wheel YAMAHA YZ250LC 2007 Betriebsanleitungen (in German)

CHAPTER 4
ENGINE
SEAT, FUEL TANK AND SIDE
COVERS.....................................................4-1
EXHAUST PIPE AND SILENCER..............4-3
RADIATOR..................................................4-4
CARBURETOR AND REED VALVE...........4-7
CYLINDER HEAD , CYLINDER AND
PISTON.....................................................4-18
CLUTCH AND PRIMARY DRIVEN
GEAR.......................................................4-33
KICK AXLE, SHIFT SHAFT AND
PRIMARY DRIVE GEAR...........................4-40
YPVS GOVERNOR...................................4-49
WATER PUMP..........................................4-52
CDI MAGNETO.........................................4-56
ENGINE REMOVAL..................................4-60
CRANKCASE AND CRANKSHAFT.........4-65
TRANSMISSION, SHIFT CAM AND
SHIFT FORK.............................................4-72
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL........5-1
FRONT BRAKE AND REAR BRAKE.......5-10
FRONT FORK...........................................5-26
HANDLEBAR............................................5-42
STEERING................................................5-50
SWINGARM..............................................5-55
REAR SHOCK ABSORBER.....................5-63
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1-7
SPECIAL TOOLS
GEN
INFO
EC140002
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and part number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.
NOTE:
9For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC -”.
9For others, use part number starting with “90890-”.
Part number Tool name / How to use IIIustration
YU-1135-A, 90890-01135Crankcase separating toolYU-1135-A 90890-01135
This tool is used to split the crankcase as well
as remove the crankshaft from either case.
YM-1189, 90890-01189 Flywheel puller
YM-1189 90890-01189
This tool is used to remove the flywheel magneto.
YU-1235, 90890-01235 Rotor holding tool
YU-1235 90890-01235
This tool is used when loosening or tightening the
flywheel magneto securing nut.
YU-3097, 90890-01252 Dial gauge and stand
YU-3097 90890-01252
YU-1256 Spark plug hole dial standYU-1256
These tools are used to set the ignition timing.
Crankcase installing tool
YU-90050 90890-01274
YU-90050, 90890-01274 PotYU-90063 90890-01275
YU-90050, 90890-01275 Bolt
90890-01278
YU-90063, 90890-01278 Adapter
These tools are used to install the crankshaft.
YU-1304, 90890-01304 Piston pin puller
YU-1304 90890-01304
This tool is used to remove the piston pin.
YU-24460-01,90890-01325Radiator cap testerYU-24460-01 90890-01325
YU-33984, 90890-01352 AdapterYU-33984 90890-01352
These tools are used for checking the cooling
system.
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1-16
TORQUE-CHECK POINTS
GEN
INFO
EC1A0013
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering shaft to Steering shaft to frame
handlebar Steering shaft to handle crown
Handle crown to handlebar
Suspension Front Steering shaft to Front fork to handle crown
front fork Front fork to under bracket
Rear For link type Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Rear Installation of shock Shock absorber to frame
absorber
Rear Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of front axle
Tightening of axle holder
Rear Tightening of rear axle
Wheel to sprocket
Brake Front Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tighening of union bolt
Master cylinder to frame
Tightening of air bleeder
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section in
the CHAPTER 2.
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1-17
CLEANING AND STORAGE
GEN
INFO
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will enhance
its appearance, maintain good overall perfor-
mance, and extend the life of many components.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
cC
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been hosed
off, wash all surfaces with warm water and a
mild detergent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel and
lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery clean-
er to keep the cover pliable and glossy.
8. Automotive wax may be applied to all paint-
ed or chromed surfaces. Avoid combination
cleaner-waxes, as they may contain abra-
sives.
9. After completing the above, start the engine
and allow it to idle for several minutes.
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1-18
CLEANING AND STORAGE
GEN
INFO
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be taken
to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as fol-
lows:
1. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed metal
surfaces with a film of light oil. Do not apply
oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the machine
is stored.
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2-1
GENERAL SPECIFICATIONSSPEC
Model name: YZ250W1 (USA, CDN)
YZ250 (EUROPE, ZA)
YZ250W (AUS, NZ)
Model code number: 1P89 (USA, CDN)
1P8A (EUROPE)
1P8C (AUS, NZ, ZA)
Dimensions:USA, AUS, NZ, ZAEUROPE, CDN
Overall length 2,178 mm 2,184 mm
(85.7 in) (86.0 in)
Overall width 827 mm←
(32.6 in)
Overall height 1,306 mm 1,309 mm
(51.4 in) (51.5 in)
Seat height 994 mm 997 mm
(39.1 in) (39.3 in)
Wheelbase 1,481 mm←
(58.3 in)
Minimum ground clearance 382 mm 385 mm
(15.0 in) (15.2 in)
Dry weight:
Without oil and fuel 96.0 kg (211.6 lb)
Engine:
Engine type Liquid cooled 2-stroke, gasoline
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
3(8.76 lmp oz, 8.42 US oz)
Bore ×Stroke 66.4 ×72 mm (2.614 ×2.835 in)
Compression ratio 9.2~10.9 : 1 (For USA and CDN)
8.9~10.6 : 1 (For EUROPE, AUS, NZ and ZA)
Starting system Kick starter
Lubrication system: Premix (30 : 1)(Yamalube 2-R)
Oil type or grade (2-Cycle):
Transmission oil Yamalube 4 (10W-30) or SAE 10W-30 type SE
motor oil
Periodic oil change 0.75 L (0.66 Imp qt, 0.79 US qt)
Total amount 0.80 L (0.70 Imp qt, 0.85 US qt)
Coolant capacity (including all routes): 1.20 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline
only with a research octane
number of 95 or higher
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
EC200000
SPECIFICATIONSEC211000
GENERAL SPECIFICATIONS
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2-2
GENERAL SPECIFICATIONSSPEC
Carburetor:
Type/Manufacturer PWK38S/KEIHIN
Spark plug:
Type/Manufacturer BR8EG/NGK (resistance type)
Gap 0.5~0.6 mm (0.020~0.024 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 63/21 (3.000)
Secondary reduction system Chain drive
Secondary reduction ratio 50/14 (3.571)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)
2nd 23/15 (1.533)
3rd 23/18 (1.278)
4th 24/22 (1.091)
5th 20/21 (0.952)
Chassis: USA, ZA, AUS, NZ EUROPE, CDN
Frame type Semi double cradle←
Caster angle 26.9° 27.1°
Trail 115 mm (4.53 in) 118 mm (4.65 in)
T ire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 110/90-19 62M
T ire pressure (front and rear) 100 kPa (1.0 kgf/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/Gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
2
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2-6
MAINTENANCE SPECIFICATIONSSPEC
Part to be tightened Thread size Q’tyT ightening torqueNm m•kg ft•lb
Neutral switch lead holder (Except for USA and CDN)M 6 ×1.0 1 14 1.4 10
Kick starter M 8 ×1.25 1 30 3.0 22
Ratchet wheel stopper M 6 ×1.0 2 10 1.0 7.2
Clutch cover M 6 ×1.0 6 10 1.0 7.2
Primary drive gear M10 ×1.25 1 55 5.5 40
Clutch boss M20 ×1.0 1 75 7.5 54
Clutch spring M 6 ×1.0 6 10 1.0 7.2
Clutch cable adjust bolt and locknut M 6 ×0.75 1 4 0.4 2.9
Push lever axle M 5 ×0.8 1 6 0.6 4.3
Drive sprocket M20 ×1.0 1 75 7.5 54
Shift guide M 6 ×1.0 2 10 1.0 7.2
Stopper lever M 6 ×1.0 1 10 1.0 7.2
Torsion spring (shift shaft) stopper bolt M 8 ×1.25 1 22 2.2 16
Segment M 8 ×1.25 1 30 3.0 22
Bearing plate cover (shift cam right) M 6 ×1.0 2 10 1.0 7.2
Shift pedal M 6 ×1.0 1 10 1.0 7.2
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
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2-8
MAINTENANCE SPECIFICATIONSSPEC
Item Standard Limit
Wheel:
Front wheel type Spoke wheel…
Rear wheel type Spoke wheel…
Front rim size/Material 21 ×1.60/Aluminum…
Rear rim size/Material 19 ×2.15/Aluminum…
Rim runout limit:
Radial…
2.0 mm (0.08 in)
Lateral…
2.0 mm (0.08 in)
Drive chain
Type/Manufacturer DID520DMA2 SDH/DAIDO…
Number of links 113 links + joint…
Chain slack 48~58 mm (1.9~2.3 in)…
Chain length (15 links)…
242.9 mm (9.563 in)
Front disc brake:
Disc outside dia. ×Thickness 250 ×3.0 mm 250 ×2.5 mm
(9.84 ×0.12 in) (9.84 ×0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in)…
Caliper cylinder inside dia. 27.0 mm (1.063 in) ×2…
Brake fluid type DOT #4…
Rear disc brake:
Disc outside dia. ×Thickness 245 ×4.0 mm 245 ×3.5 mm
(9.65 ×0.16 in) (9.65 ×0.14 in)
Deflection limit…
0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in)…
Caliper cylinder insdie dia. 25.4 mm (1.000 in)…
Brake fluid type DOT #4…
Brake lever & brake pedal:
Brake lever position 95 mm (3.74 in)…
Brake pedal height Zero mm (Zero in)…
(vertical height above footrest top)
Clutch lever free play (lever end) 8~13 mm (0.31~0.51 in)…
Throttle grip free play 3~5 mm (0.12~0.20 in)…
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2-9
MAINTENANCE SPECIFICATIONSSPEC
15
15
105
20
29
22
40
21
21
0.7
5.1
5.1
0.7
2.9
2.9
2.9
6.5
1.4
4.3
4.3
3.6
2.9
22
22
17
7.2
2.2
13
4.3
75
15
8.7
10
40
19
7.2M 8 × 1.25
M 8 × 1.25
M24 × 1.0
M 8 × 1.25
M12 × 1.25
M28 × 1.0
M51 × 1.5
M22 × 1.25
M42 × 1.5
M12 × 1.25
M 5 × 0.8
M 6 × 1.0
M 6 × 1.0
M 4 × 0.7
M 6 × 1.0
M 6 × 1.0
M 5 × 0.8
M 6 × 1.0
M 4 × 0.7
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M10 × 1.25
M10 × 1.25
M 8 × 1.25
M 6 × 1.0
M10 × 1.0
M10 × 1.0
M 8 × 1.25
M16 × 1.5
M 8 × 1.25
M 6 × 1.0
M 6 × 1.0
M10 × 1.25
M 8 × 1.25
M 6 × 1.0 Handle crown and outer tube
Under bracket and outer tube
Handle crown and steering shaft
Handlebar holder (upper)
Handlebar holder (lower)
Steering ring nut
Front fork and damper assembly
Front fork and adjuster
Damper assembly and base valve
Adjuster and damper assembly
Bleed screw (front fork) and base valve
Front fork and protector
Protector and brake hose holder
Throttle cable cap
Grip cap upper and lower
Clutch lever (nut)
Clutch lever holder
Front brake master cylinder and bracket
Front brake master cylinder cap
Brake lever mounting (bolt)
Brake lever mounting (nut)
Brake lever position locknut
Cable guide (front brake hose) and under bracket
Front brake hose union bolt (master cylinder)
Front brake hose union bolt (caliper)
Front brake caliper and front fork
Front brake caliper and brake hose holder
Brake caliper (front and rear) and pad pin plug
Brake caliper (front and rear) and pad pin
Brake caliper (front and rear) and bleed screw
Front wheel axle and nut
Front wheel axle holder
Front brake disc and wheel hub
Rear brake disc and wheel hub
Footrest bracket and frame
Brake pedal mounting
Rear brake master cylinder and framePart to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
4
4
1
4
2
1
2
2
2
2
2
6
2
2
2
1
2
2
2
1
1
1
1
1
1
2
1
2
2
2
1
4
6
6
4
1
221
21
145
28
40
30
55
29
29
1
7
7
1
4
4
4
9
2
6
6
5
4
30
30
23
10
3
18
6
105
21
12
14
55
26
102.1
2.1
14.5
2.8
4.0
3.0
5.5
2.9
2.9
0.1
0.7
0.7
0.1
0.4
0.4
0.4
0.9
0.2
0.6
0.6
0.5
0.4
3.0
3.0
2.3
1.0
0.3
1.8
0.6
10.5
2.1
1.2
1.4
5.5
2.6
1.0
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the ring nut wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
Refer to NOTE.
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