2003 YAMAHA YZ250F clutch

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 4 23 2.3 17
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
Handlebar holder and upper bracket M8 × 1.25 4 28 2.8 20
Steering stem and steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M48 × 1.0 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 × 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 10 1.0 7.2
Front fork and brake hose guide M5 × 0.8 1 4 0.4 2.2
Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2
Front fork and brake hose cover (M8) M8 × 1.25 1 16 1.6 11
(M6) M6 × 1.0 1 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.2
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever holder M5 × 0.8 2 4 0.4 2.2
Clutch lever mounting bolt M6 × 1.0 1 2 0.2 1.4
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 30 3.0 22
Front brake caliper M8 × 1.25 2 23 2.3 17
Pad pin plug M10 × 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc M6 × 1.0 6 12 1.2 8.7
Rear brake disc M6 × 1.0 6 14 1.4 10
Brake pedal M8 × 1.25 1 26 2.6 19
Rear brake master cylinder M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 2.2
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90

2 - 18
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Clutch cable
3Oil tank breather hose
4Hot starter cable
5Cylinder head breather hose
6Cable guide
7Hose guide
8Brake hose
9Engine stop switch lead
0Clamp
ASub-wire harness
BThrottle position sensor lead
CNeutral switch lead
DOil hose
ECDI magneto lead
FRadiator breather hose
GCarburetor breather hose
HCarburetor overflow hoseÅPass the fuel tank breather hose
between the handlebar and ten-
sion bar, then insert its end into
the hole of the number plate.
ıPass the hot starter cable
between the cylinder head
breather hose, oil tank breather
hose and ignition coil, then on
the outside of the left engine
bracket.
ÇPass the clutch cable through
the cable guides.
ÎPass the clutch cable in front of
the radiator mounting boss.
‰Fit the brake hose into the
guides on the protector.ÏFasten the neutral switch lead
and CDI magneto lead to the
cable guide with a plastic locking
tie and cut off the tie end.
ÌFasten the engine stop switch
lead, neutral switch lead and
CDI magneto lead.
ÓFasten the engine stop switch
lead and sub-wire harness.
ÈFasten the sub-wire harness
and hot starter cable at the white
tape for the sub-wire harness.
ÔFasten the sub-wire harness.
Pass the sub-wire harness
between the engine brackets.

2 - 22
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Fuel tank breather hose
3Clamp
4Clutch cable
5Hot starter cable
6Engine stop switch lead
7Brake hose
8Hose guideÅFasten the engine stop switch lead to the handlebar.
ıPass the brake hose in front of the number plate.
ÇPass the clutch cable through the cable guide.
ÎPass the throttle cables and hot starter cable through the cable
guide.
1
23
4
5
6
7
83
6 Îı
ÇÅ
40˚±10˚
A
A

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
Inspect
●
●●

●
OIL FILTER ELEMENT, OIL STRAINER
Clean
●
VALVES
Check the valve clearances
Inspect
Replace
● ●
●
● The engine must be cold.
Check the valve seats
and valve stems for wear.
VALVE SPRINGS
Inspect
Replace
●
● Check the free length and
the tilt.
VALVE LIFTERS
Inspect
Replace
●
● Check for scratches and
wear.
CAMSHAFTS
Inspect
Replace
●
● Inspect the camshaft sur-
face.
Inspect the decompres-
sion system.
TIMING CHAIN SPROCKETS, TIMING
CHAIN
Inspect
Replace
●
● Check for wear on the
teeth and for damage.
PISTON
Inspect
Clean
Replace
● ●
●
● Inspect crack
Inspect carbon deposits
and eliminate them.
PISTON RING
Inspect
Replace
●
● ● Check ring end gap
PISTON PIN
Inspect
Replace
●
●
CYLINDER HEAD
Inspect and clean
● Inspect carbon deposits
and eliminate them.
Change gasket
CYLINDER
Inspect and clean
Replace
●
● Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
● ●
● Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Inspect
Replace bearing
●
●

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
●
●
●
●
● Suspension oil “01”
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
● ● Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
●
●
●
●
●
(After
rain ride)
●Molybdenum disulfide
grease
DRIVE CHAIN GUIDE AND ROLLERS
Inspect
● ●
SWINGARM
Inspect, lube and retighten
● ● Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retighten
● ● Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
● ●
●
● Lithium base grease
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate
●
●
●
●
●
●
●
Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Lubricate
Inspect and clean (throttle cable)
●
●
● ●

●
● Yamaha cable lube or
SAE 10W-30 motor oil
Inspect dirt and wear on
the throttle cable on the
carburetor side.
HOT STARTER, CLUTCH LEVER
Inspect free play
●
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks

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 ~ 16
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
Brakes Check the play of front brake and effect of front and rear brake. P.3-24 ~ 30
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-31 ~ 33
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-41 ~ 42
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-42 ~ 43
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-33 ~ 40
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.4-3
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-31
Lubrication Check for smooth operation. Lubricate if necessary. P.3-44
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 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Repair.
Radiator 1
Radiator hose joint 2
Coolant leakage → Repair or replace.
Radiator hose 3
Swelling → Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side
using the adjuster 2.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknuts 1.
Adjust the free play by changing their
tightening position.
Tighten the locknuts.

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
(For USA and CDN)
CAUTION:
Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD a or higher.
Do not use oils labeled “ENERGY CON-
SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
5. Install:
Oil tank cap
6. Start the engine and let it warm up for
several minutes.
7. Turn off the engine and inspect the oil
level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
Recommended oil:
At 5 ˚C (40 ˚F) or higher Å
Yamalube 4 (20W-40) or SAE
20W-40 type SG motor oil (Non-
Friction modified)
At 15 ˚C (60 ˚F) or lower ı
Yamalube 4 (10W-30) or SAE
10W-30 type SG motor oil (Non-
Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SG” or higher grade
(Designed primarily for motor-
cycles)
-20
-4-10
140
3010
5020
6830
8640 50
104
122°CTemp.
°F
10W-30
10W-40
20W-40
20W-50
15W-40
a
b