2004 YAMAHA YZ250F maintenance

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufac-
turer5SF-00/YAMAHA ----
Charging coil 1 resistance (color) 720 ~ 1,080 Ω at 20 ˚C (68 ˚F)
(Green – Brown)----
Charging coil 2 resistance (color) 44 ~ 66 Ω at 20 ˚C (68 ˚F)
(Black – Pink)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5XC-00/YAMAHA ----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08 ~ 0.10 Ω at 20 ˚C (68 ˚F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9

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 - 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 - 3
INSP
ADJ

MAINTENANCE INTERVALS
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 ~ 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 - 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

5 - 52
CHASSWINGARM
EC573000
REMOVAL POINTS
EC573200
Bearing
1. Remove:
Bearing 1
NOTE:
Remove the bearing by pressing its outer race.
INSPECTION
Wash the bearings, bushings, collars, and cov-
ers in a solvent.
Swingarm
1. Inspect:
Bearing 1
Bushing 2
Free play exists/unsmooth revolution/
rust → Replace bearing and bushing as
a set.
2. Inspect:
Oil seal 3
Damage → Replace.
EC574210
Relay arm
1. Inspect:
Bearing (polylube bearing) 1
Collar 2
Free play exists/unsmooth revolution/rust
→ Replace bearing and collar as a set.
2. Inspect:
Bearing (polylube bearing) 1
Loss of solid lubrication → Replace.
Oil seal 3
Damage → Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the nee-
dle bearings, used in this model, maintenance
free. With polylube bearings, no grease nipple
and regular lubrication is necessary. However,
grease should be applied to all oil seals and
collars when removed or installed.

5 - 52
CHAS
BRAS OSCILLANT
SCHWINGE
FORCELLONE OSCILLANTE
AUSBAU
Lager
1. Demontieren:
Lager 1
HINWEIS:
Das Lager am äußeren Laufring ein-
pressen.
PRÜFUNG
Die Lager, Buchsen, Hülsen und
Anlaufscheiben in Lösungsmittel
waschen.
Schwinge
1. Kontrollieren:
Lager 1
Buchse 2
Spiel/Schwergängigkeit/
Rost → Lager und Buchse
im Satz erneuern.
2. Kontrollieren:
Dichtring 3
Beschädigung → Erneuern.
Umlenkhebel
1. Kontrollieren:
Lager (Polylube-Lager) 1
Hülse 2
Spiel/Schwergängigkeit/
Rost → Lager und Hülse im
Satz erneuern.
2. Kontrollieren:
Lager (Polylube-Lager) 1
Verlust der Trockenschmie-
rung → Erneuern.
Dichtring 3
Beschädigung → Erneuern.
HINWEIS:
Polylube-Lager mit Trockenschmie-
rung werden eingesetzt, um die in
diesem Modell verwendeten Nadella-
ger wartungsfrei zu machen. Bei Po-
lylube-Lagern gibt es keine Schmier-
nippel, und regelmäßige Schmierung
ist nicht erforderlich. Es sollte aber
beim Ausbau oder Einbau Fett auf
alle Ölabdichtungen und Hülsen auf-
getragen werden. POINTS DE DEPOSE
Roulement
1. Déposer:
Roulement 1
N.B.:
Retirer le roulement en appuyant sur la
cage extérieure.
CONTROLE
Laver les roulements, les bagues, les col-
lerettes et les caches dans un dissolvant.
Bras oscillant
1. Contrôler:
Roulement 1
Bague 2
Jeu/rotation irrégulière/rouille
→ Remplacer à la fois le roule-
ment et la bague.
2. Contrôler:
Bague d’étanchéité 3
Endommagement → Changer.
Bras de relais
1. Contrôler:
Roulement (roulement poly-
lube) 1
Collerette 2
Jeu/rotation irrégulière/rouille
→ Remplacer à la fois le roule-
ment et la collerette.
2. Contrôler:
Roulement (roulement poly-
lube) 1
Perte de lubrification solide →
Remplacer.
Bague d’étanchéité 3
Endommagement → Rempla-
cer.
N.B.:
Les roulements polylube, à lubrification
solide, ont été adoptés pour éliminer la
maintenance des roulements à aiguilles,
utilisés sur ce modèle. Les roulements
polylube rendent le graissage par les
graisseurs et le graissage ordinaire inuti-
les. Tous les colliers et joints à huile doi-
vent néanmoins être graissés lorsqu’ils
sont retirés ou installés. PUNTI DI RIMOZIONE
Cuscinetto
1. Rimuovere:
Cuscinetto 1
NOTA:
Rimuovere il cuscinetto premendo
sull’anello esterno.
ISPEZIONE
Lavare i cuscinetti, le boccole, i collarini
e i coperchi con un solvente.
Forcellone oscillante
1. Ispezionare:
Cuscinetto 1
Boccola 2
Gioco/movimento non agevole/
ruggine → Sostituire in blocco
il cuscinetto e la boccola.
2. Ispezionare:
Paraolio 3
Danni → Sostituire.
Leva di rinvio
1. Ispezionare:
Cuscinetto
(cuscinetto polylube) 1
Collarino 2
Gioco/movimento non agevole/
ruggine → Sostituire in blocco
il cuscinetto e il collarino.
2. Ispezionare:
Cuscinetto
(cuscinetto polylube) 1
Perdita di lubrificazione solida
→ Sostituire.
Paraolio 3
Danni → Sostituire.
NOTA:
I cuscinetti polylube, con lubrificazione
solida, sono stati adottati in modo che i
cuscinetti a spillo usati in questo modello
non necessitino di manutenzione. Con
cuscinetti polylube, non è necessario un
ingrassatore o una lubrificazione perio-
dica. Tuttavia, si deve applicare grasso a
tutti i paraolio e collarini quando ven-
gono rimossi o installati.