2003 YAMAHA YZ250F air filter

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Engine stop switch
8Kickstarter crank
9Fuel tank
0Radiator
ACoolant drain bolt
BRear brake pedal
CValve joint
DFuel cock
ECold starter knob
FDrive chain
GAir filter
HShift pedal
IDipstick
JFront forkNOTE:
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
1Kupplungshebel
2Heißstarter-Hebel
3Handbremshebel
4Gasdrehgriff
5Kühlerverschlußdeckel
6Kraftstoffankverschluß
7Motorstoppschalter
8Kickstarterhebel
9Kraftstofftank
0Kühler
AKühlmittel-Ablaßschraube
BFußbremshebel
CAuslaufschutzventil
DKraftstoffhahn
EKaltstarterknopf
FAntriebskette
GLuftfilter
HSchalthebel
IMeßstab
JTeleskopgabel
HINWEIS:
Leichte Modell-Abweichungen
möglich.
Änderungen an Design und techni-
schen Daten jederzeit vorbehalten.
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1Levier d’embrayage
2Levier de démarreur à chaud
3Levier de frein avant
4Poignée des gaz
5Bouchon de radiateur
6Bouchon de réservoir de carburant
7Coupe-circuit du moteur
8Kick
9Réservoir de carburant
0Radiateur
ABoulon de vidange du liquide de
refroidissement
BPédale de frein arrière
CJoint de robinet
DRobinet de carburant
EBouton de démarrage à froid
FChaîne de transmission
GFiltre à air
HSélecteur
IJauge
JFourche 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
1Leva della frizione
2Leva dell’avviamento a caldo
3Leva del freno anteriore
4Manopola dell’acceleratore
5Tappo del radiatore
6Tappo del serbatoio del carburante
7Interruttore di arresto motore
8Pedivella di avviamento
9Serbatoio del carburante
0Radiatore
ABullone di scarico del refrigerante
BPedale del freno posteriore
CGiunto a valvola
DRubinetto del carburante
EManopola di avviamento a freddo
FCatena di trasmissione
GFiltro aria
HPedale del cambio
IAstina dell’olio
JForcella 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 - 11
GEN
INFO
CONTROL FUNCTIONS
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
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 LEVER
The hot starter lever 1 is used when starting a
warm engine.
Use the hot starter lever when starting the
engine again immediately after it was stopped
(the engine is still warm). Pulling the hot starter
lever injects secondary air to thin the air-fuel
mixture temporarily, allowing the engine to be
started more easily.

SPEC

2 - 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 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 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
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 51R (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
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 2 0.2 1.4
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 hose M6
×
1.0 2 10 1.0 7.2
Oil hose clamp—2 2 0.2 1.4
Oil strainer and frame M14
×
1.5 1 70 7.0 50
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 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
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 or
equivalent oil
OIL FILTER
Replace
●●
OIL STRAINER (frame)
Clean
●
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 ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
3

3 - 11
INSP
ADJHOT STARTER LEVER ADJUSTMENT/
AIR FILTER CLEANING
HOT STARTER LEVER ADJUSTMENT
1. Check:
Hot starter lever free play a
Out of specification → Adjust.
2. Adjust:
Hot starter lever free play
NOTE:
After adjustment, check proper operation of
hot starter.
Hot starter lever free play a:
3 ~ 6 mm (0.12 ~ 0.24 in)
Hot starter lever free play adjustment
steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
Seat
Fitting bolt 1
Washer 2
Air filter element 3
Air filter guide 4

INSP
ADJ
REGLAGE DU LEVIER DE DEMARREUR A CHAUD/NETTOYAGE DU FILTRE A AIR
WARMSTART-HEBEL-EINSTELLUNG/LUFTFILTER REINIGEN
REGOLAZIONE DELLA LEVA DELL’AVVIAMENTO A CALDO/
PULIZIA FILTRO DELL’ARIA
WARMSTART-HEBEL-EINSTEL-
LUNG
1. Prüfen:
Spiel des Heißstarter-He-
bels a
Unvorschriftsmäßig → Ein-
stellen.
2. Einstellen:
Spiel des Heißstarter-He-
bels
HINWEIS:
Nach der Einstellung auf richtige
Funktion des Heißstarters prüfen.
Spiel des Heißstarter-
Hebels a
3–6 mm
Einstellschritte für Spiel des
Heißstarter-Hebels:
Die Gegenmutter 1 lösen.
Den Einsteller 2 drehen, bis
das Spiel a innerhalb des Soll-
bereichs erzielt wird.
Die Gegenmutter festziehen.
LUFTFILTER REINIGEN
HINWEIS:
Frühzeitige und sachgemäße
Luftfilterwartung hilft, Motorver-
schleiß und -beschädigung vorzu-
beugen.
ACHTUNG:
Den Motor niemals ohne Luftfilter
betreiben, da eindringende Staub-
partikel erhöhten Verschleiß am
Kolben und/oder Zylinder verursa-
chen.
1. Demontieren:
Sitzbank
Schraube 1
Scheibe 2
Luftfiltereinsatz 3
Luftfilter führung 4 REGLAGE DU LEVIER DE
DEMARREUR A CHAUD
1. Contrôler:
Jeu du levier de démarreur à
chaud a
Hors spécification → Ajuster.
2. Ajuster:
Jeu du levier de démarreur à
chaud
N.B.:
Après le réglage, s’assurer du bon fonc-
tionnement du démarreur à chaud.
Jeu du levier de démar-
reur à chaud a:
3 à 6 mm (0,12 à 0,24 in)
Points de réglage du jeu de démar-
reur à chaud:
Desserrer le contre-écrou 1.
Tourner le régulateur 2 jusqu’à ce
que le jeu a soit dans les limites
spécifiées.
Serrer le contre-écrou.
NETTOYAGE DU FILTRE A AIR
N.B.:
Un entretien convenable du filtre à air est
la clé pour éviter l’usure prématurée et
l’endommagement du moteur.
ATTENTION:
Ne jamais faire tourner le moteur lors-
que l’élément du filtre à air n’est pas
en place; ceci permettrait la pénétra-
tion de poussière dans le moteur et
causerait son usure rapide et son
endommagement.
1. Déposer:
Selle
Boulon de fixation 1
Rondelle 2
Elément du filtre à air 3
Guide de filtre à air 4REGOLAZIONE DELLA LEVA
DELL’AVVIAMENTO A CALDO
1. Controllare:
Gioco della leva dell’avvia-
mento a caldo a
Fuori specifica → Regolare.
2. Regolare:
Gioco della leva dell’avvia-
mento a caldo
NOTA:
Dopo la regolazione, controllare che
l’avviamento a caldo funzioni corretta-
mente.
Gioco della leva dell’avvia-
mento a caldo a:
3 ~ 6 mm (0,12 ~ 0,24 in)
Fasi per la regolazione del gioco
della leva dell’avviamento a caldo:
Allentare il controdado 1.
Girare il registro 2 fino a che il
gioco a rientra nei limiti specifi-
cati.
Serrare il controdado.
PULIZIA FILTRO DELL’ARIA
NOTA:
Una corretta manutenzione del filtro
dell’aria è il metodo migliore per evitare
un’usura prematura del motore e i danni
conseguenti.
ATTENZIONE:
Non mettere mai in funzione il motore
senza l’elemento filtrante, altrimenti
sporco e polvere penetrerebbero nel
motore causando la rapida usura e
probabili danni al motore.
1. Rimuovere:
Sella
Bullone di fissaggio 1
Rondella 2
Elemento filtrante 3
Guida del filtro dell’aria 4
3 - 11