light YAMAHA YZ250LC 2004 Notices Demploi (in French)

3-38
ELECTRICAL/SPARK PLUG INSPECTION
INSP
ADJ
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
9Spark plug
2. Inspect:
9Electrode 1
Wear/Damage Replace.
9Insulator color 2
Normal condition is a medium to light tan
color.
Distinctly different color Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
9Plug gap a
Use a wire gauge or thickness gauge.
Out of specification Regap.
4. Clean the plug with a spark plug cleaner if
necessary.
5. Tighten:
9Spark plug
NOTE:
9Before installing a spark plug, clean the
gasket surface and plug surface.
9Finger-tighten athe spark plug before torquing
to specification b.
Spark plug gap:
0.5~0.6 mm (0.020~0.024 in)
Standard spark plug:
BR8EG (NGK)
20 Nm (2.0 m•kg, 14 ft•lb)
5XF-9-30-3B 5/6/03 6:32 PM Page 40

3. Install:
9Pilot air screw 1
9Throttle stop screw 2
*For EUROPE
4. Install:
9Starter plunger 1
4-14
ENGCARBURETOR AND REED VALVE
Pilot air screw:
1 turn out
*7/8 turns out
(for reference only)
Note the following installation points:
9Turn in the pilot air screw until it is lightly
seated.
9Turn out the pilot air screw by the number of
turns recorded before removing.
5. Install:
9Pilot jet 1
9Main jet 2
6. Install:
9Needle valve 1
9Float 2
9Float pin 3
NOTE:
9After installing the needle valve to the float,
install them to the carburetor.
9Check the float for smooth movement.
5XF-9-30-4A 5/7/03 1:35 PM Page 28

4-66
CRANKCASE AND CRANKSHAFTENG
NOTE:
9Make appropriate bolts 3as shown available
by yourself and attach the tool with them.
9Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
9As pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
cC
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw,
realign, and start over. If the cases do not
separate, check for a remaining case
screw or fitting. Do not force.
EC4N3000
REMOVAL POINTS
EC4N3100
Segment
1. Remove:
9Bolt (segment) 1
9Segment 2
NOTE:
Turn the segment counterclockwise until it stops
and loosen the bolt.
EC4N3212
Crankcase
1. Remove:
9Crankcase (right) 1
Use the crankcase separating tool 2.
Crankcase separating tool:
YU-1135-A/90890-01135
5XF-9-30-4C 5/8/03 11:50 AM Page 34

4-70
CRANKCASE AND CRANKSHAFTENG
3. Install:
9O-ring 1
To crankcase (right) 2.
5. Install:
9Dowel pin 1
9Crankcase (right) 2
To crankcase (left) 3.
NOTE:
9Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft hammer.
9When installing the crankcase, the connecting
rod should be positioned at TDC (top dead
center).
cC
In order to prevent the oil seal lipa a
from
being turned up or damaged, wrap a vinyl
tape or the likeb b
around the right end of
the crankshaft and apply the lithium soap
base grease over the tape.
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
4. Apply:
9Sealant
On the crankcase (right) 1.
Quick gasket®:
ACC-QUICK-GS-KT
Yamaha bond No. 1215:
90890-85505
5XF-9-30-4C 5/8/03 11:50 AM Page 42

4-73
TRANSMISSION, SHIFT CAM AND SHIFT FORKENG
EC4H4600
Bearing
1. Inspect:
9Bearing 1
Rotate inner race with a finger.
Rough spot/Seizure
Replace. 2. Inspect:
9O-ring 1
Damage
Replace.
3. Check:
9Gears movement
Unsmooth movement
Repair or replace.
EC4H4000
INSPECTION
EC4H4230
Gears
1. Inspect:
9Matching dog a
9Gear teeth b
9Shift fork groove c
Wear/Damage
Replace.
EC4H3000
REMOVAL POINTS
EC4H3230
Transmission
1. Remove:
9Main axle 1
9Drive axle 2
9Shift cam
9Shift fork 3
9Shift fork 2
9Shift fork 1
NOTE:
9Remove assembly carefully. Note the position
of each part. Pay particular attention to the
location and direction of shift forks.
9Remove the main axle, drive axle, shift cam
and shift fork all together by tapping lightly on
the transmission drive axle with a soft hammer.
5XF-9-30-4C 5/8/03 11:50 AM Page 48

5-18
CHASFRONT BRAKE AND REAR BRAKE
3. Install:
9Brake hose holder 1
9Caliper 2
9Bolt (caliper) 3
NOTE:
Fit the brake hose holder cut aover the projec-
tion bon the front fork and clamp the brake
hose.
4. Tighten:
9Pad pin 4
5. Install:
9Pad pin plug 5
EC5A5121
Rear caliper
1. Install:
9Pad support 1
9Brake pad 2
9Pad pin 3
NOTE:
9Install the brake pads with their projections
ainto the caliper recesses b.
9Temporarily tighten the pad pin at this point.
2. Install:
9Copper washer 1
9Union bolt 2
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion a a
directs as shown and lightly touch-
es the projection b b
on the caliper.
30 Nm (3.0 m•kg, 22 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
3 Nm (0.3 m•kg, 2.2 ft•lb)
5XF-9-30-5A 4/21/03 9:58 PM Page 36

5-21
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
9Brake lever 1
9Bolt (brake lever) 2
9Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
6 Nm (0.6 m•kg, 4.3 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
EC5A5401
Rear master cylinder
1. Install:
9Copper washer 1
9Brake hose 2
9Union bolt 3
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion
a adirects as shown and lightly touch-
es the projection
b bon the master cylinder.
30 Nm (3.0 m•kg, 22 ft•lb)
2. Install:
9Master cylinder 1
9Bolt (master cylinder) 2
10 Nm (1.0 m•kg, 7.2 ft•lb)
5XF-9-30-5A 4/21/03 9:58 PM Page 42

5-23
CHASFRONT BRAKE AND REAR BRAKE
3. Pass the brake hose through the cable
guide 1, then through the guide aon the
protector 2.
4. Install:
9Copper washer 1
9Brake hose 2
9Union bolt 3
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion a a
directs as shown and lightly touch-
es the projection b b
on the master cylinder.
30 Nm (3.0 m•kg, 22 ft•lb)
EC5A5502
Rear brake hose
1. Install:
9Copper washer 1
9Brake hose 2
9Union bolt 3
w
Always use new copper washers.
cC
Install the brake hose so that its pipe por-
tion a a
directs as shown and lightly touch-
es the projection b b
on the caliper.
30 Nm (3.0 m•kg, 22 ft•lb)
5XF-9-30-5A 4/21/03 9:58 PM Page 46

7-10
SETTINGTUN
EC71D021
Examples of carburetor setting depending on symptom
Symptom Setting Checking
At full throttle Increase main jet calibration No. Discoloration of spark plug 
Hard breathing (Gradually) If tan color, it is in good condition.
Shearing noise If can not be normalized:
Whitish spark plug Clogged float valve seat
Clogged fuel hose
Lean mixture Clogged fuel cock
At full-throttle Decrease main jet calibration No. Discoloration of spark plug 
Stop of speed pick-up (Gradually) If tan color, it is in good condition.
Slow speed pick-up *In case of racing slight enrichment If not effect:
Slow response of mixture reduces engine trouble. Clogged air cleaner
Sooty spark plug Fuel overflow from carburetor
Rich mixture
Lean mixture Lower jet needle clip position.
(1 groove down)
Rich mixture Raise jet needle clip position.
(1 groove up)
1/4~3/4 throttle Lower jet needle clip position.
Hard breathing (1 groove down)
Lack of speed
1/4~1/2 throttle Raise jet needle clip position. Clip position indicates the position of
Slow speed pick-up (1 groove up) jet needle groove, to which the clip is
White smoke fitted. The position is numbered from
Poor acceleration the top.
Leaner
(Standard)
Richer


EC71C030
Road condition and examples of carburetor setting
Conditions General condition Sandy condition
Under 10°C 10~25°C Over 25°C Under 10°C 10~25°C Over 25°C
(50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F)
Parts (Winter)(Spring, Autumn)(Summer) (Winter)(Spring, Autumn)(Summer)
Main jet#178
#178 #178#180 #178
#178
*#180 *#182 *#180
Jet needle N3EW-3N3EJ-2 N3CJ-2 N3CW-3 N3CW-3 N3CW-3
*N3CW-3 *N3EW-2 *N3CW-4 *N3EW-3 *N3EW-3
Pilot jet #50 #50 #50 #52 #52 #52
Pilot air screw-1/4 Zero ZeroZero
Zero +1/4*-1/4
Power jet #50 #50 #50 #50 #50 #50
*For EUROPE
NOTE:
Optimum pilot air screw setting can be abtained by adding the ex-factory number of the same screw
back-out turns to any required value provided in the chart.
For example, if the ex-factory number is “1”, add “1” to the value chosen in the chart.
5XF-9-30-7 4/22/03 8:56 AM Page 20

7-12
SETTINGTUN
EC71M010
Change of the heat range of spark plugs
Judging from the discoloration of spark plugs, if
they are found improper, it can be corrected by
the following two methods; changing carburetor
settings and changing the heat range of spark
plug.
9In principle, it is advisable to first use spark
plugs of standard heat range, and judging from
the discoloration of spark plugs, adjust carbure-
tor settings.
9If the calibration No. of the main jet must be
changed by ±15, it is advisable to change the
heat range of spark plugs and newly select the
proper main jet.
NOTE:
9When checking the discoloration of spark
plugs, be sure to stop the engine immediately
after a run and check.
9Avoid racing.
9When changing the heat range of spark plugs,
never attempt to change it more than ±1 rank.
9When using a spark plug other than standard,
check its heat range against the standard and
check that it is a resistance type.
9Note that even if the discoloration seems prop-
er, it may slightly vary with the spark plug
maker and oil in use.
Standard spark plugBR8EG/NGK(resistance type)
5XF-9-30-7 4/22/03 8:56 AM Page 28