2004 YAMAHA YZ250F fuel cap

GEN
INFO

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

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) (Except for EUROPE)
49/13 (3.769) (For EUROPE)
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 NHS (For EUROPE except F)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2

, 15 psi)
1
2

2 - 18
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Fuel tank breather hose
2
Clutch cable
3
Oil tank breather hose
4
Hot starter cable
5
Cylinder head breather hose
6
Cable guide
7
Hose guide
8
Brake hose
9
Engine stop switch lead
0
Clamp
A
Sub-wire harness
B
Throttle position sensor lead
C
Neutral switch lead
D
Oil hose
E
CDI magneto lead
F
Radiator breather hose
G
Carburetor breather hose
H
Carburetor overflow hose
Å
Insert the end of the fuel tank
breather hose into the hole in
the steering stem cap.
ı
Pass 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.
Ç
Pass the clutch cable through
the cable guides.
Î
Pass the clutch cable in front of
the radiator mounting boss.
‰
Fit the brake hose into the
guides on the protector.
Ï
Fasten the neutral switch lead
and CDI magneto lead to the
cable guide with a plastic locking
tie and cut off the tie end.
Ì
Fasten the engine stop switch
lead, neutral switch lead and
CDI magneto lead.
Ó
Fasten the engine stop switch
lead and sub-wire harness at the
protecting tube for the engine
stop switch lead.
È
Fasten the sub-wire harness
and hot starter cable at the white
tape for the sub-wire harness.
Ô
Fasten the sub-wire harness.

Pass the sub-wire harness
between the engine brackets.
A
C-C
B
CC
A
D
F
C
1
2
3
4
5 6 6 78
G
H
G0
0DCB0 0 0
A 9
0
0
B
0 Ï
Ì
Ó
Ô

Ô
Ò
˜
ˆ Ø 0 E F
∏ Œ Å
ı
Ç Î Ç ‰
Â
0
È

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
●

●

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
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
1
2
3

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 ~ 17
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 ~ 4
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 - 43
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Apply the lithium soap base grease on the
thread of the steering stem.
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
Loosen the steering ring nut one turn.
Retighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tightening):
7 Nm (0.7 m • kg, 5.1 ft • lb)
Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
Install the washer 5, upper bracket 6,
washer 7, steering stem nut 8, steering
stem cap 9, handlebar 0, handlebar
upper holder A and number plate B.
NOTE:
The upper handlebar holder should be
installed with the punched mark a forward.
Insert the end of fuel breather hose C into
the hole in the steering stem cap.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar upper holder:
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (upper bracket):
23 Nm (2.3 m • kg, 17 ft • lb)
Number plate:
7 Nm (0.7 m • kg, 5.1 ft • lb)
6 7 8 9 CB
0

5 - 44
CHASHANDLEBAR
12. Clamp the clamp portion a of the num-
ber plate to the handlebar.
13. Insert the end of the fuel tank breather
hose 1 into the hole in the steering stem
cap 2.
2 1a