2004 YAMAHA YZ250LC engine

2-15
CABLE ROUTING DIAGRAMSPEC
1Radiator breather hose
2Ground lead
3Clamp
4Wireharness
5High tension cord
6Ignition coil
7Throttle cable
8“ENGINE STOP” button lead
9Clutch cable
0Engine bracketAClamp 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.
BPosition the CDI magneto lead
coupler between the radiators.
CInstall the radiator hose with the
paint facing the right of the frame
so that the hose does not come
in contact with the CDI unit.
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 bolts.FFasten the ground lead together
with the front installation portion
of the ignition coil.
GPass the radiator breather hose
at the rear of the radiator hose
and in front of the ignition coil
bracket.
H
Position each lead at the lower
left of the main tube (frame)
and put the clamp ends within
the area as shown by the
arrow.
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2-15
SCHEMA DE CHEMINEMENT DES CABLES
KABELFÜHRUNGSÜBERSICHTPLAN
DIAGRAMMA DEL PASSAGGIO DEI CAVISPEC
1Kühlerentlüfterschlauch
2Massekabel
3Klemme
4Kabelbaum
5Hochspannungskabel
6Zündspule
7Gasseil
8Leitungskabel des Motorstoppknopfes
„ENGINE STOP”
9Kupplungskabel
0Motorhalterung
AKupplungskabel, Hochspannungs-
schnur und Kabelbaum so am Schutz
der Hochspannungsschnur festklem-
men, dass die Verschlussklemme, mit
den Enden nach unten, durchgeführt
wird.
BCDI-Magnetleitungsstecker zwischen
den Kühlern anbringen.
CDen Kühler-Belüftungsschlauch so
installieren, dass die farbige Seite zur
rechten Seite des Rahmens weist,
damit der Schlauch nicht mit der CDI-
Einheit in Kontakt kommt.
DKabelbaum an der rechten Motorhalte-
rung festklemmen.
EHochspannungsschnur, Gaskabel und
Kabelbaum mit den Enden der Ver-
schlussklemme nach unten so festklem-
men, dass die Hochspannungsschnur
nicht mit den Einbauschrauben der
Motorhalterung in Berührung gelangt.
FDas Massekabel gemeinsam mit dem
vorderen Befestigungsteil der Zündspu-
le befestigen.
GKühlerlüfterschlauch hinter dem Kühler-
schlauch und vor der Zündspulenhalte-
rung durchführen.
HJede Leitung an der unteren Seite links
am Hauptrohr (Rahmen) anbringen und
Enden der Schelle in den vom Pfeil
angegebenen Bereich verbringen.1Tuyau de reniflard de radiateur
2Fil de masse
3Bride
4Faisceau de fils
5Cordon de haute-tension
6Bobine d’allumage
7Câble d’accélérateur
8Fil de bouton d’arrêt du moteur “ENGI-
NE STOP”
9Câble d’embrayage
0Support du moteur
ABridez le câble d’embrayage, le cordon
de haute tension et le faisceau de fils sur
la protection du cordon de haute tension
de façon à ce que la bride soit orientée
avec ses extrémités vers le bas comme
illustré.
BPositionnez le raccord du fil de magnéto
CDI entre les radiateurs.
CInstallez le tuyau du radiateur avec la
marque de peinture orientée vers la droi-
te du cadre de sorte que le tuyau n’entre
pas en contact avec l’unité CDI.
DBridez le faisceau de fils sur le support
droit du moteur.
EBridez le cordon de haute tension, le
câble d’accélérateur et le faisceau de fils
en orientant les extrémités de la bride
vers le bas de façon à ce que le cordon de
haute tension ne soit pas en contact avec
les boulons de montage du support du
moteur.
FFixer le fil de masse avec la partie avant
de fixation de la bobine d’allumage.
GFaites passer le tuyau de reniflard du
radiateur à l’arrière de la durite du radia-
teur et à l’avant du support de la bobine
d’allumage.
HPositionnez chaque fil de la partie infé-
rieure gauche du tube principal (cadre) et
placez les extrémités de la bride dans la
zone indiquée par la flèche.1Tubo di sfiato del radiatore
2Conduttore di terra
3Brida
4Complesso conduttori
5Cavo ad alta tensione
6Bobina di accensione
7Cavo dell’acceleratore
8Conduttore del pulsante “ARRESTO
MOTORE”
9Cavo della frizione
0Staffa del motore
AAgganciare il cavo della frizione, il cavo
ad alta tensione e il complesso conduttori
alla protezione del cavo ad alta tensione,
con la fascia di serraggio passata con le
estremità rivolte verso il basso, come
illustrato.
BPosizionare l’accoppiatore del conduttore
del magnete CDI tra i radiatori.
CInstallare il manicotto flessibile del
radiatore con il lato verniciato rivolto a
destra del telaio, in modo che il manicot-
to non venga a contatto con l’unità CDI.
DAgganciare il complesso conduttori alla
staffa destra del motore.
EAgganciare il cavo ad alta tensione, il
cavo dell'acceleratore e il complesso con-
duttori con le estremità della fascia di
serraggio rivolte verso il basso, in modo
che il cavo ad alta tensione non entri in
contatto con i bulloni d'installazione
della staffa del motore.
FFissare il conduttore di terra con la parte
della bobina di accensione installata
anteriormente.
GFar passare il tubo di sfiato del radiatore
dietro al tubo del radiatore e davanti alla
staffa della bobina d’accensione.
HPosizionare ciascun conduttore nella
parte inferiore sinistra del tubo principale
(telaio) e posizionare le estremità della
brida nel punto indicato dalla freccia.
5XF-9-30-2 5/15/03 3:54 PM Page 55

SPEC
2-17
CABLE ROUTING DIAGRAM
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
directs as shown and lightly touches the
projection on the master cylinder.
BPass the “ENGINE STOP” button lead in
the middle of the clutch holder.
CClamp the “ENGINE STOP” button lead to
the handlebar to 3 clicks.
DPass the brake hose in front of the number
plate and through the cable guide.
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SPEC
2-17
SCHEMA DE CHEMINEMENT DES CABLES
KABELFÜHRUNGSÜBERSICHTPLAN
DIAGRAMMA DEL PASSAGGIO DEI CAVI
1Bremsschlauch
2Hauptbremszylinder
3Leitungskabel des Motorstoppknopfes
„ENGINE STOP“
4Motorstoppknopf „ENGINE STOP“
5Gasseil
6Kupplungskabel
7Klemme
8Kabelführung
ADen Bremsschlauch so einbauen, daß
sein Rohrteil gemäß Abbildung ange-
ordnet ist und den Überstand am
Hauptbremszylinder leicht berührt.
BDas Leitungskabel des Motorstopp-
knopfes „ENGINE STOP“ in der Mitte
des Kupplungshalters durchführen.
CKabel des Motorausschaltknopfes
„ENGINE STOP“ am Lenker festklem-
men mit 3 klicks.
DDen Bremsschlauch vor dem Num-
mernschild und durch die Kabelführung
durchführen.1Tuyau de frein
2Maître-cylindre
3Fil de bouton d’arrêt du moteur “ENGI-
NE STOP”
4Bouton d’arrêt du moteur “ENGINE
STOP”
5Câble d’accélérateur
6Câble d’embrayage
7Bride
8Guide de câble
åIstaller la tuyau de frein de manière que
la partie avec le tuyau soit dirigée
comme indipué et touche légèrement la
saillie sur le maîtrecylindre.
∫Faire passer le fil de bouton d’arrêt du
moteur “ENGINE STOP” au centre du
support d’embrayage.
çFixer le fil du bouton d’arrêt du “ENGI-
NE STOP” sur le guidon (3 déclics).
∂Faire passer le tuyau de frein devant la
plaque d’immatriculation et à travers le
guide de câble.1Tubo flessibile del freno
2Cilindro principale
3Conduttore del pulsante “ARRESTO
MOTORE”
4Pulsante “ARRESTO MOTORE”
5Cavo dell’acceleratore
6Cavo della frizione
7Nastro
8Guida per cavi
åInstallare il tubo flessibile del freno in
modo che la sua parte di tubo sia rivolta
come illustrato e tocchi leggermente la
sporgenza sul cilindro principale.
∫Far passare il conduttore del pulsante
“ARRESTO MOTORE” nel mezzo del
supporto della frizione.
çBloccare il conduttore del pulsante
“ARRESTO MOTORE” sul manubrio
dopo 3 scatti.
∂Far passare il tubo flessibile del freno
davanti alla targa e attraverso la guida
per cavi.
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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?
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INSP
ADJ
3-5
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT
EC350000
ENGINE
EC351011
COOLANT LEVEL INSPECTION
w
Do not remove the radiator cap 1 1
, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding 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 radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
cC
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. Remove:
9Radiator cap
3. Check:
9Coolant level a
Coolant level lowAdd coolant.
1Radiator
EC353011
COOLANT REPLACEMENT
w
Do not remove the radiator cap when the
engine is hot.
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INSP
ADJ
3-6
COOLANT REPLACEMENT
cC
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:
9Coolant drain bolt 1
3. Remove:
9Radiator cap
Drain the coolant completely.
4. Clean:
9Cooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:
9Copper washer
9Coolant drain bolt
6. Fill:
9Radiator
9Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant 1and water
(soft water) 2mixing ratio:
50%/50%
Coolant capacity:
1.20 L (1.06 Imp qt, 1.27 US qt)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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INSP
ADJ
3-7
RADIATOR CAP INSPECTION
cC
9Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
9Do not use water containing impurities
or oil.
7. Install:
9Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
9Coolant level
Coolant level lowAdd coolant.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
9Seal (radiator cap) 1
9Valve and valve seat 2
Crack/DamageReplace.
Exist fur deposits 3Clean or replace.
Handling notes of coolant:
The coolant is harmful so it should be handled
with special care.
w
9When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
9When coolant splashes to your clothes.
Quickly wash it away with water and then
with soap.
9When coolant is swallowed.
Quickly make him vomit and take him to
a doctor.
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