2003 YAMAHA WR 250F coolant

SPEC
2 - 103
CABLE ROUTING DIAGRAM
1Hot starter cable
2Cable guide
3Throttle cable (return)
4Throttle cable (pull)
5Ignition coil
6Coolant reservoir breather hose
7Rectifier/regulator
8Coolant reservoir hose
9Rectifier/regulator lead
0Clamp
ACDI unit lead
BCDI unit
CCDI unit bandDCDI unit stay
ERectifier/regulator bracket
ÈPass the throttle cables and hot starter cable through the cable
guides.
ÉPass the throttle cables and hot starter cable between the radi-
ator and frame, then under the radiator mounting boss.
ÊPass the throttle cables on the outside of the ignition coil.
ËPass the carburetor breather hose (of the throttle cable cover)
through the hose holder.

SPEC
2 - 105
ÌFasten the coolant reservoir breather hose and carburetor
breather hoses together.
ÍFasten the CDI unit lead.
ÎInsert the CDI unit band over the CDI unit stay as far as possi-
ble.
ÏFasten the rectifier/regulator lead to the rectifier/regulator
bracket with a plastic locking tie and cut off the tie end.
CABLE ROUTING DIAGRAM

SPEC
2 - 109
CABLE ROUTING DIAGRAM
1Starter motor lead
2Negative battery lead
3Wire harness
4Clamp
5Taillight lead
6Coolant reservoir breather hose
7Coolant reservoir hose
8Positive battery lead
9Starting circuit cut-off relay
0BatteryÈPosition the starter motor lead, negative battery lead and wire
harness in the tank damper slit.
ÉFasten the wire harness.
ÊDo not allow the taillight lead to slacken.
ËFasten the coolant reservoir breather hose, coolant reservoir
hose and rectifier/regulator lead.
ÌFasten the coolant reservoir breather hose and coolant reser-
voir hose.
ÍPass the coolant reservoir hose on the outside of the coolant
reservoir breather hose.

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
ROTOR NUT
Retighten
EXHAUST PIPE, SILENCER,
PROTECTOR
Inspect and retighten
Clean
Replace* Whichever comes first
*SPARK ARRESTER
Clean
(Every
six
months)
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAINUse chain lube
Chain slack:
40 ~ 50 mm (1.6 ~ 2.0 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolantEvery two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING AND
BREAK-IN” section in the
CHAPTER 1. Retighten
AIR FILTER
Clean and lubricate Use foam air-filter oil or
equivalent oil
Replace
OIL FILTER
Replace
OIL STRAINER (frame)
Clean
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper bolts,
master cylinder bolts and union bolts
Replace pads
Replace brake fluid Every one yearItemAfter
break-inEvery
race
Every third
(or
500 km)Every fifth
(or
1,000 km)As
requiredRemarks
1
2
3
4
5
6
7

3 - 16
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 the cooling system for leakage.P.3-21 ~ 29
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-35
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-39 ~ 47
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-29 ~ 31
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-31 ~ 33
Brakes Check the play of front brake and effect of front and rear brake. P.3-65 ~ 77
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-79 ~ 83
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-99 ~ 101
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-101 ~ 103
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-83 ~ 97
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.4-7 ~ 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-77
Lubrication Check for smooth operation. Lubricate if necessary. P.3-105
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-45
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are
connected tightly.P.1-9
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 ~ 42

3 - 21
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap 1,
drain bolt and hoses when the
engine and radiator are hot. Scald-
ing 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 radia-
tor cap, slowly rotate the cap
counterclockwise to the detent.
This procedure allows any resid-
ual pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
CAUTION:
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. Inspect:
Coolant level
Coolant level should be
between the maximum
a and
minimum
b marks.
Coolant level is below the
“LOW” level line
→ Add soft
water (tap water) up to the
proper level.
3. Start the engine and let it warm
up for several minutes.
4. Turn off the engine and check
the coolant level again.
NOTE:Before checking the coolant level,
wait a few minutes until the coolant
settles.
LOWFULLCOOLANTa
b
MOTEUR
CONTROLE DU NIVEAU DU
LIQUIDE DE REFROIDISSEMENT
AVERTISSEMENT
Ne pas déposer le bouchon du radia-
teur 1
, le boulon de vidange et les
tuyaux quand le moteur et le radia-
teur sont chauds. Le liquide bouillant
et de la vapeur pourraient être éjectés
sous pression, ce qui pourrait causer
de graves brûlures. Quand le moteur
est froid, mettre un chiffon épais sur le
bouchon du radiateur et tourner len-
tement le bouchon à gauche jusqu’au
point de détente. Cette procédure per-
met de faire tomber toute pression
résiduelle. Quand le sifflement s’est
arrêté, appuyer sur le bouchon tout en
le tournant à droite pour le déposer.
ATTENTION:
L’eau calcaire et l’eau salée sont nuisi-
bles pour les pièces du moteur. Si on
ne dispose pas d’eau douce, on peut
utiliser de l’eau distillée.
1. Placer la machine sur un sol de
niveau, puis tenir bien vertical.
2. Contrôler:
Niveau du liquide de refroidisse-
ment
Le niveau du liquide de refroidis-
sement devrait se trouver entre
les lignes de maximum a et de
minimum b.
Le niveau du liquide de refroidis-
sement est en dessous de la ligne
de niveau “LOW” → ajouter de
l’eau douce (eau de robinet)
jusqu’au niveau correct.
3. Démarrer le moteur et le laisser
chauffer quelques minutes.
4. Arrêtez le moteur et vérifier à nou-
veau le niveau du liquide de refroi-
dissement.
N.B.:
Avant de vérifier le niveau du liquide de
refroidissement, attendre quelques minu-
tes que le liquide de refroidissement soit
reposé.
ENGINE
MOTEUR

3 - 23
INSP
ADJ
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap
when the engine is hot.
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
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 hose
LOWFULLCOOLANT1
5. Remove:
Engine guard
1
Coolant drain bolt
2
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
Engine guard
Bolt [engine guard (front)]
Bolt [engine guard (rear)]
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
New
CHANGEMENT DU LIQUIDE DE
REFROIDISSEMENT
AVERTISSEMENT
Ne jamais enlever le bouchon du
radiateur quand le moteur est chaud.
ATTENTION:
Prendre garde à ne pas verser de
liquide de refroidissement sur les sur-
faces peintes. Si cela devait se pro-
duire, nettoyer à l’eau.
1. Mettre un récipient sous le moteur.
2. Déposer:
Selle
Se reporter à la section “SELLE,
RESERVOIR DE CARBURANT
ET CACHES LATERAUX” au
CHAPITRE 4.
3. Déconnecter:
Durit du vase d’expansion 1
Vidanger complètement le liquide
de refroidissement.
4. Connecter:
Durit du vase d’expansion
5. Déposer:
Protège-carter 1
Boulon de vidange de refroidisse-
ment 2
6. Déposer:
Bouchon du radiateur
Vidanger complètement le liquide
de refroidissement.
7. Nettoyer:
Circuit de refroidissement
Bien rincer le circuit de refroidis-
sement avec de l’eau du robinet.
8. Monter:
Rondelle en cuivre
Boulon de vidange de refroidisse-
ment
Protège-carter
Boulon [protège-carter (avant)]
Boulon [protège-carter (arrière)]
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..34 Nm (3,4 m · kg, 24 ft · lb)
T R..23 Nm (2,3 m · kg, 17 ft · lb)
New
ENGINE
MOTEUR

3 - 25
INSP
ADJ
9. Fill:
Radiator
Engine
To specified level.
CAUTION:
Do not mix more than one type
of ethylene glycol antifreeze
containing corrosion inhibitors
for aluminum engine.
Do not use water containing
impurities or oil.
Recommended coolant:
High quality ethylene
glycol anti-freeze con-
taining 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)
Handling notes of coolant:
The coolant is harmful so it should
be handled with special care.
WARNING
When coolant splashes to
your eye.
Thoroughly wash your eye
with water and see your doc-
tor.
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.
10. Install:
Radiator cap
11. Fill:
Coolant reservoir tank
Midway
a between maximum
and minimum marks on the
tank.
LOWFULLCOOLANTa
9. Remplir:
Radiateur
Moteur
Au niveau spécifié.
ATTENTION:
Ne pas mélanger plusieurs solutions
antigel à l’éthylène glycol contenant
des produits anticorrosion pour
moteurs en aluminium.
Ne pas utiliser d’eau contenant des
impuretés ou de l’huile.
Liquide de refroidissement
recommandé:
Antigel à l’éthylène gly-
col de haute qualité con-
tenant un agent anticor-
rosion pour moteurs en
aluminium
Taux du mélange liquide de
refroidissement 1/eau (eau
douce) 2:
50 %/50 %
Capacité de
refroidissement:
1,3 L
(1,14 Imp qt, 1,37 US qt)
Notes concernant la manipulation
du liquide de refroidissement:
Le liquide de refroidissement étant
dangereux, il doit être manipulé avec
une attention particulière.
AVERTISSEMENT
En cas d’éclaboussures de
liquide de refroidissement dans
les yeux: Rincer soigneusement les
yeux à l’eau et consulter un méde-
cin dans les plus brefs délais.
En cas d’éclaboussures de
liquide de refroidissement sur les
vêtements: Eliminer rapidement
à l’eau puis à l’eau savonneuse.
En cas d’ingestion de liquide de
refroidissement: Provoquer rapi-
dement un vomissement puis
consulter un médecin dans les
plus brefs délais.
10. Monter:
Bouchon de radiateur
11. Remplir:
Vase d’expansion
A mi-chemin a entre les repères
de niveau minimum et maximum
du réservoir.
ENGINE
MOTEUR