2001 YAMAHA YZ250LC engine

2-15
SCHEMA DE CHEMINEMENT DES CABLES
KABELFÜHRUNGSÜBERSICHTPLAN
DIAGRAMMA DEL PASSAGGIO DEI CAVISPEC
1Bremsschlauchhalter
2Hauptbremszylinder
3Bremsschlauch
4Ausgleichsschlauch
5Schlauchführung
6Klemme
7Hochspannungskabel
8Zündspule
9Kupplungskabel
0Kabelführung
qMassekabel
wKühlerentlüfterschlauch
e
Leitungskabel des CDI-MagnetzündersrGasseil
tCDI-Einheitsleitung
yLeitungskabel des Motorstoppknopfes
„ENGINE STOP“
uKraftstofftankdämpfer
iMotorhalterung
ADen Bremsschlauch in den Brems-
schlauchhalter führen.
BFalls der Bremsschlauch die Feder
(Hinterrad-Stoßdämpfer) berührt, seine
Verdrehung berichtigen.
CDen Bremsschlauch so einbauen, daß
sein Rohrteil gemäß Abbildung ange-
ordnet ist und den Überstand am
Hauptbremszylinder leicht berührt.
DDen Ausgleichschlauch zwischen dem
Bremsschlauch und der Schwingenhal-
terung durchführen.
EDen Ansgleichsschlauch in die
Schlauchführung einsetzen.
FMassekabel, TPS-Leitungskabel (Dros-
selstellungssensor) und Magnetventil-
leitungskabel so festklemmen, daß das
Massekabel die Montagemuttern der
Motoraufhängung nicht berührt.
GDas Massekabel gemeinsam mit dem
vorderen Befestigungsteil der Zündspu-
le befestigen.
HDas Kupplungskabel in die Kabel-
führung einführen.
ICDI-Magnetleitungsstecker zwischen
den Kühlern anbringen.
JBremsschlauch am Taster befestigen,
wobei die Farbe am Rohr gegenüber
dem Taster ist und das Rohr den
Tastervorsprung berührt.
KKühlerentlüftungsschlauch zwischen
dem Rahmen und dem Kühlerschlauch
so führen, daß er weder geknickt noch
verklemmt wird.
LDrosselkabel, CDI-Einheitsleitung, Lei-
ungskabel des Motorstoppknopfes
„ENGINE STOP“ und Kupplungskabel
zwischen den Dämpferrohrenden des
Kraftstofftanks durchführen.
1Support de tuyau de frein
2Maître-cylindre
3Tuyau de frein
4Tuyau de réserve
5Guide de tuyau
6Bride
7Cordon de haute-tension
8Bobine d’allumage
9Câble d’embrayage
0Guide de câble
qFil de masse
wTuyau de reniflard du radiateur
eFil de magnéto CDI
rCâble d’accélérateur
tFil de l'unité CDI
yFil de bouton d’arrêt du moteur “ENGI-
NE STOP”
uAmortisseur de réservoir d’essence
iSupport du moteur
AFaire passer le tuyau de frein dans les
pattes de support de tuyau de frein.
BSi le tuyau de frein touche le ressort
(amortisseur arrière), ajuster le coude.
CInstaller le tuyau de frein de manière que
la partie avec le tuyau soit dirigée
comme indiqué et touche légèrement la
saillie sur le maître-cylindre.
DFaire passer le tuyau de réserve entre le
tuyau de frein et le support du bras oscil-
lant.
EFaire passer le tuyau de réserve dans le
guide de tuyau.
FBridez le câble haute tension, le câble
d’accélérateur, le fil du capteur de posi-
tion du papillon (TPS) et le fil d’électro-
vanne de façon à ce que le câble haute
tension ne soit pas en contact avec les
écrous de montage du support du moteur.
GFixer le fil de masse avec la partie avant
de fixation de la bobine d’allumage.
HFaire passer le tuyau de réserve dans le
guide de tuyau.
IPositionnez le raccord du fil de magnéto
CDI entre les radiateurs.
JInstallez le tuyau de frein sur l’étrier en
veillant à ce que la peinture du tuyau soit
orientée face à l’étrier et que le tuyau soit
en contact avec la saillie de l'étrier.
KFaire passer le tuyau reniflard du radia-
teur entre le châssis et la durite du radia-
teur de façon à ce qu’il ne soit pas plié ni
coincé.
LFaites passer le câble d'accélérateur, le fil
de l'unité CDI, le fil du bouton “ENGI-
NE STOP” et le câble d’embrayage entre
les extrémités du tube amortisseur du
réservoir à carburant.1Supporto del tubo flessibile del freno
2Cilindro principale
3Tubo flessibile del freno
4Tubo del serbatoio
5Guida per tubo flessibile
6Brida
7Cavo ad alta tensione
8Bobina di accensione
9Cavo della frizione
0Guida per cavi
qConduttore di terra
wTubo di sfiato del radiatore
eConduttore del magneto CDI
rCavo dell’acceleratore
tConduttore dell’unità CDI
yConduttore del pulsante “ARRESTO
MOTORE”
uAmmortizzatore serbatoio carburante
iStaffa del motore.
AFar passare il tubo flessibile del freno nel
supporto del tubo flessibile del freno.
BSe il tubo flessibile del freno tocca la
molla (ammortizzatore posteriore), cor-
reggerne la torsione.
CInstallare il tubo flessibile del freno in
maniera tale che la sua parte di tubo sia
rivolta come illustrato e tocchi legger-
mente la sporgenza sul cilindro principa-
le.
DFar passare il tubo flessibile del serbatoio
fra il tubo flessibile del freno e la staffa
del forcellone oscillante.
EPassare il tubo del serbatoio nell’apposita
guida.
FFissare il cavo di alta tensione, il cavo
dell’acceleratore, il conduttore TPS (sen-
sore di posizione gas) e il conduttore
dell’elettrovalvola in modo che il cavo di
alta tensione non tocchi i dadi di montag-
gio del cavalletto di fissaggio del motore.
GFissare il conduttore di terra con la parte
della bobina di accensione installata
anteriormente.
HFar passare il cavo della frizione nella
guida per cavi.
IPosizionare l’accoppiatore del conduttore
del magnete CDI tra i radiatori.
JInstallare il tubo flessibile del freno sulla
pinza con la vernice sul tubo rivolta
verso la pinza e con il tubo che tocchi la
sporgenza della pinza.
KFare scorrere il tubo di sfiato del radiato-
re tra il telaio e il tubo del radiatore in
modo che non si attorcigli e non rimanga
schiacciato.
LFar scorrere il cavo del gas, il conduttore
dell’unità CDI, il conduttore del pulsante
“ARRESTO MOTORE” e il cavo della
frizione tra le estremità del tubo
dell’ammortizzatore del serbatoio del
carburante.
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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.
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2-16
SCHEMA DE CHEMINEMENT DES CABLES
KABELFÜHRUNGSÜBERSICHTPLAN
DIAGRAMMA DEL PASSAGGIO DEI CAVISPEC
1Bremsschlauch
2Hauptbremszylinder
3Leitungskabel des Motorstoppknopfes
„ENGINE STOP“
4Motorstoppknopf „ENGINE STOP“
5Gasseil
6Kupplungskabel
7Klemme
8Kabelführung
ADen Bremsschlauch so einbauen, daß
sein Rohrteil gamäß Abbildung ange-
ordnet ist und den Überstand am
Hauptbremszylinder leicht berührt.
BDas Leitungskabel des Motorstopp-
knopfes „ENGINE STOP“ in der Mitte
des Kupplungshalters durchführen.
CDas Kupplungsseil vor dem Gasseil
durchführen.
DKabel des Motorausschaltknopfes
„ENGINE STOP“ am Lenker festklem-
men mit 3 klicks.
EDen Bremsschlauch vor dem Num-
mernschild und durch die Kabelführung
durchführen.
FDas Kupplungsseil und das Gasseil
über der Nummernschild-Befesti-
gungsnabe überkreuzen.1Tuyau de frein
2Maître-cylindre
3Fil de bouton d’arrêt du moteur “ENGI-
NE STOP”
4Bouton d’arrêt du moteur “ENGINE
STOP”
5Câble d’accélérateur
6Câble d’embrayage
7Bride
8Guide de câble
AInstaller la tuyau de frein de manière que
la partie avec le tuyau soit dirigée
comme indiqué et touche légèrement la
saillie sur le maîtrecylindre.
BFaire passer le fil de bouton d’arrêt du
moteur “ENGINE STOP” au centre du
support d’embrayage.
CFaire passer le câble d’embrayage devant
le câble d’accélérateur.
DFixer le fil du bouton d’arrêt du “ENGI-
NE STOP” sur le guidon (3 déclics).
EFaire passer le tuyau de frein devant la
plaque d’immatriculation et à travers le
guide de câble.
FCroiser le câble d’embrayage et le câble
d’accélérateur sur le bossage de fixation
de la plaque minéralogique.1Tubo flessibile del freno
2Cilindro principale
3Conduttore del pulsante “ARRESTO
MOTORE”
4Pulsante “ARRESTO MOTORE”
5Cavo dell’acceleratore
6Cavo della frizione
7Nastro
8Guida per cavi
AInstallare il tubo flessibile del freno in
modo che la sua parte di tubo sia rivolta
come illustrato e tocchi leggermente la
sporgenza sul cilindro principale.
BFar passare il conduttore del pulsante
“ARRESTO MOTORE” nel mezzo del
supporto della frizione.
CFar passare il cavo della frizione davanti
al cavo dell’acceleratore.
DBloccare il conduttore del pulsante
“ARRESTO MOTORE” sul manubrio
dopo 3 scatti.
EFar passare il tubo flessibile del freno
davanti alla targa e attraverso la guida
per cavi.
FIncrociare il cavo della frizione e il cavo
dell’acceleratore sopra il mozzo della
targa.
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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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INSP
ADJ
3-5
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT
EC350000
ENGINE
EC351011
COOLANT LEVEL INSPECTION
w
Do not remove the radiator cap 1 1
, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
cC
Hard water or salt water is harmful to the
engine parts. You may use distilled water,
if you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
9Radiator cap
3. Check:
9Coolant level a
Coolant level lowÕAdd coolant.
1Radiator
EC353011
COOLANT REPLACEMENT
w
Do not remove the radiator cap when the
engine is hot.
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INSP
ADJ
3-6
COOLANT REPLACEMENT
cC
Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
9Coolant drain bolt 1
3. Remove:
9Radiator cap
Drain the coolant completely.
4. Clean:
9Cooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:
9Copper washer
9Coolant drain bolt
6. Fill:
9Radiator
9Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant 1and water
(soft water) 2mixing ratio:
50%/50%
Coolant capacity:
1.20 L (1.06 Imp qt, 1.27 US qt)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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INSP
ADJ
3-7
RADIATOR CAP INSPECTION
cC
9Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
9Do not use water containing impurities
or oil.
7. Install:
9Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
9Coolant level
Coolant level lowÕAdd coolant.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
9Seal (radiator cap) 1
9Valve and valve seat 2
Crack/DamageÕReplace.
Exist fur deposits 3ÕClean or replace.
Handling notes of coolant:
The coolant is harmful so it should be handled
with special care.
w
9When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
9When coolant splashes to your clothes.
Quickly wash it away with water and then
with soap.
9When coolant is swallowed.
Quickly make him vomit and take him to
a doctor.
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INSP
ADJ
3-10
THROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
9Throttle grip free play a
Out of specificationÕAdjust.
2. Adjust:
9Throttle grip free play
EC35S002
THROTTLE LUBRICATION
1. Remove:
9Cap cover 1
9Throttle cable cap 2
2. Apply:
9Lithium soap base grease
On the throttle cable end a, tube guide
cable winding portion band roller sliding
surface c.
Throttle grip free play adjustment steps:
9Loosen the locknut 1.
9Turn the adjuster 2until the specified free
play is obtained.
9Tighten the locknut.
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
w
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
Throttle grip free play ?a:
3~5 mm (0.12~0.20 in)
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