2004 YAMAHA YZ250F engine

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ENGCYLINDER HEAD
CYLINDER HEAD
Extent of removal:1 Cylinder head removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator hose 1 Disconnect at cylinder head side.
Carburetor Refer to “CARBURETOR” section.
Camshaft Refer to “CAMSHAFTS” section.
Upper engine bracket Refer to “ENGINE REMOVAL” section.
1 Radiator pipe 1
2 Oil delivery pipe 1
3 Nut 2
4 Bolt [L=135 mm (5.31 in)] 2
5 Bolt [L=145 mm (5.71 in)] 2
6 Cylinder head 1
7 Timing chain guard (exhaust side) 1
1

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ENGVALVES AND VALVE SPRINGS
5. Install:
Adjusting pad 1
Valve lifter 2
NOTE:
Apply the molybdenum disulfide oil on the
valve stem end.
Apply the engine oil on the valve lifters.
Valve lifter must turn smoothly when rotated
with a finger.
Be careful to reinstall valve lifters and pads
in their original place.

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ENGCYLINDER AND PISTON
Piston pin
1. Inspect:
Piston pin
Blue discoloration/grooves → Replace,
then inspect the lubrication system.
2. Measure:
Piston pin-to-piston clearance
ASSEMBLY AND INSTALLATION
Piston ring and piston
1. Install:
Piston ring
Onto the piston.
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
Lubricate the piston and piston rings liberally
with engine oil. Measurement steps:
Measure the outside diameter (piston pin)
a.
If out of specification, replace the piston
pin.
Outside diameter (piston pin):
15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)
Measure the inside diameter (piston) b.
Inside diameter (piston):
16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)
Calculate the piston pin-to-piston clear-
ance with the following formula.
Piston pin-to-piston clearance =
Inside diameter (piston) b –
Outside diameter (piston pin) a
If out of specification, replace the piston.
Piston pin-to-piston clearance:
0.002 ~ 0.022 mm
(0.0001 ~ 0.0009 in)
: 0.07 mm (0.003 in)

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ENGCYLINDER AND PISTON
2. Position:
Top ring
2nd ring
Oil ring
Offset the piston ring end gaps as
shown.
aTop ring end
b2nd ring end
cOil ring end (upper)
dOil ring
eOil ring end (lower)
3. Install:
Piston 1
Piston pin 2
Piston pin clip 3
NOTE:
Apply engine oil onto the piston pin and pis-
ton.
Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the
piston pin clip from falling into the crankcase.
Install the piston pin clips with their ends fac-
ing downward.
45°
135°135°
a
b ced
3New
Cylinder
1. Lubricate:
Piston
Piston ring
Cylinder
NOTE:
Apply a liberal coating of engine oil.
2. Install:
Dowel pin 1
O-ring 2
NOTE:
Apply the lithium soap base grease on the O-
ring.

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ENGCLUTCH
EC4A0000
CLUTCH
Extent of removal:1 Push rod 1, 2 and push lever shaft removal2 Push pod 1 disassembly
3 Friction plate and clutch plate removal4 Primary driven gear removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8 Ball 1
9Push rod 2
1
4
1
12
3

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ENG

CLUTCH
EC4A5000
ASSEMBLY AND INSTALLATION
Push lever shaft
1. Install:

Push lever shaft
1


Bolt (push lever shaft)
2

NOTE:


Apply the lithium soap base grease on the oil
seal lip.

Apply the engine oil on the push lever shaft.

Fit the seat plate
3
in the groove
a
of the
push lever shaft and tighten the bolt (seat
plate).
3
1a2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

Clutch
1. Install:

Primary driven gear 1
Thrust washer 2
Clutch boss 3
NOTE:
Apply the engine oil on the primary driven gear
inner circumference.
2. Install:
Lock washer 1
Nut (clutch boss) 2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
T R..60 Nm (6.0 m · kg, 43 ft · lb)
Å
ı

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ENG
3. Bend the lock washer 1 tab.
4. Install:
Seat plate 1
Cushion spring 2
NOTE:
Install the seat plate with its chamfered por-
tion a facing the clutch boss 3.
Install the seat plate so that it is not caught
on the step b.
Install the cushion spring with the paint c
facing out.
1
2
c
3
a
b
5. Install:
Friction plate 1 1
Clutch plate 1 2
Friction plate 2 3
Clutch plate 2 4
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Use the friction plates 1 for the first and final
while paying attention to the difference in
surface pattern.
Apply the engine oil on the friction plates and
clutch plates.
Unlike the clutch plate 2, the clutch plate 1
has no surface gloss. Use the clutch plate 1
for the first while paying attention to the dif-
ference in surface gloss.
6. Install:
Bearing 1
Washer 2
Circlip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and
washer.
CLUTCH

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ENGCLUTCH
7. Install:
Push rod 2 1
Ball 2
Push rod 1 3
NOTE:
Apply the engine oil on the push rod 1, 2 and
ball.
8. Install:
Pressure plate 1
9. Install:
Clutch spring 1
Bolt (clutch spring) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
10. Install:
Dowel pin 1
Gasket (clutch cover) 2
11. Install:
Clutch cover 1
Bolt (clutch cover)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)