2004 YAMAHA YZ250F Owners Manual

GEN
INFO
NETTOYAGE ET RANGEMENT
REINIGUNG UND STILLEGUNG
PULIZIA ED IMMAGAZZINAGGIO
STILLEGUNG
Vor einer mehr als zweimonatigen
Stillegung sollten einige Schutzvor-
kehrungen getroffen werden, um
Schäden zu verhindern. Das Fahr-
zeug zuerst gründlich reinigen und
dann folgendermaßen zur Stillegung
vorbereiten:
1. Kraftstofftank, Kraftstoffleitun-
gen und Vergaser-Schwim-
merkammer entleeren.
2. Die Zündkerze herausschrau-
ben, ungefähr einen Teelöffel
Motoröl in die Kerzenbohrung
geben und die Zündkerze wie-
der hineinschrauben. Bei ge-
drücktem Motorstoppschalter
den Kickstarter mehrmals
durchtreten, um das Öl in der
Zylinderlaufbuchse zu vertei-
len.
3. Die Antriebskette lösen,
gründlich reinigen und dann
schmieren. Die Kette wieder
montieren oder in einem am
Rahmen befestigten Plastik-
beutel aufbewahren.
4. Alle Seilzüge ölen.
5. Das Fahrzeug ganz aufbok-
ken, um beide Räder vom Bo-
den abzuheben.
6. Eine Plastiktüte über die
Schalldämpferöffnung stül-
pen, um Eindringen von
Feuchtigkeit zu verhindern.
7. Bei Lagerung in extrem feuch-
ter oder salzhaltiger Luft auf
alle Metalloberflächen einen
dünnen Ölfilm auftragen. Je-
doch niemals Gummiteile oder
den Sitzbankbezug einölen.
HINWEIS:
Anfallende Reparaturen vor der Still-
legung ausführen. RANGEMENT
Si l’on remise la machine pour 60 jours
ou plus, il faut prendre des mesures de
conservation pour éviter sa détérioration.
Après un nettoyage soigné, préparer la
machine de la manière suivante:
1. Vider le réservoir, les conduites
d’essence et la cuve du carbura-
teur.
2. Déposer la bougie, verser une
cuillère à soupe d’huile moteur
SAE 10W-30 dans le trou de bou-
gie, et la remettre en place.
Coupe-circuit à la position arrêt,
donner plusieurs coups de kick
pour enduire le cylindre d’huile.
3. Déposer la chaîne, la nettoyer soi-
gneusement au dissolvant et
lubrifier. Remonter la chaîne ou
la ranger dans un sachet plastique
fermé fixé au cadre.
4. Lubrifier tous les câbles de com-
mande.
5. Mettre le cadre sur plots pour
soulever les roues du sol.
6. Fixer un sachet plastique sur la
sortie du pot d’échappement pour
éviter l’introduction d’humidité.
7. Si la machine est placée dans une
atmosphère humide ou marine,
enduire toutes les surfaces métal-
liques nues d’une fine couche
d’huile. Ne pas appliquer d’huile
sur les parties en caoutchouc ou
sur la selle.
N.B.:
Avant de ranger la machine, effectuer
toutes les réparations nécessaires.IMMAGAZZINAGGIO
Se il veicolo va immagazzinato 60 giorni
o oltre, è necessario prendere alcune
misure precauzionali per evitarne il dete-
rioramento. Dopo aver pulito accurata-
mente il veicolo, prepararlo nel modo
seguente:
1. Scaricare il serbatoio del carbu-
rante, le linee carburante e la
vaschetta del galleggiante del car-
buratore.
2. Rimuovere la candela, versare un
cucchiaio di olio motore SAE
10W-30 nel foro della candela e
reinserire la candela. Con l’inter-
ruttore di arresto del motore pre-
muto, agire sulla pedivella di
avviamento più volte in modo da
ricoprire d’olio le pareti dei cilin-
dri.
3. Rimuovere la catena di trasmis-
sione, pulirla accuratamente con
un solvente e lubrificarla. Rimon-
tarla o conservarla in un sacchetto
di plastica legato al telaio.
4. Lubrificare tutti i cavi dei
comandi.
5. Bloccare in alto il telaio in modo
da sollevare le ruote dal terreno.
6. Legare un sacchetto di plastica
sul tubo di scarico per impedire la
penetrazione dell’umidità.
7. Se il veicolo viene immagazzi-
nato in un ambiente umido o con
aria salmastra, ricoprire tutte le
superfici in metallo esposte con
un leggero strato d’olio. Non
applicare olio sui componenti in
gomma o al rivestimento della
sella.
NOTA:
Effettuare tutti gli eventuali interventi di
riparazione necessari prima di immagaz-
zinare il veicolo.
1 - 20

SPEC

2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: YZ250FS (USA)
YZ250F (EUROPE)
YZ250F(S) (CDN, AUS, NZ, ZA)
Model code number: 5XC1 (USA)
5XC2 (EUROPE)
5XC4 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,165 mm (85.2 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 995 mm (39.2 in)
Wheelbase 1,475 mm (58.1 in)
Minimum ground clearance 382 mm (15.0 in)
Dry weight:
Without oil and fuel 93.5 kg (206 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
3

(8.76 Imp oz, 8.42 US oz)
Bore

×

stroke 77.0
×
53.6 mm (3.03
×
2.11 in)
Compression ratio 12.5 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
At 5 ˚C (40 ˚F) or higher
Å
Yamalube 4 (20W-40) or SAE 20W-40 type
SG motor oil
(Non-Friction modified)
At 15 ˚C (60 ˚F) or lower
ı

Yamalube 4 (10W-30) or SAE 10W-30 type
SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
(Except for USA and CDN)
API “SG” or higher grade
-20
-4-10
140
3010
5020
6830
8640 50
104
122°CTemp.
°F
10W-30
10W-40
20W-40
20W-50
15W-40

2

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

SPEC

2 - 3
GENERAL SPECIFICATIONS
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto

SPEC

2 - 4
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 77.00 ~ 77.01 mm
(3.0315 ~ 3.0319 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft outside diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)----
Shaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)0.08 mm
(0.003 in)
Cam dimensions
Intake“A”30.296 ~ 30.346 mm
(1.1923 ~ 1.1947 in)30.196 mm
(1.1888 in)
“B”22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)22.35 mm
(0.8799 in)
Exhaust“A”30.399 ~ 30.499 mm
(1.1968 ~ 1.2007 in)30.299 mm
(1.1929 in)
“B”22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)22.35 mm
(0.8799 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B

SPEC

2 - 5
MAINTENANCE SPECIFICATIONS
Timing chain:
Timing chain type/No. of links 92RH2010-114M/114 ----
Timing chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)----
EX 0.17 ~ 0.22 mm
(0.0067 ~ 0.0087 in)----
Valve dimensions:
“A” head diameter IN 22.9 ~ 23.1 mm
(0.9016 ~ 0.9094 in)----
EX 24.4 ~ 24.6 mm
(0.9606 ~ 0.9685 in)----
“B” face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089 in) ----
“C” seat width IN0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
“D” margin thickness IN 0.8 mm (0.0315 in) ----
EX 0.7 mm (0.0276 in) ----
Stem outside diameter IN3.975 ~ 3.990 mm
(0.1565 ~ 0.1571 in)3.945 mm
(0.1553 in)
EX 4.460 ~ 4.475 mm
(0.1756 ~ 0.1762 in)4.430 mm
(0.1744 in)
Guide inside diameter IN 4.000 ~ 4.012 mm
(0.1575 ~ 0.1580 in)4.050 mm
(0.1594 in)
EX 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)4.550 mm
(0.1791 in)
Stem-to-guide clearance IN0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)0.08 mm
(0.003 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)0.10 mm
(0.004 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA

SPEC

2 - 6
MAINTENANCE SPECIFICATIONS
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 37.81 mm (1.49 in) 36.81 mm
(1.45 in)
EX 37.54 mm (1.48 in) 36.54 mm
(1.44 in)
Set length (valve closed) IN 29.13 mm (1.15 in) ----
EX 29.30 mm (1.15 in) ----
Compressed force
(installed) IN 99 ~ 114 N at 29.13 mm
(9.9 ~ 11.4 kg at 29.13 mm,
22.27 ~ 25.57 lb at 1.15 in)----
EX 126 ~ 144 N at 29.30 mm
(12.6 ~ 14.4 kg at 29.30 mm,
28.44 ~ 32.41 lb at 1.15 in)----
Tilt limit IN ---- 2.5˚/ 1.7 mm
(2.5˚/0.067 in)
EX ---- 2.5˚/1.6 mm
(2.5˚/0.063 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”76.955 ~ 76.970 mm
(3.0297 ~ 3.0303 in)----
Measuring point “H”8 mm (0.31 in) ----
Piston off-set 0.5 mm (0.020 in)/IN-side ----Item Standard Limit
*
H
D

SPEC

2 - 7
MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)16.043 mm
(0.6316 in)
Piston pin outside diameter15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B

×

T) 0.90
×
2.75 mm (0.04
×
0.11 in) ----
End gap (installed) 0.15 ~ 0.25 mm
(0.006 ~ 0.010 in)0.50 mm
(0.020 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B

×

T) 0.80
×
2.75 mm (0.03
×
0.11 in) ----
End gap (installed) 0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)0.80 mm
(0.031 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring:
Dimensions (B

×

T) 1.50
×
2.25 mm (0.06
×
0.09 in) ----
End gap (installed) 0.10 ~ 0.40 mm
(0.004 ~ 0.016 in)----
Crankshaft:
Crank width “A”55.95 ~ 56.00 mm
(2.203 ~ 2.205 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F”0.4 ~ 1.0 mm
(0.02 ~ 0.04 in)2.0 mm
(0.08 in) Item Standard Limit
T
B
B
T
B
T