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Yamaha YZ250 2001, Repair Manual, Page: 5 / 39

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Yamaha YZ250 2001 Repair Manual Download Page 5

Table of Contents 

 

v 

Tools Needed ........................................................................................... 29

 

How to Test PSI ....................................................................................... 30

 

Works Cited .................................................................................................. 31

 

Index ............................................................................................................ 31

 

 

 

 

Summary of Contents for YZ250 2001

Page 1: ...Yamaha YZ250 Front Tire Repair ...

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Page 3: ...equired 7 Chapter 1 3 1 1 Clean Your Motorcycle 3 Rinse Wash and Dry 3 1 2 Clean Workspace 4 Clear Debris 4 1 3 Prop Motorcycle on Stand 5 Different Stands Available 5 Removal of Front Wheel 7 Chapter 2 9 2 1 Loosen Fork Bolts 9 Tools Needed 9 Procedures 9 2 2 Remove Axel and Wheel from Forks 10 Tools Needed 10 Remove Axel Lug Nut 10 2 3 Remove Wheel from Forks 11 Remove Axle and Spacers 11 Remove...

Page 4: ...Reassembly 17 Chapter 3 19 3 1 Replace Inner Tube into Tire 19 3 2 Replace Tire onto Rim 19 Tools and Supplies Needed 19 Procedures 20 3 3 Replace Wheel between Forks 21 Tools Needed 21 Procedures 22 3 4 Tighten Fork Bolts 22 Tools Needed 22 Procedures 23 Testing Repair 25 Chapter 4 27 4 1 Spin Test 27 How to Perform the Spin Test 27 4 2 Break Test 28 How to Perform the Break Test 28 4 3 Standing ...

Page 5: ...Table of Contents v Tools Needed 29 How to Test PSI 30 Works Cited 31 Index 31 ...

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Page 7: ...al experience It is not suggested to attempt to replace or repair any parts without proper experience The Yamaha 2001 YZ250 has a very specific front end designed to be solid and dependable yet relatively easy to replace or repair With the proper tools this manual will guide you through the step by step processes necessary to maintaining your front end Please be careful to follow each step thoroug...

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Page 9: ...Preparing Motorcycle for Repair 1 1 Clean Motorcycle 1 2 Clean Work Space 1 3 Prop Motorcycle on Stand 1 4 Tools Required ...

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Page 11: ...jor damages Rinse Wash and Dry First start by rinsing all loose particles off of you motorcycle making sure to wet the entire bike Next apply soap to a wet rag or sponge and begin to thoroughly scrub off all remaining dirt and grime After all the dirt has been removed proceed to rinsing any remaining particles off with water Finally dry your motorcycle with a towel ensuring not to leave any parts ...

Page 12: ...a necessary step prior to working on your motorcycle to help prevent you from losing any parts As displayed in the photo to the right you should have a work space free of any debris Also be sure to have plenty of room to move around the bike This is crucial in order to Maintain leverage when removing bolts Step back incase bike falls Have room to place parts you have removed ...

Page 13: ...rcycle on Stand To remove the front tire from your motorcycle you must first place the dirt bike onto its stand Different Stands Available There are many different stands available Classic floor stand Foot Jack Motorcycle Jack ...

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Page 15: ...Removal of Front Wheel ...

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Page 17: ...u must loosen the bolts squeezing the forks front suspension to the bolts Tools Needed Socket set Procedures First locate the 8mm socket and attach it to the wrench Find the two bolts located at the bottom of each fork Ensure your ratchet is set to loosen and twist the bolts off to the left ...

Page 18: ... from falling Tools Needed Tire Iron o Remove Axel Lug Nut Start by locating the end of the tire iron that is 22mm in diameter Next loosen the lug nut until it is almost off but still attached to the axel Now use your hammer to tap on the lug nut until the axel is pushed most of the way through Remove the lug nut Finally grab the axel from the opposite end of lug nut side and pull while securing t...

Page 19: ...m Caliper Pull front wheel directly forward to be sure the disc break is not bent or warped To the left is an image of the front caliper Warning The disc fits directly between the two brake pads and must be pulled out straight to prevent any damage Prepare front Wheel Prepare front wheel to remove the tire and inner tube from the rim Deflate inner tube completely by removing the valve stem Do this...

Page 20: ... requires much strength and skill Do not attempt to remove the tire without previous experience or help from a professional Pinching may occur causing harm to you and or your tire Tools and Supplies Needed Tire Irons o Dish Soap o Bowl of Water o Valve Stem Remover o Socket Set o ...

Page 21: ...you Please do not attempt to remove tire from rim without previous experience or under the supervision of a professional Removing Tire from Rim Step1 Start by wedging your tire irons between the tire and the rim Step2 Push down on tire iron as to force the tire up over the rim Step3 Do the same for the tire irons on either side Step4 Repeat until the first edge of your tire is completely off of th...

Page 22: ...ube while rotating the entire tube through the water When you see bubbles you have found the source of the leak If your inner tube is punctured or shows signs of excessive wear replace immediately If the inner tube has a very minor puncture then you may attempt to patch the leak but it is highly recommended that you replace the inner tube Warning Failure to properly patch a puncture could cause a ...

Page 23: ... for any signs of compromise in the rims structural integrity Things to look for Large indents where the rim and tire make contact Deep scratches or server scuffing of rim Rim that is warped cracked or missing spokes such as in the picture to the right ...

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Page 25: ...Front Wheel Reassembly ...

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Page 27: ...ube being pinched and torn Fill your inner tube with a small amount of air just enough to help hold the tube inside the tire Be sure to tuck any excess tubing into the tire to avoid any accidental pinching The inner tube should be tucked within the tire 3 2 Replace Tire onto Rim Be careful to not pinch yourself or your inner tube when replacing your front tire onto its rim Tools and Supplies Neede...

Page 28: ...tart by lubing the tire and rim with the soapy water to ease the process of replacing the tire Step2 Locate the valve stem hole in the rim and correctly position the stem into the hole Step3 Place the rim disc side down Step4 Sit the tire on top of the rim first ensuring the rim lock is securely in between the tire and inner tube Step4 Use your tire irons to pry the first side of the tire onto the...

Page 29: ...Iron o Air Pump o Step5 Turn the wheel over so that the disc break is now facing up Step6 Begin prying the other side of the tire onto the rim attempting to avoid pinching the tube Step7 Once the tire has been put back onto the rim completely use your socket set to tighten the valve stem and rim lock nuts Step8 Replace the valve back into the valve stem with the valve stem remover tool Hammer o ...

Page 30: ...cedures Tools Needed Socket Set 8mm o Step1 Take the front wheel and slide the disc break into the gap of the caliper Step2 Align the hole in the rim with the forks Step3 Fit the left and right spacers between the rim and forks Step4 Slide the axel through the fork and rim with the lug nut on the left side of the motorcycle Step5 Use the tire iron to tighten the lug nut after you reassure the axel...

Page 31: ...ter III 23 Procedures Locate the two bolts at the bottom of each fork directly next to the axle and ready your wrench and 8mm socket Step1 Set your wrench to tighten Step2 Tighten all four bolts to the axle ...

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Page 33: ...25 Testing Repair ...

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Page 35: ... Spin the front tire to check for any problems that may exist Step1 To perform the test you must first make sure that your front tire is off of the ground Step2 Begin to rotate the front wheel in either direction Step3 Interpret your results o Tire is wobbling Either rim is bent or the axle was not reassembled properly o Tire swings back and forth to a stop Something in the tire is off balance ...

Page 36: ...king caliper o If the wheel slows but does not stop immediately then check your brake pads for wear o If the wheel stops abruptly then the front breaks were installed correctly Step1 To perform the test you must first make sure that your front tire is off of the ground Step2 Begin to rotate the front wheel in either direction Step3 Interpret your results o Tire is wobbling Either rim is bent or th...

Page 37: ...st will prove if you were successful in repairing your 2001 YZ250 Tools Needed PSI Guage o Step1 Prepare a large empty area where you will stand your motorcycle at Step2 Pull your motorcycle from its stand and allow it to hold its own weight Step3 Interpret your results o If the bike falls and the wheel becomes disconnected from the forks then an error occurred with the axle o If the bike stands t...

Page 38: ...emove valve cap from valve stem Step2 Firmly press your PSI gauge into the valve stem until the stick comes to a complete stop Step3 Interpret your results o If your PSI gauge reads below 20psi then add air to your tire and test again o If your gauge reads above 20psi then remove some air and test again ...

Page 39: ...torcycle Article Dirt Bike Tire Change Guide aspx Index Axel iii 10 Bolts iii iv 9 23 Break Test iv 28 Dry iii 3 Forks iii iv 10 11 21 inner tube 12 13 14 15 19 Lug Nut iii 10 motorcycle v 3 4 5 15 29 31 PSI Test iv 29 repair v Rim iv 12 14 15 16 19 Rinse iii 3 Socket set 9 Spin Test iv 27 Standing Test iv 29 Stands iii 5 Tire iv 10 12 14 15 19 21 31 Tire Iron 10 21 Tools iii iv v 7 9 10 12 19 21 ...

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