2002 YAMAHA YZ250F air filter

GEN
INFO

1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Decompression lever
3
Front brake lever
4
Throttle grip
5
Radiator cap
6
Fuel tank cap
7
Oil tank cap
8
Engine stop switch
9
Kickstarter crank
0
Fuel tank
A
Radiator
B
Coolant drain bolt
C
Rear brake pedal
D
Valve joint
E
Fuel cock
F
Cold starter knob
G
Hot starter knob (red)
H
Drive chain
I
Air filter
J
Shift pedal
K
Front fork
NOTE:


The machine you have purchased may differ
slightly from those shown in the following.

Designs and specifications are subject to
change without notice.

GEN
INFO

DESCRIPTION
FAHRZEUGBESCHREIBUNG
DESCRIZIONE
ALLGEMEINE
ANGABEN
FAHRZEUGBESCHREI-
BUNG
1
Kupplungshebel
2
Dekompressionshebel
3
Handbremshebel
4
Gasdrehgriff
5
Kühlerverschlußdeckel
6
Kraftstoffankverschluß
7
Öltankdeckel
8
Motorstoppschalter
9
Kickstarterhebel
0
Kraftstofftank
A
Kühler
B
Kühlmittel-Ablaßschraube
C
Fußbremshebel
D
Auslaufschutzventil
E
Kraftstoffhahn
F
Kaltstarterknopf
G
Heißstarterknopf (rot)
H
Antriebskette
I
Luftfilter
J
Schalthebel
K
Teleskopgabel
HINWEIS:


Leichte Modell-Abweichungen
möglich.

Änderungen an Design und techni-
schen Daten jederzeit vorbehalten.
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1
Levier d’embrayage
2
Levier de décompression
3
Levier de frein avant
4
Poignée des gaz
5
Bouchon de radiateur
6
Bouchon de réservoir de carburant
7
Bouchon du réservoir d’huile
8
Coupe-circuit du moteur
9
Kick
0
Réservoir de carburant
A
Radiateur
B
Boulon de vidange du liquide de
refroidissement
C
Pédale de frein arrière
D
Joint de robinet
E
Robinet de carburant
F
Bouton de démarrage à froid
G
Bouton de démarrage à chaud
(rouge)
H
Chaîne de transmission
I
Filtre à air
J
Sélecteur
K
Fourche avant
N.B.:


Votre machine diffère peut-être par-
tiellement de celle montrée sur ces
photos.

La conception et les caractéristiques
peuvent êtres changées sans préavis.
1 - 1
INFORMAZIONI
GENERALI
DESCRIZIONE
1
Leva della frizione
2
Leva della decompressione
3
Leva del freno anteriore
4
Manopola dell’acceleratore
5
Tappo del radiatore
6Tappo del serbatoio del carburante
7Tappo del serbatoio dell’olio
8Interruttore di arresto motore
9Pedivella di avviamento
0Serbatoio del carburante
ARadiatore
BBullone di scarico del refrigerante
CPedale del freno posteriore
DGiunto a valvola
ERubinetto del carburante
FManopola di avviamento a freddo
GManopola di avviamento a caldo
(rossa)
HCatena di trasmissione
IFiltro aria
JPedale del cambio
KForcella anteriore
NOTA:
Il veicolo acquistato potrebbe differire
leggermente da quelli illustrati qui di
seguito.
I modelli e le specifiche sono soggetti
a variazioni senza preavviso.
1

1 - 3
GEN
INFO

IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
EC131010
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassem-
bly.
When washing the machine with high
pressured water, cover the parts follows.

Silencer end

Air filter intake hole

Water pump housing hole at the bottom

Carburetor accelerator pump
2. Use proper tools and cleaning equip-
ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep
mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine disassembly, clean
all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5. Keep away from fire.

GEN
INFO
INFORMATIONS IMPORTANTES
WICHTIGE INFORMATIONEN
INFORMAZIONI IMPORTANTI
WICHTIGE INFORMATIO-
NEN
VORBEREITUNG FÜR AUSBAU
UND ZERLEGUNG
1. Vor dem Ausbau oder Zerle-
gen der Bauteile sämtlichen
Schmutz, Schlamm, Staub so-
wie andere Fremdkörper ent-
fernen.
Wenn das Motorrad mit einem
Hochdruckwascher gereinigt
wird, sind folgende Teile sorg-
fältig abzudecken.
Schalldämpferende
Luftfilter-Einlaßöffnung
Wasserpumpengehäuse-
loch unten
Vergaser-Beschleuniger-
pumpe
2. Nur geeignete Werkzeuge und
Reinigungsmittel verwenden.
Siehe unter “SPEZIALWERK-
ZEUGE”.
3. Beim Zerlegen zusammenge-
hörige Teile immer gemein-
sam ablegen. Dies gilt beson-
ders für Zahnräder, Zylinder,
Kolben und alle beweglichen
Teile, die miteinander arbei-
ten. Solche Baugruppen dür-
fen nur komplett wiederver-
wendet oder ausgetauscht
werden.
4. Alle ausgebauten Teile reini-
gen und in der Reihenfolge
des Ausbaus auf einer saube-
ren Unterlage ablegen. Dies
gewährleistet einen zügigen
und korrekten Zusammenbau.
5. Alle Teile von offenem Feuer
fernhalten.
INFORMATIONS IMPOR-
TANTES
PREPARATION POUR LA DEPOSE
ET DEMONTAGE
1. Eliminer soigneusement crasse,
boue, poussière et corps étrangers
avant la dépose et le démontage.
Avant de laver le véhicule à l’eau
pressurisée, recouvrir les parties
suivantes:
Extrémité du silencieux
Orifice d’admission du filtre à
air
Orifice au fond du carter de la
pompe à eau
Pompe d’accélération du car-
burateur
2. Utiliser les outils et le matériel de
nettoyage correct. Se reporter à la
section “OUTILS SPECIAUX”.
3. Lors du démontage de la
machine, garder les pièces conne-
xes ensemble. Ils comprennent
les engrenages, cylindres, pistons
et autres pièces connexes qui se
sont “accouplées” par usure nor-
male. Les pièces connexes doi-
vent être réutilisées en un
ensemble ou changées.
4. Lors du démontage de la
machine, nettoyer toutes les piè-
ces et les mettre dans des pla-
teaux dans l’ordre du démontage.
Ceci diminuera le temps de
remontage et permettra d’être sûr
que toutes les pièces sont correc-
tement remontées.
5. Tenir éloigné du feu.
1 - 3
INFORMAZIONI IMPOR-
TANTI
PREPARATIVI PER LA RIMO-
ZIONE E IL DISASSEMBLAGGIO
1. Rimuovere tutto lo sporco, il
fango, la polvere e il materiale
estraneo prima della rimozione e
del disassemblaggio.
Durante il lavaggio del veicolo
con acqua ad alta pressione,
coprire le parti seguenti:
Estremità del silenziatore
Foro di ingresso del filtro
dell’aria
Foro di alloggiamento della
pompa dell’acqua in basso
Pompa di circolazione del car-
buratore
2. Utilizzare utensili e strumenta-
zione per la pulizia adatti. Fare
riferimento al paragrafo “UTEN-
SILI SPECIALI”.
3. Nello smontaggio del veicolo,
non separare parti accoppiate. Ciò
comprende gli ingranaggi, i cilin-
dri, i pistoni e altri pezzi accop-
piati, che si sono adattati l’uno
all’altro attraverso la normale
usura. Le parti accoppiate vanno
riutilizzate come una sola unità o
sostituite.
4. Durante lo smontaggio del vei-
colo, pulire tutti i pezzi e posizio-
narli sui vassoi nell’ordine in cui
sono stati smontati. Ciò abbrevia i
tempi di rimontaggio e assicura
che tutti i pezzi siano reinstallati
correttamente.
5. Tenere lontano dal fuoco.

1 - 12
GEN
INFO
CONTROL FUNCTIONS
EC158001
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the two positions:
OFF:With the lever in this position, fuel will not
flow. Always return the lever to this posi-
tion when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
COLD STARTER KNOB
When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the cold starter knob 1,
supplies this mixture. Pull the cold starter knob
out to open the circuit for starting. When the
engine has warmed up, push it in to close the
circuit.
HOT STARTER KNOB
The hot starter knob (red) 1 is used when
starting a warm engine.
Use the hot starter knob when starting the
engine again immediately after it was stopped
(the engine is still warm). Pulling out the hot
starter knob injects secondary air to thin the
air-fuel mixture temporarily, allowing the
engine to be started more easily.
CAUTION:
After the engine has started, be sure to
push the hot starter knob back in.

SPEC

2 - 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt)
With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt)
Total amount 1.7 L (1.50 Imp qt, 1.80 US qt)
Coolant capacity (including all routes): 0.9 L (0.79 Imp qt, 0.95 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
(Except for ZA)
Premium gasoline (For ZA)
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK
U24ESR-N/DENSO
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 48/13 (3.692)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 30/14 (2.143)
2nd 28/16 (1.750)
3rd 29/20 (1.450)
4th 27/22 (1.227)
5th 25/24 (1.042)
Chassis:
Frame type Semi double cradle
Caster angle 27.1˚
Trail 117.4 mm (4.62 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN, ZA, AUS, NZ
and F)
80/100-21 MT320 (For EUROPE except F)
Size (rear) 100/90-19 57M (For USA, CDN, ZA, AUS, NZ
and F)
100/90-19 MT320 (For EUROPE except F)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2

, 15 psi)

2

SPEC

2 - 10
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S
×
1.0 1 13 1.3 9.4
Camshaft cap M6
×
1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12
×
1.0 1 37 3.7 27
Cylinder head (stud bolt) M6
×
1.0 2 7 0.7 5.1
(stud bolt) M8
×
1.25 1 15 1.5 11
(bolt) M9
×
1.25 4 38 3.8 27
(nut) M6
×
1.0 2 10 1.0 7.2
Cylinder head cover M6
×
1.0 2 10 1.0 7.2
Cylinder M6
×
1.0 1 10 1.0 7.2
Balancer weight M6
×
1.0 2 10 1.0 7.2
Balancer shaft driven gear M14
×
1.0 1 50 5.0 36
Timing chain guide (intake side) M6
×
1.0 2 10 1.0 7.2
Decompression shaft M6
×
1.0 1 7 0.7 5.1
Decompression cable guide M6
×
1.0 1 10 1.0 7.2
Timing chain tensioner M6
×
1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6
×
1.0 1 7 0.7 5.1
Impeller M8
×
1.25 1 14 1.4 10
Radiator hose clamp M6
×
1.0 8 2 0.2 1.4
Coolant drain bolt M6
×
1.0 1 10 1.0 7.2
Water pump housing M6
×
1.0 4 10 1.0 7.2
Radiator M6
×
1.0 6 10 1.0 7.2
Radiator guard M6
×
1.0 2 10 1.0 7.2
Radiator pipe M6
×
1.0 1 10 1.0 7.2
Oil pump cover M4
×
0.7 1 3 0.3 2.2
Oil pump M6
×
1.0 3 10 1.0 7.2
Oil filter element drain bolt M6
×
1.0 1 10 1.0 7.2
Oil filter element cover M6
×
1.0 2 10 1.0 7.2
Oil strainer M6
×
1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10
×
1.25 1 20 2.0 14
(M8) M8
×
1.25 2 18 1.8 13
Oil delivery pipe 2 M6
×
1.0 1 10 1.0 7.2
Oil hose M6
×
1.0 3 10 1.0 7.2
Oil hose clamp—2 2 0.2 1.4
Oil strainer and frame M18
×
1.5 1 90 9.0 65
Carburetor joint clamp M4
× 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable cover M5 × 0.8 1 4 0.4 2.9
Air filter joint M5 × 0.8 2 5 0.5 3.6
Air filter joint and air filter case M5 × 0.8 5 1 0.1 0.7
Air filter element M6 × 1.0 1 2 0.2 1.4
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

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
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
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks


3