2003 YAMAHA YZ250F light

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols
1
to
7
are designed as
thumb tabs to indicate the chapter’s number
and content.
1
General information
2
Specifications
3
Regular inspection and adjustments
4
Engine
5
Chassis
6
Electrical
7
Tuning
Illustrated symbols
8
to
D
are used to identify
the specifications appearing in the text.
8
With engine mounted
9
Special tool
0
Filling fluid
A
Lubricant
B
Tightening
C
Specified value, Service limit
D
Resistance (
Ω
), Voltage (V), Electric current (A)
Illustrated symbols
E
to
H
in the exploded
diagrams indicate grade of lubricant and loca-
tion of lubrication point.
E
Apply engine oil
F
Apply molybdenum disulfide oil
G
Apply lightweight lithium-soap base grease
H
Apply molybdenum disulfide grease
Illustrated symbols
I
to
J
in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
EF
GH
IJ
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
TUN
T R..
EM
BM

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.

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.

GEN
INFO
1 - 8
SPECIAL TOOLS
YU-33975, 90890-01403 Steering nut wrench
This tool is used when tighten the steering ring nut to
specification.YU-33975 90890-01403
YM-1423, 90890-01423 Damper rod holder
Use this tool to remove and install the damper rod.YM-1423 90890-01423
YM-01442, 90890-01442 Fork seal driver
This tool is used when install the fork oil seal.YM-01442 90890-01442
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-33277-A, 90890-03141 Timing light
This tool is necessary for checking ignition timing.YM-33277-A 90890-03141
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YM-4111, 90890-04111
YM-4116, 90890-04116Valve guide remover
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
This tool is needed to remove and install the valve
guide.YM-4111
YM-411690890-04111
90890-04116
Part number Tool name/How to use Illustration

1 - 10
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch 1 is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter crank so the engine
can be started in any gear if the clutch is dis-
engaged. In normal practices, however, shift to
neutral before starting.
1
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.

1 - 20
GEN
INFO
CLEANING AND STORAGE
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the
carburetor float bowl.
2. Remove the spark plug, pour a table-
spoon of SAE 10W-30 motor oil in the
spark plug hole, and reinstall the plug.
With the engine stop switch pushed in,
kick the engine over several times to coat
the cylinder walls with oil.
3. Remove the drive chain, clean it thor-
oughly with solvent, and lubricate it.
Reinstall the chain or store it in a plastic
bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid
or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do
not apply oil to rubber parts or the seat
cover.
NOTE:
Make any necessary repairs before the
machine is stored.

2 - 21
SPECCABLE ROUTING DIAGRAM
1Brake master cylinder
2Brake hose holder
3Brake hoseÅInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projection
on the brake caliper.
ıPass the brake hose into the brake hose holders.
ÇIf the brake hose contacts the spring (rear shock
absorber), correct its twist.
ÎInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projection
on the brake master cylinder.

3 - 13
INSP
ADJ
7. Install:
Air filter element 1
Washer
Fitting bolt
NOTE:
Align the projection a on filter guide with the
hole b in air filter case.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
Oil tank cap 1
1
4. Inspect:
Oil level
Oil level should be between maximum
a and minimum b marks.
Oil level is low → Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
oil tank cap into the oil tank. Insert the gauge
lightly.
a
b
ENGINE OIL LEVEL INSPECTION