2001 YAMAHA YZ250LC brake

2-10
MAINTENANCE SPECIFICATIONSSPEC
M 6 ´ 1.0
M10 ´ 1.25
M10 ´ 1.25
M20 ´ 1.5
M 8 ´ 1.25
–
M 6 ´ 1.0
M 6 ´ 1.0
M 8 ´ 1.25
M10 ´ 1.25
M10 ´ 1.25
M10 ´ 1.25
M16 ´ 1.5
M14 ´ 1.5
M14 ´ 1.5
M14 ´ 1.5
M10 ´ 1.25
M10 ´ 1.25
M 8 ´ 1.25
M 5 ´ –
M 8 ´ 1.25
M 6 ´ 1.0
M 5 ´0.8
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0
M 6 ´ 1.0 Rear brake reservoir tank and frame
Rear brake hose union bolt (caliper)
Rear brake hose union bolt (master cylinder)
Rear wheel axle and nut
Driven sprocket and wheel hub
Nipple (spoke)
Disc cover and rear brake caliper
Protector and rear brake caliper
Engine mounting:
Engine bracket and frame
Engine and frame (front)
Engine and frame (upper)
Engine and frame (lower)
Pivot shaft and nut
Relay arm and swingarm
Relay arm and connecting rod
Connecting rod and frame
Rear shock absorber and frame
Rear shock absorber and relay arm
Rear frame and frame
Swingarm and brake hose holder
Drive chain tensioner mounting
Chain support and swingarm
Seal guard and swingarm
Fuel tank mounting
Fuel tank and fuel cock
Fuel tank and seat set bracket
Fuel tank and hooking screw (fitting band)
Fuel tank and fuel tank bracket
Seat mounting
Side cover mounting
Air scoop mounting
Front fender mounting
Rear fender mounting
Number platePart to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
1
1
1
1
6
72
2
2
2
1
1
1
1
1
1
1
1
1
3
4
2
3
4
2
2
1
1
4
2
4
8
4
4
17
30
30
125
42
3
7
7
34
69
69
69
85
80
80
80
56
53
29
4
19
7
5
10
7
7
7
7
7
7
3
7
7
70.7
3.0
3.0
12.5
4.2
0.3
0.7
0.7
3.4
6.9
6.9
6.9
8.5
8.0
8.0
8.0
5.6
5.3
2.9
0.4
1.9
0.7
0.5
1.0
0.7
0.7
0.7
0.7
0.7
0.7
0.3
0.7
0.7
0.75.1
22
22
90
30
2.2
5.1
5.1
24
50
50
50
61
58
58
58
40
38
21
2.9
13
5.1
3.6
7.2
5.1
5.1
5.1
5.1
5.1
5.1
2.2
5.1
5.1
5.1
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
5MW-9-30-2 7/3/00 2:20 PM Page 11

2-14
CABLE ROUTING DIAGRAMSPEC
1CDI magneto lead
2YPVS breather hose
3Clamp
4Clutch cable
5Radiator breather hose
6CDI unit lead
7Cable guideAPass the radiator breather hose
outside the engine bracket and
inside the down-tube.Pass the
radiator breather hose inside
the CDI magneto lead.
BClamp the CDI magneto lead,
radiator breather hose and
YPVS breather hose. In so
doing, clamp the CDI magneto
lead at the rear of the down-
tube with the clamp ends for-
ward.
CClamp the radiator breather
hose and CDI magneto lead at
the rear of the down-tube with
the clamp ends outward.
DPass the clutch cable a little for-
ward of the extreme left nut that
holds the cylinder head.EPass the radiator breather hose
and CDI magneto lead in front
of the radiator hose.
FPass the radiator breather hose
and CDI magneto lead between
the frame and radiator.
GAlign the top of the brake hose
neck with the brake hose holder
bottom.
HPass the brake hose in front of
the axle boss,then fit it into the
hose groove so that the brake
hose does not contact the nut
(wheel axle).
IFit the brake hose into the guide
on the protector.
5MW-9-30-2 7/3/00 2:25 PM Page 52

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.
5MW-9-30-2 7/3/00 2:26 PM Page 54

2-16
CABLE ROUTING DIAGRAMSPEC
1Brake hose
2Master cylinder
3“ENGINE STOP” button lead
4“ENGINE STOP” button
5Throttle cable
6Clutch cable
7Clamp
8Cable guideAInstall the brake hose so that its pipe portion
dirrects as show and lightly touches the projection
on the master cylinder.
BPass the “ENGINE STOP” button lead in the middle
of the clutch holder.
CPass the clutch cable in front of the throttle cable.
DClamp the “ENGINE STOP” button lead to the han-
dlebar to 3 clicks.
EPass the brake hose in front of the number plate
and through the cable guide.
FCross the clutch cable and throttle cable over the
number plate mounting boss.
5MW-9-30-2 7/3/00 2:27 PM Page 56

INSP
ADJ
3-2
MAINTENANCE INTERVALS
3
Item Remarks
COOLING SYSTEM
Check coolant level and leakagell
Check radiator cap operationl
Replace coolantlEvery two years
Inspect hosesl
OUTSIDE NUTS AND BOLTS Refer to “STARTING
RetightenllAND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricatellUse foam air-filter oil
Replacel
FRAME
Clean and inspectll
FUEL TANK, COCK
Clean and inspectll
BRAKES
Adjust lever position and pedal heightll
Lubricate pivot pointll
Check brake disc surfacell
Check fluid level and leakagell
Retighten brake disc bolts, caliper bolts,
ll
master cylinder bolts and union bolts
Replace padsl
Replace brake fluidlEvery one year
FRONT FORKS
Inspect and adjustll
Replace oilllSuspension oil “01”
Replace oil seall
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubellLithium base grease
REAR SHOCK ABSORBER
Inspect and adjustll
Lube ll
Molybdenum disulfide grease
Retightenll
CHAIN GUARD AND ROLLERS
Inspectll
SWINGARM
Inspect and retightenll
RELAY ARM, CONNECTING ROD
Inspect and lubellMolybdenum disulfide grease
STEERING HEAD
Inspect free play and retightenll
Clean and lubelLithium base grease
Replace bearingl
TIRE, WHEELS
Inspect air pressure, wheel run-out,
ll
tire wear and spoke looseness
Retighten sprocket boltll
Inspect bearingsl
Replace bearingsl
LubricatelLithium base grease
THROTTLE, CONTROL CABLE
Check routing and connectionllYamaha cable lube or
LubricatellSAE 10W-30 motor oil
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
5MW-9-30-3A 7/3/00 2:46 PM Page 3

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?
5MW-9-30-3A 7/3/00 2:47 PM Page 14

3-17
CHASSIS/BRAKE SYSTEM AIR BLEEDING
INSP
ADJ
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING
w
Bleed the brake system if:
9The system has been disassembled.
9A brake hose has been loosened or removed.
9The brake fluid is very low.
9The brake operation is faulty.
A dangerous loss of braking performance may
occur if the brake system is not properly bleed.
1. Remove:
9Master cylinder cap
9Diaphragm
9Protector (rear brake)
2. Bleed:
9Brake fluid
Front
õRear
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube
2tightly to
the caliper bleed screw 1.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever or pedal sev-
eral times.
f. Pull the lever in or push down on the ped-
al. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or
pedal limit has been reached; then re-
lease the lever or pedal.
i. Repeat steps (e) to (h) until of the air
bubbles have been removed from the
system.
Bleed screw:
6 Nm (0.6 m•kg, 4.3 ft•lb)
5MW-9-30-3B 7/3/00 3:16 PM Page 2

3-18
FRONT BRAKE ADJUSTMENT
INSP
ADJ
3. Install:
9Protector (rear brake)
9Diaphragm
9Master cylinder cap
EC362040
FRONT BRAKE ADJUSTMENT
1. Check:
9Brake lever position a
2. Adjust:
9Brake lever position
NOTE:
If bleeding is difficult, it may be necessary
to let the brake fluid system stabilize for a
few hours. Repeat the bleeding procedure
when the tiny bubbles in the system have
disappeared.
j. Add brake fluid to the level line on the
reservoir.
w
Check the operation of the brake after
bleeding the brake system.
Brake lever position a a
:
Standard position Extent of adjutment
95 mm (3.74 in)76 ~ 97 mm
(2.99 ~ 3.82 in)
Brake lever position adjustment steps:
9Loosen the locknut 1.
9Turn the adjusting bolt 2until the lever posi-
tion a is within specified position.
9Tighten the locknut.
cC
Be sure to tighten the locknut, as it will
cause poor brake performance.
Locknut:
5 Nm (0.5 m•kg, 3.6 ft•lb)
5MW-9-30-3B 7/3/00 3:17 PM Page 4