 90890-01352 AdapterYU-33984 90890-01352
These tools are used for checking the cooling
system.
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1-8
SPECIAL TOOLS
GEN
INFO
Part number Tool name / How to use IIIustration
YU-33975, 90890-01403 Ring nut wrenchYU-33975 90890-01403
This tool is used when tighten the steering ring nut
to specification.
YM-1423, 90890-01423 Damper rod holder
YM-1423 90890-01423
Use this tool to remove and install the damper rod.
YM-01442, 90890-01442 Fork seal driver
YM-01442 90890-01442
This tool is used when install the fork oil seal.
YU-3112-C, 90890-03112 Yamaha pocket tester
YM-3112-C 90890-03112
Use this tool to inspect the coil resistance,
output voltage and amperage.
YU-8036-B Inductive tachometer
YU-8036-B 90890-03113
90890-03113 Engine tachometer
This tool is needed for observing engine rpm.
YM-91042, 90890-04086 Clutch holding tool
YM-91042 90890-04086
This tool is used to hold the clutch when removing
or installing the clutch boss securing nut.
YM-34487 Dynamic spark tester
YM-34487 90890-06754
90890-06754 Ignition checker
This instrument is necessary for checking the igni-
tion system components.
ACC-QUICK-GS-KT Quick gasket
®ACC-QUICK-GS-KT 90890-85505
90890-85505 YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating
surface, etc.
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2-2
GENERAL SPECIFICATIONSSPEC
Carburetor:
Type/Manufacturer PWK38S/KEIHIN
Spark plug:
Type/Manufacturer BR8EG/NGK
Gap 0.5~0.6 mm (0.020~0.024 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 63/21 (3.000)
Secondary reduction system Chain drive
Secondary reduction ratio 50/14 (3.571)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)
2nd 25/16 (1.563)
3rd 23/18 (1.278)
4th 24/22 (1.091)
5th 20/21 (0.952)
Chassis:USA, CDN, ZA, AUS, NZEUROPE
Frame type Semi double cradle¬
Caster angle 27.2° 26.9°
Trail 118 mm (4.65 in) 115 mm (4.53 in)
T ire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 110/90-19 62M
T ire pressure (front and rear) 100 kPa (1.0 kg/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/Gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
2
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2-11
MAINTENANCE SPECIFICATIONSSPEC
EC212300
ELECTRICAL
Part to be tightened Thread size Q’tyT ightening torqueNm m•kg ft•lb
Stator M 6 ´1.0 3 8 0.8 5.8
Rotor M10 ´1.25 1 41 4.1 30
Ignition coil M 6 ´1.0 2 7 0.7 5.1
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.) 0.18 mm (0.007 in)…
Advancer type Electrical…
CDI:
Magneto-model/Manufacturer F5CU10/YAMAHA…
Source coil 1 resistance (color) 720~1,080 ½at 20°C (68°F)…
(Black-Black/Red)
Source coil 2 resistance (color) 44~66 ½at 20°C (68°F)…
(Green/Blue-Green/White)
Pickup coil resistance (color) 248~372 ½at 20°C (68°F)…
(White/Blue-White/Red)
CDI unit-model/Manufacturer 5HC-00/YAMAHA…
Ignition coil:
Model/Manufacturer 5BE-00/YAMAHA…
Minimum spark gap 6 mm (0.24 in)…
Primary winding resistance 0.20~0.30 ½at 20°C (68°F)…
Secondary winding resistance 9.5~14.3 k½at 20°C (68°F)…
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2-15
CABLE ROUTING DIAGRAMSPEC
1Brake hose holder
2Master cylinder
3Brake hose
4Reservoir hose
5Hose guide
6Clamp
7High tension cord
8Ignition coil
9Clutch cable
0Cable guide
qGround lead
wRadiator breather hose
eCDI magneto lead
rThrottle cable
tCDI unit lead
y“ENGINE STOP” button lead
uFuel tank damper
iEngine bracket
APass the brake hose into the
brake hose holder.BIf the brake hose contacts the
spring (rear shock absorber),
correct its twist.
CInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the master cylinder.
DPass the reservoir hose
between the brake hose and
swingarm bracket.
EPass the reservoir hose into the
hose guide.
FClamp the high tension cord,
throttle cable, TPS (throttle posi-
tion sensor) and solenoid valve
lead so that the high tension
cord does not contact the
engine bracket installation nuts.
G
Fasten the ground lead together
with the front installation portion
of the ingnition coil.
HPass the clutch cable into the
cable guide.
IPosition the CDI magneto lead
coupler between the radiators.
JInstall the brake hose to the
caliper with the paint on the pipe
facing the caliper and with the
pipe contacting the caliper pro-
jection.
KPass the radiator breather hose
between the frame and radiator
hose so that it is not kinked or
wedged.
LPass the throttle cable, CDI unit
lead, “ENGINE STOP” button
lead and clutch cable between
the fuel tank damper tube ends.
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3-4
PRE-OPERATION INSPECTION AND MAINTENANCE
INSP
ADJ
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EC321000
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Coolant Check that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P3-5~9
Fuel Check that a fresh mixture of oil and gasoline is filled in
the fuel tank. Check the fuel line for leakage.P1-12
Transmission oil Check that the oil level is correct. Check the crankcase
for leakage.P3-12~14
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly.P3-9
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and P3-10~11
housing, if necessary.
Brakes Check the play of front brake and effect of front and
rear brake.P3-17~23
Chain Check chain slack and alignment. Check that the chain
is lubricated properly.P3-24~26
Wheels Check for excessive wear and tire pressure. Check for
loose spokes and have no excessive play.P3-34~35
Steering Check that the handlebar can be turned smoothly and
have no excessive play.P3-35~36
Front forks and Check that they operate smoothly and there is no oil
rear shock absorber leakage.P3-26~33
Cables (wires) Check that the clutch and throttle cables move smooth-
ly. Check that they are not caught when the handlebars —
are turned or when the front forks travel up and down.
Muffler Check that the muffler is tightly mounted and has no
cracks.P3-15~16
Sprocket Check that the driven sprocket tightening bolt is
not loose.P3-24
Lubrication Check for smooth operation. Lubricate if necessary. P3-37
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P1-16
Lead connectors Check that the CDI magneto, CDI unit, and ignition coil
are connected tightly.P1-6
Settings Is the machine set suitably for the condition of the
racing course and weather or by taking into account the
P7-1~24
results of test runs before racing? Are inspection and
maintenance completely done?
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3-39
IGNITION TIMING CHECK
INSP
ADJ
EC372051
IGNITION TIMING CHECK
1. Remove:
9Cylinder head
Refer to “CYLINDER HEAD, CYLINDER
AND PISTON” section in the CHAPTER 4.
9Crankcase cover (left)
2. Attach:
9Dial gauge 1
9Dial gauge stand 2
3. Rotate the magneto rotor 1until the piston
reaches top dead center (TDC). When this
happens, the needle on the dial gauge will
stop and reverse directions even though the
rotor is being turned in the same direction.
4. Set the dial gauge to zero at TDC.
5. From TDC, rotate the rotor clockwise until
the dial gauge indicates that the piston is at
a specified distance from TDC.
6. Check:
9Ignition timing
Punch mark aon rotor should be aligned
with punch mark bon stator.
Not aligned ÕAdjust.
Dial gauge:
YU-3097/90890-01252
Stand:
YU-1256
Ignition timing (B.T.D.C.):
0.18 mm (0.007 in)
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