2001 YAMAHA YZ250LC light

EC085002
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 7are designed as
thumb tabs to indicate the chapter’s number and
content.
1
General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
7Tuning
Illustrated symbols 8to rare used to identify
the specifications appearing in the text.
8
With engine mounted
9Special tool
0Filling fluid
qLubricant
wTightening
eSpecified value, Service limit
rResistance (½), Voltage (V), Electric current (A)
Illustrated symbols tto oin the exploded dia-
grams indicate grade of lubricant and location of
lubrication point.
t
Apply transmission oil
yApply engine mixing oil
uApply molybdenum disulfide oil
iApply lightweight lithium-soap base grease
oApply molybdenum disulfide grease
Illustrated symbols pto ain the exploded dia-
grams indicate where to apply a locking agent
and where to install new parts.
p
Apply locking agent (LOCTITER)
aUse new one
GEN
INFO
12
3
5
74
6
8
90
qw
er
tyu
io
pa
SPEC
INSP
ADJENG
CHASELEC
TUN
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1-1
DESCRIPTION
GEN
INFO
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2“ENGINE STOP” button
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Kick starter
8Fuel tank
9Radiator
0Coolant drain bolt
qCheck bolt (Transmission oil level)
wRear brake pedal
eValve joint
rFuel cock
tStarter knob
yDrive chain
uAir cleaner
iShift pedal
oFront fork
NOTE:
9The machine you have purchased may differ
slightly from those shown in the following.
9Designs and specifications are subject to
change without notice.
1
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1-4
IMPORTANT INFORMATION
GEN
INFO
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing (s) 1and oil seal (s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil seal(s),
apply a light coating of light-weight lithium
base grease to the seal lip(s). Oil the bear-
ings liberally when installing.
cC
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
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1-9
CONTROL FUNCTIONS
GEN
INFO
EC150000
CONTROL FUNCTIONS
EC151000
“ENGINE STOP” BUTTON
The “ENGINE STOP” button 1is located on the
left handlebar. Continue pushing the “ENGINE
STOP” button till the engine comes to a stop.
EC152000
CLUTCH LEVER
The clutch lever 1is located on the left handle-
bar; it disengages or engages the clutch. Pull
the clutch lever to the handlebar to disengage
the clutch, and release the lever to engage the
clutch. The lever should be pulled rapidly and
released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears can
be shifted by using the shift pedal 1on the left
side of the engine.
EC154000
KICK STARTER
Rotate the kick starter 1away from the engine.
Push the starter down lightly with your foot until
the gears engage, then kick smoothly and force-
fully to start the engine. This model has a prima-
ry kick starter so the engine can be started in
any gear if the clutch is disengaged. In normal
practices, however, shift to neutral before start-
ing.
EC155001
THROTTLE GRIP
The throttle grip 1is located on the right han-
dlebar; it accelerates or decelerates the engine.
For acceleration, turn the grip toward you; for
deceleration, turn it away from you.
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1-13
STARTING AND BREAK-IN
GEN
INFO
EC190000
STARTING AND BREAK-IN
cC
Before starting the machine, perform the
checks in the pre-operation check list.
w
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
EC191001
STARTING A COLD ENGINE
1. Shift the transmission into neutral.
2. Turn the fuel cock to “ON” and full open the
starter knob (CHOKE).
3. With the throttle completely closed start the
engine by kicking the kick starter forcefully
with firm stroke.
4. Run the engine at idle or slightly higher until
it warms up: this usually takes about one or
two minutes.
5. The engine is warmed up when it responds
normally to the throttle with the starter knob
(CHOKE) turned off.
cC
Do not warm up the engine for extended peri-
ods.
EC193001
STARTING A WARM ENGINE
Do not operate the starter knob (CHOKE). Open
the throttle slightly and start the engine by kick-
ing the kick starter forcefully with firm stroke.
cC
Observe the following break-in procedures
during initial operation to ensure optimum
performance and avoid engine damage.
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1-18
CLEANING AND STORAGE
GEN
INFO
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be taken
to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as fol-
lows:
1. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed metal
surfaces with a film of light oil. Do not apply
oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the machine
is stored.
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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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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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