2003 YAMAHA YZ250LC oil

2-8
CARACTERISTIQUES D’ENTRETIENSPEC
Article Standard Limite
Roue:
Type de roue avant Roue à rayons…
Type de roue arrière Roue à rayons…
Taille/matériau de jante avant 21 ×1,60/Aluminum…
Taille/matériau de jante arrière 19 ×2,15/Aluminum…
Limite de voile de jante:
Radial…
2,0 mm (0,08 in)
Latéral…
2,0 mm (0,08 in)
Chaîne de transmission:
Type/fabricant DID520DMA2 SDH/DAIDO…
Nombre de maillons 113 maillons + attache…
Flèche de la chaîne 40~50 mm (1,6~2,0 in)…
Longueur de chaîne (10 maillons)…
152,5 mm (6,004 in)
Frein à disque avant:
Dia. extérieur ×épaisseur 250 ×3,0 mm 250 ×2,5 mm
(9,84 ×0,12 in) (9,84 ×0,10 in)
Epaisseur de plaquette 4,4 mm (0,17 in) 1,0 mm (0,04 in)
Dia. intérieur de maître-cylindre 11,0 mm (0,433 in)…
Dia. intérieur de cylindre d’etrier 27,0 mm (1,063 in) ×2…
Type de liquide de frein DOT #4…
Frein à disque arrière:
Dia. extérieur ×épaisseur 245 ×4,0 mm 245 ×3,5 mm
(9,65 ×0,16 in) (9,65 ×0,14 in)
Limite de flèche…
0,15 mm (0,006 in)
Epaisseur de plaquette 6,4 mm (0,25 in) 1,0 mm (0,04 in)
Dia. intérieur de maître-cylindre 11,0 mm (0,433 in)…
Dia. intérieur de cylindre d’etrier 25,4 mm (1,000 in)…
Type de liquide de frein DOT #4…
Levier de frein & pédale de frein:
Position du levier de frein 95 mm (3,74 in)…
Hauteur de la pédale de frein Zéro mm (Zéro in)…
(hauteur au-dessus du haut du repose-pied)
Jeu de levier d’embrayage (côté levier) 8~13 mm (0,31~0,51 in)…
Jeu à la poignée d’accélération 3~5 mm (0,12~0,20 in)…
5UP-9-30-2 5/24/02 5:18 PM Page 21

2-13
CABLE ROUTING DIAGRAMSPEC
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Cable guide
3Throttle cable
4Clamp
5Clutch cable
6Wireharness
7“ENGINE STOP” button lead
8CDI unit
9CDI unit stay
0CDI unit band
qTPS (throttle position sensor)
lead
wSolenoid valve lead
eAir vent hose (left)
rTransmission oil breather hose
tOverflow hose
yAir vent hose (right)APass the fuel tank breather hose
between the handlebar and ten-
sion bar, then insert its end into
the hole of the number plate.
BPass the throttle cable and
“ENGINE STOP” button lead into
the cable guide. Align with the
cable guide the front end of the
tape on the throttle cable.
CPass the throttle cable and
“ENGINE STOP” button lead
over the radiator hose.
DClamp the throttle cable and
“ENGINE STOP” button lead with
the clamp ends downward.
EPass the clutch cable a little for-
ward of the extreme left nut that
holds the cylinder head.
FPass the wireharness between
the engine brackets.GPass the air vent hoses, overflow
hose and transmission oil
breather hose between the frame
and connecting rod.
HFit the CDI unit band into the CDI
unit stay till it stops.
IInsert the CDI unit into the CDI
unit band till it stops.
JClamp the TPS (throttle position
sensor) lead and solenoid valve
lead at the side of the TPS with
the clamp ends backward.
KClamp the air vent hoses.
LPass the air vent hoses, overflow
hose and transmission oil
breather hose so that all these
hoses do not contact the rear
shock absorber.
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2-14
CABLE ROUTING DIAGRAMSPEC
1Ground lead
2Ignition coil lead
3Clamp
4Wireharness
5CDI magneto lead
6YPVS breather hose
7Radiator breather hose
8Cable guide
9“ENGINE STOP” button lead
0Brake hose
APass the “ENGINE STOP” but-
ton lead on the inside of the
ignition coil lead and ground
lead.BClamp the “ENGINE STOP” but-
ton lead, ground lead, ignition
coil lead, wireharness and CDI
magneto lead with the clamp
ends downward.
In so doing, clamp the “ENGINE
STOP” button lead at its coupler
and do not allow the CDI mag-
neto lead to slacken.
CPass the radiator breather hose
outside the engine bracket and
inside the down-tube.Pass the
radiator breather hose inside
the CDI magneto lead.
DClamp 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 out-
ward.EClamp the radiator breather
hose and CDI magneto lead at
the rear of the down-tube with
the clamp ends outward.
FPass the radiator breather hose
and CDI magneto lead in front
of the radiator hose.
GPass the radiator breather hose
between the frame and radiator.
HAlign the top of the brake hose
neck with the brake hose holder
bottom.
IPass 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).
JFit the brake hose into the guide
on the protector.
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2-15
CABLE ROUTING DIAGRAMSPEC
1Clutch cable
2Cable guide
3Ground lead
4Clamp
5Wireharness
6High tension cord
7Ignition coil
8Radiator breather hose
9“ENGINE STOP” button lead
0Throttle cable
qEngine bracketAPass the clutch cable into the
cable guide.
BClamp the clutch cable, high
tension cord and wireharness at
the protector of the high tension
cord so that the clamp passes
with its ends downward, as
shown.
CPosition the CDI magneto lead
coupler between the radiators.
DClamp the wireharness to the
right engine bracket.
EClamp the high tension cord,
throttle cable and wireharness
with the clamp ends downward,
so that the high tension cord
does not contact the engine
bracket installation nuts.FFasten the ground lead together
with the front installation portion
of the ingnition coil.
GPass the radiator breather hose
at the rear of the radiator hose
and in front of the ignition coil
bracket.
HPosition the throttle cable,
“ENGINE STOP” button lead
and clutch cable as shown.
5UP-9-30-2 5/24/02 5:18 PM Page 54

INSP
ADJ
3-1
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
EC310013
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the required
maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining
and lubricating your machine, consult your Yamaha dealer.
Item Remarks
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
Inspect crack
Inspect carbon deposits
and eliminate them
Check ring end gap
Inspect carbon deposits
and eliminate them
Check gasket
Inspect score marks
Inspect wear
Inspect carbon deposits
and eliminate them
Inspect housing, friction
plate, clutch plate and
spring
Yamalube 4 (10W-30) or
SAE 10W-30 SE motor oil
Inspect wear
Use chain lube
Chain slack: 40~50 mm
(1.6~2.0 in) PISTON
Inspect and clean
Replace
PISTON RING
Inspect
Replace
PISTON PIN, SMALL END BEARING
Inspect
Replace
CYLINDER HEAD
Inspect and clean
Retighten
CYLINDER
Inspect and clean
Replace
YPVS
Inspect and clean
CLUTCH
Inspect and adjust
Replace
TRANSMISSION
Replace oil
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
ROTOR NUT
Retighten
MUFFLER
Inspect
Clean
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Lubricate, slack, alignment
Replace
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INSP
ADJ
3-2
MAINTENANCE INTERVALS
3
Item Remarks
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolantEvery two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
RetightenAND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricateUse foam air-filter oil or
Replaceequivalent oil
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 fluidEvery one year
FRONT FORKS
Inspect and adjust
Replace oilSuspension oil “01”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
REAR SHOCK ABSORBER
(After
Inspect and adjustrain ride)
Lube Molybdenum disulfide grease
Retighten
CHAIN GUARD AND ROLLERS
Inspect
SWINGARM
Inspect, lube and retightenMolybdenum disulfide grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retightenMolybdenum disulfide grease
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,

tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE
Check routing and connectionYamaha cable lube or
LubricateSAE 10W-30 motor oil
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
5UP-9-30-3A 5/24/02 5:19 PM Page 3

3-3
PROGRAMME D’ENTRETIEN
INSP
ADJ
PartieAprès Chaque Chaque Chaque Si
Remarques
rodage coursetrois- cinquiè- nécessa-
ième me ire
BRAS OSCILLANT
Contrôler, lubrifier et resserrer
66
BRAS RELAIS, BIELLE
Contrôler, lubrifier et resserrer66
TETE DE FOURCHE
Contrôler le jeu66
Nettoyer et lubrifier6
Changer le roulement6
PNEU; ROUES
Contrôler la pression de gonflage,
le voile de roue et l’usure des
66pneus et voir s’il n’y a pas de
rayon détendu
Resserrer les boulons de la roue
66dentée
Contrôler les roulements6
Changer les roulements6
Graisser6
ACCELERATEUR, CABLES DE
COMMANDE
Contrôler le chaminement et le
66branchement
Graisser66
Graisse au bisulfure de
molybdène
Graisse au bisulfure de
molybdène
Graisse à base de lithium
Graisse à base de lithium
Yamaha lube pour câble ou
Huile moteur SAE 10W-30
5UP-9-30-3A 5/24/02 5:19 PM Page 7

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?
5UP-9-30-3A 5/24/02 5:19 PM Page 14