2002 YAMAHA WR 250F coolant reservoir

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Headlight stay (lower) and lower bracket M8 × 1.25 2 7 0.7 5.1
Headlight (left and right) M6 × 1.0 2 10 1.0 7.2
Headlight (lower) M6 × 1.0 1 7 0.7 5.1
Taillight M6 × 1.0 3 4 0.4 2.9
Taillight lead clamp and rear fender M4 × 1.59 2 1 0.1 0.7
Coolant reservoir (front) M6 × 1.0 1 7 0.7 5.1
Coolant reservoir (rear) M6 × 1.0 1 11 1.1 8.0
Sidestand bracket and frame M10 × 1.25 2 66 6.6 48
Sidestand M10 × 1.25 1 64 6.4 46 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

2 - 19
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Hose guide
2
Brake hose
3
Voltage regulator
4
Light switch lead
5
Fuel tank breather hose
6
Engine stop switch lead
7
Clamp
8
Oil tank breather hose
9
Sub-wire harness
0
Taillight lead
A
Throttle position sensor lead
B
Neutral switch lead
C
Oil hose
D
Cylinder head breather hose
E
CDI magneto lead
F
Clutch cable
G
Cable guide
H
Carburetor breather hose
I
Carburetor overflow hose
J
Coolant reservoir breather hose
K
Decompression cable
L
Ground lead
M
Ignition coil lead
N
CDI unit lead
O
Voltage regulator lead
Å
Pass the fuel tank breather hose
behind handlebar, then insert it
into the steering stem hole.
ı
Pass the decompression cable,
engine stop switch lead and light
switch lead under where the oil
hose is attached.
Ç
Pass the voltage regulator lead,
engine stop switch lead and light
switch lead over the radiator
hose.
Î
Fasten the engine stop switch
lead, light switch lead and igni-
tion coil lead of the sub-wire har-
ness.
‰
Fasten the sub-wire harness
and engine stop switch lead.
Ï
Pass the cylinder head breather
hose along the right side of the
oil tank breather hose.
Ì
Fasten the sub-wire harness
and light switch lead in front of
the upper engine brackets.
Ó
Fasten the sub-wire harness.
È
Pass the sub-wire harness
between the upper engine
brackets.
Ô
Fasten the sub-wire harness.

Fasten the throttle position sen-
sor lead.

2 - 20
SPEC

CABLE ROUTING DIAGRAM
Ò
Make sure that the throttle
position sensor lead coupler
does not go outside the chas-
sis.
˜
Pass the carburetor breather
hoses and overflow hose
between the connecting rod
and cross tube (frame).
ˆ
Fasten the neutral switch lead
on the oil hose with a plastic
locking tie and cut off the tie
end.
Ø
Pass the cylinder head
breather hose through the hose
guide.
∏
Pass the clutch cable through
the cable guide.
Œ
Fasten the neutral switch lead
and CDI magneto lead.
Â
Pass the clutch cable along the
inner side of the cylinder head
breather hose.
Í
Pass the cylinder head
breather hose along the inner
side of the radiator hose.
Ê
Pass the clutch cable in front of
the radiator mounting boss.
Ë
Fit the brake hose into the
guides on the protector.
◊
Pass the neutral switch lead
and CDI magneto lead through
the cable guide.
„
Fasten the ground lead
together with the ignition coil
lead.
Ù
Do not allow the light switch
lead to slacken between the
two clamps.
Á
Pass the decompression cable
along the right side of the cylin-
der head breather hose.
Û
Pass the clutch cable through
the cable guides.
Pass the carburetor breather
hoses, overflow hose and
coolant reservoir breather
hose so that all there hoses
do not contact the rear shock
absorber.
Position each lead at the
lower left of the main tube
(frame).
AA
AB

2 - 21
SPEC

1
Coolant reservoir breather hose
2
Radiator breather hose
3Ignition coil
4CDI unit
5CDI unit band
6Throttle cable (return)
7Throttle cable (pull)
8Cable guide
9CDI unit lead
0Spark plug lead
ACDI unit stayÅFasten the coolant reservoir breather hose and
carburetor breather hoses together.
ıPass the throttle cables along inner side of the
spark plug lead.
ÇPass the CDI unit lead between the radiator hose
and radiator mounting boss.
ÎPass the throttle cables through the cable guides.
‰Insert the CDI unit band over the CDI unit stay
(frame) as far as possible.
CABLE ROUTING DIAGRAM

2 - 22
SPEC
1Coolant reservoir hose
2Coolant reservoir breather hose
3Clamp
4Taillight lead
5Hose guideÅFasten the coolant reservoir hose and coolant
reservoir breather hose.
ıDo not allow the taillight lead to slacken.
ÇPass the coolant reservoir hose and coolant res-
ervoir breather hose through the hose guide.
CABLE ROUTING DIAGRAM

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
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.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check that the coolant level is correct in the coolant reservoir.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-14
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-26 ~ 32
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-33 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 45
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 23

3 - 6
INSP
ADJ
COOLANT REPLACEMENT
CAUTION:
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:
Seat
Left side cover
Refer to ”SEAT FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
3. Disconnect:
Coolant reservoir hose 1
Drain the coolant completely.
4. Connect:
Coolant reservoir hoseLOWFULLCOOLANT1
5. Remove:
Coolant drain bolt 1
6. Remove:
Radiator cap
Drain the coolant completely.
7. Clean:
Cooling system
Thoroughly flush the cooling system
with clean tap water.
8. Install:
Copper washer
Coolant drain bolt
9. Fill:
Radiator
Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant 1 and water
(soft water) 2 mixing ratio:
50%/50%
Coolant capacity:
1.3 L (1.14 Imp qt, 1.37 US qt)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or oil.
10. Install:
Radiator cap
11. Fill:
Coolant reservoir
Midway a between maximum and min-
imum marks on the tank.
12. Install:
Coolant reservoir cap
13. Start the engine and let it warm up for
several minutes.
14. Turn off the engine and inspect the cool-
ant level.
Refer to “COOLANT LEVEL INSPEC-
TION” section.
NOTE:
Before checking the coolant level wait a few
minutes until the coolant settles.Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
LOWFULLCOOLANTa
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap) 1
Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or
replace.