2006 YAMAHA YZ250F radiator cap

2 - 19
SPEC
1Warmstartzug
2Kühlerschlauch 2
3Klemme
4Zündspulenkabel
5Drosselklappensensor-Kabel
6Buckel (Rahmen)
7Ölschlauch
8Schlauchführung
9Leerlaufschalter-Kabel
0CDI-Schwunglichtmagnetzünder-
Kabel
AKupplungszug
BKühler-Entlüftungsschlauch
CMotorstoppschalter-Kabel
DNebenkabelbaum
EZündbox-Halterung
FZündbox
GGaszug
HZylinderkopf-Entlüftungsschlauch
ÈDen Warmstartzug, die Gaszüge, das
Drosselklappensensorkabel und
Zündspulenkabel befestigen.
ÉDas Drosselklappensensorkabel hin-
ter dem Buckel am Rahmen befesti-
gen.
ÊDas Leerlaufschalterkabel am
Ölschlauch befestigen.
ËDas Leerlaufschalterkabel an der
Innenseite des Ölschlauchs entlang
führen.
ÌDas Leerlaufschalterkabel, das CDI-
Schwunglichtmagnetzünder-Kabel
und den Kühler-Entlüftungsschlauch
befestigen.
ÍDas Leerlaufschalterkabel, das CDI-
Schwunglichtmagnetzünder-Kabel,
den Kühler-Entlüftungsschlauch und
den Kupplungszug über der Kühler-
Montagenabe befestigen. 1Câble de starter à chaud
2Durit de radiateur 2
3Collier à pince
4Fil de la bobine d’allumage
5Fil du capteur de position de papillon des
gaz
6Bosse (cadre)
7Durit d’huile
8Guide de durit
9Fil du contacteur de point mort
0Fil du volant magnétique C.D.I.
ACâble d’embrayage
BDurit de mise à l’air du radiateur
CFil du coupe-circuit du moteur
DFaisceau de fils secondaire
ESupport de boîtier CDI
FBoîtier C.D.I.
GCâble des gaz
HDurit de mise à l’air de la culasse
ÈAttacher ensemble le câble de starter à
chaud, les câbles des gaz, le fil du capteur
de position de papillon des gaz et le fil de
la bobine d’allumage.
ÉAttacher le fil du capteur de position de
papillon des gaz derrière la bosse du
cadre.
ÊAttacher le fil du contacteur de point mort
à la durit d’huile.
ËAcheminer le fil du contacteur de point
mort vers l’intérieur de la durit d’huile.
ÌAttacher ensemble le fil du contacteur de
point mort, le fil du volant magnétique
CDI et la durit de mise à l’air du radiateur.
ÍAttacher le fil du contacteur de point
mort, le fil du volant magnétique CDI, la
durit de mise à l’air du radiateur et le
câble d’embrayage à la noix de montage
du radiateur.1Cavo starter per partenze a caldo
2Flessibile radiatore 2
3Morsetto
4Cavo bobina di accensione
5Cavo sensore posizione farfalla
6Gobba (telaio)
7Flessibile olio
8Guida flessibile
9Cavo interruttore folle
0Cavo magnete CDI
ACavo frizione
BFlessibile di sfiato radiatore
CCavo interruttore di arresto motore
DCablaggio secondario
EStaffa unità CDI
FUnità CDI
GCavo acceleratore
HFlessibile di sfiato testata
ÈFissare il cavo starter per partenze a
caldo, i cavi dell’acceleratore, il cavo sen-
sore posizione farfalla e il cavo bobina di
accensione.
ÉFissare il cavo sensore posizione farfalla
dietro la gobba del telaio.
ÊFissare il cavo dell’interruttore folle al
flessibile olio.
ËFar passare il cavo dell’interruttore folle
all’interno del flessibile olio.
ÌFissare il cavo dell’interruttore folle, il
cavo magnete CDI e il flessibile di sfiato
radiatore.
ÍFissare il cavo dell’interruttore folle, il
cavo magnete CDI, il flessibile di sfiato
radiatore e il cavo frizione oltre la spor-
genza di montaggio del radiatore.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
SCHEMA PERCORSO DEI CAVI

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear
ROTOR NUT
Retighten
EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace * Whichever comes first
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every 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
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 year
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil sealItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks


3

INSP
ADJ
FRIZIONE Controllare la campana, il
disco conduttore, il disco
condotto e la molla della fri-
zione Controllare e regolare
Sostituire
TRASMISSIONE
Controllare
Sostituire il cuscinetto
FORCELLA DEL CAMBIO, CAMMA
DEL CAMBIO, BARRA DI GUIDA
Controllare Controllare l’usura
DADO ROTORE
Serrare
TUBO DI SCARICO, SILENZIATORE,
PROTEZIONE
Controllare e serrare
Pulire
Sostituire * In qualsiasi ordine
GOMITO
Controllare e pulire
CARBURATORE
Controllare, regolare e pulire
CANDELA DI ACCENSIONE
Controllare e pulire
Sostituire
CATENA DI TRASMISSIONE Utilizzare un lubrificante per
catene
Gioco della catena:
48 ~ 58 mm (1,9 ~ 2,3 in) Lubrificare, gioco, allineamento
Sostituire
SISTEMA DI RAFFREDDAMENTO
Controllare il livello del refrigerante e la
presenza di eventuali perdite
Controllare il funzionamento del coper-
chio del radiatore
Sostituire il refrigerante Ogni due anni
Controllare i flessibili
DADI E BULLONI ESTERNI Fare riferimento al paragrafo
“AVVIAMENTO E
RODAGGIO” nel CAPI-
TOLO 1. Serrare
FILTRO ARIA
Pulire e lubrificare Applicare l’olio schiuma fil-
tro aria o un prodotto equi-
valente Sostituire
FILTRO OLIO
Sostituire
FILTRO OLIO
Pulire
TELAIO
Pulire e controllare
SERBATOIO E RUBINETTO DEL CAR-
BURANTE
Pulire e controllareElementoDopo il
rodaggioAd ogni
compe-
tizione
Ogni tre
competi-
zioni
(o 500 km)Ogni
cinque com-
petizioni
(o
1.000 km)Se ne-
cessarioOsservazioni
INTERVALLI DI MANUTENZIONE
3 - 2

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 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.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and oil
line for leakage.P.3-13 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9 ~ 10
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.3-23 ~ 29
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-30 ~ 32
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-40 ~ 41
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-41 ~ 43
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-32 ~ 39
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.4-3 ~ 5
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-30
Lubrication Check for smooth operation. Lubricate if necessary. P.3-44
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 ~ 21

3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
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.
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. Remove:
Radiator cap
3. Check:
Coolant level a
Coolant level low → Add coolant.
1Radiator
1a
ENGINE/COOLANT LEVEL INSPECTION

3 - 6
INSP
ADJ
COOLANT REPLACEMENT
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:
Coolant drain bolt 1
3. Remove:
Radiator cap
Drain the coolant completely.
4. Clean:
Cooling system
Thoroughly flush the cooling system with
clean tap water.
5. Install:
Copper washer
Coolant drain bolt
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. 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:
0.99 L (0.87 Imp qt, 1.05 US qt)

INSP
ADJ
KÜHLFLÜSSIGKEIT WECHSELN
WARNUNG
Der Kühlerverschlussdeckel darf
niemals bei heißem Motor abge-
nommen werden.
ACHTUNG:
Keine Kühlflüssigkeit an lackierte
Flächen lassen. Spritzer sofort mit
Wasser abwaschen.
1. Ein Auffanggefäß unter den
Motor stellen.
2. Demontieren:
Kühlflüssigkeits-Ablass-
schraube 1
3. Demontieren:
Kühlerverschlussdeckel
Die Kühlflüssigkeit vollständig
ablaufen lassen.
4. Reinigen:
Kühlsystem
Das Kühlsystem gründlich mit
sauberem Leitungswasser
spülen.
5. Montieren:
Kupferscheibe
Kühlflüssigkeits-Ablass-
schraube
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Einfüllen:
Kühler
Motor
(bis zum vorgeschriebenen
Stand)
Empfohlene Kühlflüssig-
keit:
Hochwertiges
Frostschutzmittel auf
Äthylenglykolbasis mit
Korrosionsschutz-
Additiv für
Aluminiummotoren
Mischverhältnis Wasser
2/Frostschutzmittel 1:
50%/50%
Kühlmittel-Füllmenge:
0,99 L
(0,87 Imp qt, 1,05 US qt)
CHANGEMENT DU LIQUIDE DE
REFROIDISSEMENT
AVERTISSEMENT
Ne jamais enlever le bouchon de
radiateur quand le moteur est chaud.
ATTENTION:
Veiller à ne pas laisser échapper de
liquide de refroidissement sur les sur-
faces peintes. Si cela devait se pro-
duire, rincer à l’eau.
1. Placer un récipient sous le moteur.
2. Déposer:
Boulon de vidange du liquide de
refroidissement 1
3. Déposer:
Bouchon de radiateur
Vidanger entièrement le liquide
de refroidissement.
4. Nettoyer:
Circuit de refroidissement
Rincer soigneusement le circuit
de refroidissement à l’eau claire.
5. Monter:
Rondelle en cuivre
Boulon de vidange du liquide de
refroidissement
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Remplir:
Radiateur
Moteur
au niveau spécifié.
Liquide de refroidissement
recommandé:
Antigel à l’éthylène
glycol de haute qualité
contenant un agent
anticorrosion pour
moteurs en aluminium
Rapport de mélange liquide
de refroidissement 1 et
eau (eau douce) 2:
50%/50%
Quantité de liquide de
refroidissement:
0,99 L
(0,87 Imp qt, 1,05 US qt)
SOSTITUZIONE DEL
REFRIGERANTE
AVVERTENZA
Non togliere il coperchio del radiatore
a motore caldo.
ATTENZIONE:
Prestare attenzione a non rovesciare il
refrigerante su superfici verniciate. Se
si rovescia, toglierlo lavando con
acqua.
1. Collocare un recipiente sotto il
motore.
2. Togliere:
Tappo di scarico refrigerante 1
3. Togliere:
Coperchio del radiatore
Scaricare completamente il refri-
gerante.
4. Pulire:
Sistema di raffreddamento
Sciacquare accuratamente il
sistema di raffreddamento con
acqua di rubinetto pulita.
5. Installare:
Rondella di rame
Tappo di scarico refrigerante
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Riempire:
Radiatore
Motore
Fino al livello indicato.
Refrigerante raccoman-
dato:
Antigelo glicole etilenico
di alta qualità con
anticorrosivo per motori
in alluminio.
Rapporto refrigerante 1 /
acqua (acqua dolce) 2:
50%/50%
Capacità refrigerante:
0,99 L
(0,87 Imp qt, 1,05 US qt)
CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT
KÜHLFLÜSSIGKEIT WECHSELN
SOSTITUZIONE DEL REFRIGERANTE
3 - 6

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.
7. Install:
Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
Coolant level
Coolant level low → Add coolant. 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.
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.