radiator cap YAMAHA YZ250F 2001 User Guide

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
frame 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
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.3-25 ~ 31
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-32 ~ 34
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-42 ~ 43
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-43 ~ 44
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-34 ~ 41
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.3-32
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
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 ~ 22

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:
lRadiator cap
3. Check:
lCoolant 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:
lCoolant drain bolt 1
3. Remove:
lRadiator cap
Drain the coolant completely.
4. Clean:
lCooling system
Thoroughly flush the cooling system
with clean tap water.
5. Install:
lCopper washer
lCoolant drain bolt
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. Fill:
lRadiator
lEngine
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:
0.9 L (0.79 Imp qt, 0.95 US qt)

INSP
ADJ
CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT
KÜHLFLÜSSIGKEIT WECHSELN
SOSTITUZIONE REFRIGERANTE
KÜHLFLÜSSIGKEIT WECHSELN
WARNUNG
Den Kühlerverschlußdeckel unter
keinen Umständen bei heißem Mo-
tor abnehmen.
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:
lKühlflüssigkeits-Ablaß-
schraube 1
3. Demontieren:
lKühlerverschlußdeckel
Das Kühlflüssigkeit vollstän-
dig ablassen.
4. Reinigen:
lKühlsystem
Die Kühlsystem gründlich
mit Leitungswasser spülen.
5. Montieren:
lKupferscheibe
lKühlflüssigkeits-Ablaß-
schraube
T R..10 Nm (1,0 m · kg)
6. Befüllen:
lKühler
lMotor
(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
0,9 L
CHANGEMENT DU LIQUIDE DE
REFROIDISSEMENT
AVERTISSEMENT
Ne jamais enlever le bouchon du
radiateur quand le moteur est chaud.
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:
lBoulon de vidange de refroi-
dissement 1
3. Déposer:
lBouchon du radiateur
Vidanger complètement le
liquide de refroidissement.
4. Nettoyer:
lCircuit de refroidissement
Bien rincer le circuit de refroi-
dissement avec de l’eau du
robinet.
5. Monter:
lRondelle en cuivre
lBoulon de vidange de refroi-
dissement
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Remplir:
lRadiateur
lMoteur
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:
0,9 L
(0,79 Imp qt, 0,95 US qt)
3 - 6
SOSTITUZIONE REFRIGERANTE
AVVERTENZA
Non rimuovere il tappo del radiatore a
motore caldo.
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:
lBullone di scarico del refrige-
rante 1
3. Rimuovere:
lTappo del radiatore
Scaricare completamente il
refrigerante.
4. Pulire:
lSistema di raffreddamento
Lavare accuratamente il
sistema di raffreddamento con
acqua corrente pulita.
5. Installare:
lRondella di rame
lBullone di scarico del refrige-
rante
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Riempire:
lRadiatore
lMotore
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:
0,9 L
(0,79 Imp qt, 0,95 US qt)

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
lDo not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
lDo not use water containing impurities or
oil.
7. Install:
lRadiator cap
Start the engine and warm it up for a
several minutes.
8. Check:
lCoolant level
Coolant level low ® Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
lWhen coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
lWhen coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
lWhen coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
lSeal (radiator cap) 1
lValve 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:
lRadiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
lPressure
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:
lCoolant level
2. Attach:
lRadiator 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:
lRechter Kühler
Siehe Abschnitt “KÜHLER”
in KAPITEL 4.
lVergaser
Siehe Abschnitt “VERGA-
SER” in KAPITEL 4.
lZündkerze
lOberer Motorbügel
lZylinderkopfdeckel
Siehe Abschnitt “NOCKEN-
WELLEN” in KAPITEL 4.
4. Demontieren:
lSteuermarkierung-Zugangs-
schraube 1
lKurbelwellenende-Zugangs-
schraube 2
lO-Ring
5. Kontrollieren:
lVentilspiel
Unvorschriftsmäßig ® Ein-
stellen.
Ventilspiel (kalt)
Einlaßventil
0,10–0,15 mm
Auslaßventil
0,17–0,22 mm
3. Déposer:
lRadiateur de droite
Se reporter à la section
“RADIATEUR” au CHAPI-
TRE 4.
lCarburateur
Se reporter à la section “CAR-
BURATEUR” au CHAPITRE
4.
lBougie
lSupport supérieur de moteur
lCouvre-culasse
Se reporter à la section
“ARBRES A CAMES” au
CHAPITRE 4.
4. Déposer:
lVis d’accès du repère de distri-
bution 1
lVis d’accès de l’extrémité de
vilebrequin 2
lJoint torique
5. Contrôler:
lJeu 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:
lRadiatore destro
Fare riferimento al paragrafo
“RADIATORE” nel CAPI-
TOLO 4.
lCarburatore
Fare riferimento al paragrafo
“CARBURATORE” nel
CAPITOLO 4.
lCandela d’accensione
lStaffa motore superiore
lCoperchio testata del cilindro
Fare riferimento al paragrafo
“ALBERI A CAMME” nel
CAPITOLO 4.
4. Rimuovere:
lVite di accesso al riferimento
per fasatura 1
lVite di accesso estremità
albero motore 2
lO-ring
5. Controllare:
lGioco 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 Kühlflüsssigkeit ablassen. Siehe unter “KÜHLFLÜSSIGKEIT WECHSELN” im
KAPITEL 3.
Sitzbank und Kraftstofftank Siehe unter “SITZBANK, KRAFTSTOFFTANK UND
SEITENABDECKUNGEN”.
1 Kühlerschutz 2
2 Kühlerschlauchschelle 8 Nur lockern.
3 Kühlerschlauch 1 1
4 Linker Kühler 1
5 Kühlerschlauch 3 1
6 Rechter Kühler 1
7 Kühlerschlauch 2 1
8 Kühlerschlauch 4 1
9 Kühlerlüftungsschlauch 1
10Kühlerleitung
1
1
RADIATEUR
Organisation de la dépose:1 Dépose du radiateur
Organisation de la dépose Ordre Nom de pièce Qté Remarques
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 et réservoir de carburant Se 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 Radiateur droit 1
7 Durit de radiateur 2 1
8 Durit de radiateur 4 1
9 Durit de mise à l’air de radiateur 1
10Tuyau de radiateur
1
1
RADIATORE
Portata dello smontaggio:1 Rimozione radiatore
Portata dello smontaggio Ordine Denominazione Quantità Osservazioni
RIMOZIONE DEL RADIATORE
Preparazione per lo smontaggio Scaricare il refrigerante. Fare riferimento al paragrafo “SOSTITUZIONE REFRI-
GERANTE” nel CAPITOLO 3.
Sella e serbatoio del carburante Fare 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 Radiatore destro 1
7 Flessibile radiatore 2 1
8 Flessibile radiatore 4 1
9 Sfiatatoio radiatore 1
10 Tubazione del radiatore 1
1

4 - 5
ENG

RADIATOR
EC456000
HANDLING NOTE
WARNING

Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
EC444100
Radiator
1. Inspect:
l
Radiator core
1

Obstruction
®
Blow out with com-
pressed air through rear of the radiator.
Bent fin
®
Repair/replace.
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:
l
O-ring
1
l
Radiator pipe
2

l
Bolt (radiator pipe)
3

NOTE:

Apply the lithium soap base grease on the O-
ring.
2. Install:
l
Radiator breather hose
1
lRadiator hose 4 (longer) 2
lRadiator hose 2 (shorter) 3
To left radiator 4.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

ENG
4 - 6
RADIATEUR
KÜHLER
RADIATORE
3. Montieren:
lRechter Kühler 1
lSchraube (rechter Kühler)
2
lKühlerschlauch 3 3
Siehe Abschnitt “SEILZUG-
FÜHRUNGSDIAGRAMM” in
KAPITEL 2.
T R..10 Nm (1,0 m · kg)
4. Montieren:
lLinker Kühler 1
lSchraube (linker Kühler) 2
lKühlerschlauch 1 3
Siehe Abschnitt “SEILZUG-
FÜHRUNGSDIAGRAMM” in
KAPITEL 2.
5. Festziehen:
lKühlerschlauchschelle 4
6. Montieren:
lKühlerschutz 1
lSchraube (Kühlerschutz) 2
HINWEIS:
Den Haken a an der Innenseite zu-
erst am Kühler einhaken.
T R..10 Nm (1,0 m · kg)
T R..2 Nm (0,2 m · kg)
T R..2 Nm (0,2 m · kg)
T R..10 Nm (1,0 m · kg)
3. Monter:
lRadiateur de droite 1
lBoulon (radiateur droite) 2
lDurit de radiateur 3 3
Se reporter à “CHEMINE-
MENT DES CÂBLES” au
CHAPITRE 2.
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
4. Monter:
lRadiateur gauche 1
lBoulon (radiateur gauche) 2
lDurit de radiateur 1 3
Se reporter à “CHEMINE-
MENT DES CÂBLES” au
CHAPITRE 2.
5. Serrer:
lBride de durit de radiateur 4
6. Monter:
lProtection de radiateur 1
lBoulon (protection de radia-
teur) 2
N.B.:
Accrocher le panneau d’abord à l’inté-
rieur a puis à l’extérieur.
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
3. Installare:
lRadiatore destro 1
lBullone (radiatore destro) 2
lFlessibile radiatore 3 3
Fare riferimento al paragrafo
“SCHEMA DEL PERCORSO
DEI CAVI” nel CAPITOLO 2.
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
4. Installare:
lRadiatore sinistro 1
lBullone (radiatore sinistro) 2
lFlessibile radiatore 1 3
Fare riferimento al paragrafo
“SCHEMA DEL PERCORSO
DEI CAVI” nel CAPITOLO 2.
5. Serrare:
lMorsetto del tubo flessibile
radiatore 4
6. Installare:
lDispositivo di protezione del
radiatore 1
lBullone (dispositivo di prote-
zione del radiatore) 2
NOTA:
Inserire il gancio a prima nel lato
interno del radiatore.
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)