2004 YAMAHA YZ250LC coolant

INSP
ADJ
3-8
RADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
EC356002
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
9Radiator cap tester 1and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
9Pressure
Impossible to maintain the specified pres-
sure for 10 secondsReplace.
EC357003
COOLING SYSTEM INSPECTION
1. Inspect:
9Coolant level
2. Attach:
9Radiator cap tester 1and adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
95~125 kPa (0.95~1.25 kg/cm
2,
13.5~17.8 psi)
Standard pressure:
180 kPa (1.8 kg/cm
2, 25.6 psi)
5XF-9-30-3A 4/21/03 2:09 PM Page 24

INSP
ADJ
3-9
CLUTCH ADJUSTMENT
NOTE:
9Do not apply pressure more than specified
pressure.
9Radiator should be filled fully.
4. Inspect:
9Pressure
Impossible to maintain the specified pres-
sure for 10 secondsRepair.
9Radiator 1
9Radiator hose joint 2
Coolant leakageRepair or replace.
9Radiator hose 3
SwellingReplace.
2. Adjust:
9Clutch lever free play
EC359020
CLUTCH ADJUSTMENT
1. Check:
9Clutch lever free play a
Out of specificationAdjust.
NOTE:
9Make minute adjustment on the lever side
using the adjuster 3.
9After adjustment, check proper operation of
clutch lever.
Clutch lever free play a a
:
8~13 mm (0.31~0.51 in)
Clutch lever free play adjustment steps:
9Loosen the locknut 1.
9Turn the adjuster 2until free play ais with-
in the specified limits.
9Tighten the locknut.
5XF-9-30-3A 4/21/03 2:09 PM Page 26

4-4
RADIATORENG
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for Drain the coolant.
Refer to “COOLANT REPLACEMENT”
removal section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section.
1 Panel 2
2 Clamp (radiator hose 2) 2 Only loosening.
3 Radiator hose 1 1
4 Radiator (left) 1
5 Radiator hose 4 1
6 Radiator (right) 1
7 Radiator hose 2 2
8 Radiator breather hose 1
EC450001
RADIATOR
Extent of removal:1Radiator removal
1
1 Nm (0.1 m•kg, 0.7 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
5XF-9-30-4A 5/7/03 1:35 PM Page 8

4-53
WATER PUMPENG
EC4G3000
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
9Impeller 1
9Plain washer 2
9Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discoloration
of coolant, or milky transmission oil.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal 1
EC4G4000
INSPECTIONEC444200
Impeller shaft
1. Inspect:
9Impeller shaft 1
Bend/Wear/Damage
Replace.
Fur deposits
Clean.
5XF-9-30-4C 5/8/03 11:49 AM Page 8

4-55
WATER PUMPENG
EC4G5220
Impeller shaft
1. Install:
9Impeller shaft 1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip and
impeller shaft. And install the shaft while turn-
ing it.
2. Install:
9Plain washer 1
9Impeller 2
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and install the
impeller.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
5XF-9-30-4C 5/8/03 11:49 AM Page 12