radiator cap YAMAHA WR 250F 2002 User Guide

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
●
Inspect wear
ROTOR NUT
Retighten
●

●

EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace
●

●

●

●
* Whichever comes first
*SPARK ARRESTER
Clean
(Every six
months)
●
CRANK
Inspect and clean
●

●

CARBURETOR
Inspect, adjust and clean
●

●
When using a high-pres-
sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace
●

●

●

DRIVE CHAIN
Lubricate, slack, alignment
Replace
●

●

●
Use chain lube
Chain slack: 40 ~ 50 mm
(1.6 ~ 2.0 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
●

●

●

●

●
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
●

●
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
●

●

●
Use foam air-filter 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 fluid
●

●

●

●

●

●

●

●

●

●

●

●
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
●

●

●

●

●
Suspension oil “01” ItemAfter
break-inEvery
race
Every
third race
or
500 km
(300 mi)Every
fifth race
or
1,000 km
(600 mi)
As re-
quiredRemarks


3

INSP
ADJ
INTERVALLI DI MANUTENZIONE
FORCELLA DEL CAMBIO, CAMMA
DEL CAMBIO, BARRA GUIDA
Ispezionare
● Controllare il grado di usura
DADO DEL ROTORE
Serrare
● ●
TUBO DI SCAPPAMENTO, SILENZIA-
TORE, PROTETTORE
Ispezionare e serrare
Pulire
Sostituire
● ●
●
● * A seconda di quale delle
due condizioni si verifica
per prima
*PARASCINTILLE
Pulire(ogni sei
mesi)●
PEDIVELLA
Ispezionare e pulire
● ●
CARBURATORE
Ispezionare, regolare e pulire
● ●
Quando si impiega un disposi-
tivo di lavaggio ad alta pres-
sione, accertarsi che l’acqua
non penetri nella pompa di cir-
colazione.
Candela
Ispezionare e pulire
Sostituire
● ●
●
CATENA DI TRASMISSIONE
Lubrificare, tendere, allineare
Sostituire
● ●
● Utilizzare un lubrificante per
catene
Allentamento della catena:
40 ~ 50 mm (1,6 ~ 2,0 in)
SISTEMA DI RAFFREDDAMENTO
Controllare il livello del refrigerante e la
presenza di eventuali perdite
Controllare l’azionamento del tappo del
radiatore
Sostituire il refrigerante
Ispezionare i flessibili
● ●
●
●
● Ogni due anni
DADI E BULLONI ESTERNI
Serrare
● ● Fare riferimento al paragrafo
“AVVIO E RODAGGIO” al
CAPITOLO 1.
FILTRO DELL’ARIA
Pulire e lubrificare
Sostituire
● ●
● Utilizzare olio per filtro
dell’aria in schiuma
TELAIO
Pulire e ispezionare
● ●
SERBATOIO DEL CARBURANTE,
RUBINETTO
Pulire e ispezionare
● ● ElementoDopo il
rodag-
gioAd ogni
gara
Ogni terza
oppure
500 km
(300 mi)Ogni
quinta
oppure
1.000 km
(600 mi)Come
richie-
stoOsservazioni
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 that the coolant level is correct in the coolant reservoir.
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.1-14
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
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.3-26 ~ 32
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-33 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 45
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
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.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
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 ~ 23

3 - 5
INSP
ADJ
EC350000
ENGINE
EC351011
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. Inspect:
Coolant level
Coolant level should be between the
maximum a and minimum b marks.
Coolant level is below the “LOW” level
line → Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for
several minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant settles.
LOWFULLCOOLANT
a
b
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT

3 - 6
INSP
ADJ
COOLANT REPLACEMENT
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:
Seat
Left side cover
Refer to ”SEAT FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
3. Disconnect:
Coolant reservoir hose 1
Drain the coolant completely.
4. Connect:
Coolant reservoir hoseLOWFULLCOOLANT1
5. Remove:
Coolant drain bolt 1
6. Remove:
Radiator cap
Drain the coolant completely.
7. Clean:
Cooling system
Thoroughly flush the cooling system
with clean tap water.
8. Install:
Copper washer
Coolant drain bolt
9. 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:
1.3 L (1.14 Imp qt, 1.37 US qt)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

INSP
ADJ
CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT
KÜHLFLÜSSIGKEIT WECHSELN
SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO
ACHTUNG:
Darauf achten, daß keine Kühlflüs-
sigkeit auf lackierte Flächen ge-
langt. Sollte dies dennoch gesche-
hen, sofort mit Wasser
abwaschen.
1. Einen Auffangbehälter unter
den Motor stellen.
2. Demontieren:
Sitzbank
Seitenabdeckung(links)
Siehe Abschnitt “SITZ-
BANK, KRAFTSTOFF-
TANK UND
SEITENABDEKKUNGEN”
in KAPITEL 4.
3. Lösen:
Schlauch des Kühlflüssig-
keitsbehälters 1
Kühlflüssigkeitsbehälter
ablassen.
4. Anschließen:
Kühlflüssigkeitsbehälters-
Schlauch
5. Demontieren:
Kühlflüssigkeits-Ablaß-
schraube 1
6. Demontieren:
Kühlerverschlußdeckel
Das Kühlflüssigkeit vollstän-
dig ablassen.
7. Reinigen:
Kühlsystem
Die Kühlsystem gründlich
mit Leitungswasser spülen.
8. Montieren:
Kupferscheibe
Kühlflüssigkeits-Ablaß-
schraube
9. Befüllen:
Kühler
Motor
(bis zum vorgeschriebenen
Stand)
Empfohlenes Frost-
schutzmittel
Hochwertiges Frost-
schutzmittel auf Äthy-
lenglykolbasis mit
Korrosionsschutz-
Additiv für Alumi-
niummotoren
Mischungsverhältnis
Frostschutzmittel 1 :
Wasser 2
50%/50%
Kühlsystem-Fassungs-
vermögen
1,3 L
T R..10 Nm (1,0 m · kg)
ATTENTION:
Prendre garde à ne pas verser de
liquide de refroidissement sur les sur-
faces peintes. Si cela devait se pro-
duire, nettoyer à l’eau.
1. Mettre un récipient sous le
moteur.
2. Déposer:
Selle
Cache latéral gauche
Vous référer à la section
“SELLE, RESERVOIR A
ESSENCE ET CACHES
LATERAUX” du CHAPITRE
4.
3. Déconnecter:
Flexible 1 du réservoir de
liquide de refroidissement
Vidanger complètement le
liquide de refroidissement.
4. Connecter:
Flexible du réservoir de liquide
de refroidissement
5. Déposer:
Boulon de vidange de refroi-
dissement 1
6. Déposer:
Bouchon du radiateur
Vidanger complètement le
liquide de refroidissement.
7. Nettoyer:
Circuit de refroidissement
Bien rincer le circuit de refroi-
dissement avec de l’eau du
robinet.
8. Monter:
Rondelle en cuivre
Boulon de vidange de refroi-
dissement
9. Remplir:
Radiateur
Moteur
Au niveau spécifié.
Liquide de refroidisse-
ment recommandé:
Antigel à l’éthylène gly-
col de haute qualité con-
tenant un agent
anticorrosion pour
moteurs en aluminium
Taux du mélange liquide
de refroidissement 1/eau
(eau douce) 2:
50 %/50 %
Capacité de refroidisse-
ment:
1,3 L
(1,14 Imp qt, 1,37 US qt)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
3 - 6
ATTENZIONE:
Fare attenzione a non far cadere refri-
gerante sulle superfici verniciate.
Eventualmente, lavarlo via con acqua.
1. Posizionare un contenitore sotto
al motore.
2. Rimuovere:
Sella
Carenatura lato sinistro
Fare riferimento al paragrafo
“SELLA, SERBATOIO DEL
CARBURANTE E CARENA-
TURE LATERALI” al CAPI-
TOLO 4.
3. Scollegare:
Tubo flessibile del serbatoio del
liquido di raffreddamento 1
Scaricare completamente il
liquido di raffreddamento.
4. Collegare:
Tubo flessibile del serbatoio
del liquido di raffreddamento
5. Rimuovere:
Bullone di scarico del liquido
di raffreddamento 1
6. Rimuovere:
Tappo del radiatore
Scaricare completamente il
liquido di raffreddamento.
7. Pulire:
Sistema di raffreddamento
Lavare accuratamente il
sistema di raffreddamento con
acqua corrente pulita.
8. Installare:
Rondella di rame
Bullone di scarico del liquido
di raffreddamento
9. Riempire:
Radiatore
Motore
Fino al livello specificato.
Refrigerante consigliato:
Antigelo glicole etile-
nico di elevata qualità
contenente un agente
anticorrosivo per motori
in alluminio
Rapporto di miscelazione
refrigerante 1 e acqua
(acqua dolce) 2:
50 %/50 %
Capacità refrigerante:
1,3 L
(1,14 Imp qt, 1,37 US qt)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)

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.
10. Install:
Radiator cap
11. Fill:
Coolant reservoir
Midway a between maximum and min-
imum marks on the tank.
12. Install:
Coolant reservoir cap
13. Start the engine and let it warm up for
several minutes.
14. Turn off the engine and inspect the cool-
ant level.
Refer to “COOLANT LEVEL INSPEC-
TION” section.
NOTE:
Before checking the coolant level wait a few
minutes until the coolant settles.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.
LOWFULLCOOLANTa
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.

3 - 8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
Radiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Replace.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
110 kPa (1.1 kg/cm2, 15.6 psi)
COOLING SYSTEM INSPECTION
1. Inspect:
Coolant level
2. Attach:
Radiator cap tester 1 and adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)

INSP
ADJ
CONTROLE ET REGLAGE DU JEU DE SOUPAPES
VENTILSPIEL KONTROLLIEREN UND EINSTELLEN
CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE
3. Demontieren:
Rechter Kühler
Siehe Abschnitt “KÜHLER”
in KAPITEL 4.
Vergaser
Siehe Abschnitt “VERGA-
SER” in KAPITEL 4.
Zündkerze
Oberer Motorbügel
Zylinderkopfdeckel
Siehe Abschnitt “NOCKEN-
WELLEN” in KAPITEL 4.
4. Demontieren:
Steuermarkierung-Zugangs-
schraube 1
Kurbelwellenende-Zugangs-
schraube 2
O-Ring
5. Kontrollieren:
Ventilspiel
Unvorschriftsmäßig → Ein-
stellen.
Ventilspiel (kalt)
Einlaßventil
0,10–0,15 mm
Auslaßventil
0,17–0,22 mm
3. Déposer:
Radiateur de droite
Se reporter à la section
“RADIATEUR” au CHAPI-
TRE 4.
Carburateur
Se reporter à la section “CAR-
BURATEUR” au CHAPITRE
4.
Bougie
Support supérieur de moteur
Couvre-culasse
Se reporter à la section
“ARBRES A CAMES” au
CHAPITRE 4.
4. Déposer:
Vis d’accès du repère de distri-
bution 1
Vis d’accès de l’extrémité de
vilebrequin 2
Joint torique
5. Contrôler:
Jeu de soupapes
Hors spécifications → Régler.
Jeu de soupapes (à froid):
Soupape d’admission:
0,10 à 0,15 mm
(0,0039 à 0,0059 in)
Soupape d’échappement:
0,17 à 0,22 mm
(0,0067 à 0,0087 in)
3. Rimuovere:
Radiatore destro
Fare riferimento al paragrafo
“RADIATORE” nel CAPI-
TOLO 4.
Carburatore
Fare riferimento al paragrafo
“CARBURATORE” nel
CAPITOLO 4.
Candela d’accensione
Staffa motore superiore
Coperchio testata del cilindro
Fare riferimento al paragrafo
“ALBERI A CAMME” nel
CAPITOLO 4.
4. Rimuovere:
Vite di accesso al riferimento
per fasatura 1
Vite di accesso estremità
albero motore 2
O-ring
5. Controllare:
Gioco valvole
Fuori specifica → Regolare.
Gioco valvole (a freddo):
Valvola di aspirazione:
0,10 ~ 0,15 mm
(0,0039 ~ 0,0059 in)
Valvola di scarico:
0,17 ~ 0,22 mm
(0,0067 ~ 0,0087 in)
3 - 20

4 - 4
ENG
RADIATEUR
KÜHLER
RADIATORE
KÜHLER
Demontage-Arbeiten:1 Kühler demontieren
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
KÜHLER DEMONTIEREN
Vorbereitung für den Ausbau Kühlflüssigkeit ablassen. Siehe unter “KÜHLFLÜSSIGKEIT WECHSELN” im
KAPITEL 3.
Sitz, Kraftstofftank und linke Seitenabdek-
kungSiehe unter “SITZBANK, KRAFTSTOFFTANK UND
SEITENABDECKUNGEN”.
1Kühlerschutz 2
2Kühlerschlauchschelle 8 Nur lockern.
3Kühlerschlauch 1 1
4 Linker Kühler 1
5Kühlerschlauch 3 1
6Kühlmittelausgleichsbehälter-Schlauch 1
7 Rechter Kühler 1
8Kühlerschlauch 2 1
9Kühlerschlauch 4 1
10 Kühlerleitung 1
11 Kühlmittelausgleichsbehälter-Lüftungs-
schlauch1
12 Kühlmittelausgleichsbehälter 1
1
RADIATEUR
Organisation de la dépose:1 Dépose du radiateur
Organisation de la dépose Ordre Nom de pièce QtéRemarques
DEPOSE DU RADIATEUR
Préparation à la dépose Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU LIQUIDE
DE REFROIDISSEMENT” du CHAPITRE 3.
Selle, réservoir de carburant et cache latéral
gaucheSe reporter à la section “SELLE, RESERVOIR A
ESSENCE ET CACHES LATERAUX”.
1 Protection de radiateur 2
2 Bride de durit de radiateur 8 Desserrer uniquement.
3 Durit de radiateur 1 1
4 Radiateur gauche 1
5 Durit de radiateur 3 1
6 Durit de vase d’expansion 1
7 Radiateur droit 1
8 Durit de radiateur 2 1
9 Durit de radiateur 4 1
10 Tuyau de radiateur 1
11 Durit de mise à l’air de vase d’expansion 1
12Vase d’expansion
1
1
RADIATORE
Portata dello smontaggio:1 Rimozione radiatore
Portata dello smontaggio Ordine Denominazione QuantitàOsservazioni
RIMOZIONE DEL RADIATORE
Preparazione per lo smontaggio Scaricare il refrigerante. Fare riferimento al paragrafo “SOSTITUZIONE REFRI-
GERANTE” nel CAPITOLO 3.
Sella, serbatoio del carburante e
carenatura laterale sinistraFare riferimento al paragrafo “SELLA, SERBATOIO
DEL CARBURANTE E CARENATURA LATERALE”.
1 Riparo del radiatore 2
2 Morsetti del tubo flessibile radiatore 8 Allentare soltanto.
3 Flessibile radiatore 1 1
4 Radiatore sinistro 1
5 Flessibile radiatore 3 1
6 Tubo flessibile del serbatoio del liquido di raf-
freddamento1
7 Radiatore destro 1
8 Flessibile radiatore 2 1
9 Flessibile radiatore 4 1
10 Tubazione del radiatore 1
11 Tubetto di sfiato del serbatoio del liquido di raf-
freddamento1
12 Serbatoio del liquido di raffreddamento 1
1