Yamaha YZ250 2001 Operating instructions

Yamaha YZ250 Front Tire Repair

Table of Contents iii
Table of Contents
Contents
....................................................................................................................... 1
Table of Contents ........................................................................................... iii
Introduction.................................................................................................... v
Legend ...................................................................................................... v
Preparing Motorcycle for Repair....................................................................... 7
•1.1 Clean Motorcycle ........................................................................... 7
•1.2 Clean Work Space.......................................................................... 7
•1.3 Prop Motorcycle on Stand .............................................................. 7
•1.4 Tools Required............................................................................... 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 Disc from Caliper........................................................................ 11

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Prepare front Wheel................................................................................. 11
2.4 Remove Tire from Rim .......................................................................... 12
Tools and Supplies Needed ...................................................................... 12
Procedures .............................................................................................. 13
Removing Tire from Rim .......................................................................... 13
2.5 Inspection of Wheel Components .......................................................... 14
Inspection of Inner Tube.......................................................................... 14
Inspection of Tire..................................................................................... 14
Inspecting the Rim .................................................................................. 15
Front Wheel 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 Test ....................................................................................... 29
How to Perform the Standing Test ........................................................... 29
4.4 PSI Test................................................................................................ 29

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

Introduction v
Introduction
In this manual are techniques and added information on how to replace
the front tire on a Yamaha, model YZ250, year 2001. This manual is to be used
for its intended purpose and will not be a reasonable substitute for any other
motorcycle. Replacing the front tire on a 2001 YZ250 can be a difficult task
requiring specific tools and prior mechanical 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 thoroughly
in order to ensure a proper and safe fix.
Legend
Here are the different symbols that will be used throughout this manual:
This symbol will be used to describe any warnings.

Preparing Motorcycle for Repair
•1.1 Clean Motorcycle
•1.2 Clean Work Space
•1.3 Prop Motorcycle on Stand
•1.4 Tools Required

Chapter I 3
Chapter 1
1.1 Clean Your Motorcycle
Cleaning your motorcycle prior to performing any maintenance is a
crucial step which must not be overlooked. Attempting to work on
your YZ250 without following this step could result in major
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
wet which could result in rust damage.

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1.2 Clean Workspace
Your workspace is an important environment which must be kept clean
in order to work efficiently.
Clear Debris
Clearing away any clutter is 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.

Chapter I 5
1.3 Prop Motorcycle 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
*

Removal of Front Wheel

Chapter II 9
Chapter 2
2.1 Loosen Fork Bolts
Before removing the wheel from your YZ250 you 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.

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2.2 Remove Axel and Wheel from Forks
Warning: When removing the axel from the forks the wheel will drop
directly toward the ground. This could cause injury. Be sure to
remove any items away from under the wheel and if possible secure
the wheel to keep it 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 the wheel. This will release the wheel and axel from the
fork.
Hammer
o

Chapter II 11
2.3 Remove Wheel from Forks
After removing the axel from the forks the wheel will be released. In order
to properly remove the wheel from the forks you should follow these steps:
Remove Axle and Spacers
Ensure the axle and spacers are completely removed from both front forks.
When removing the axle (number 24 in the picture) the spacers
number (12 and 26) will fall.
The bearings (13, 14, 15, and 25) will remain
inside the rim protected from dirt and debris.
Remove Disc from 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 by placing the two pronged side of the valve stem remover into
the valve and twist firmly to the left. Continue twisting until valve
stem falls out.
Find a hard smooth surface (preferably concrete).
Lay the front wheel on its side making sure to place the side with
the disc face up.

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2.4 Remove Tire from Rim
Warning! Removing the tire from the rim 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