2004 YAMAHA YZ250F coolant

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or
oil.
7. Install:
Radiator cap
Start the engine and warm it up for a
several minutes.
8. Check:
Coolant level
Coolant level low → Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap) 1
Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or
replace.

3 - 8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
Radiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Replace.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
110 kPa (1.1 kg/cm2, 15.6 psi)
COOLING SYSTEM INSPECTION
1. Inspect:
Coolant level
2. Attach:
Radiator cap tester 1 and adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Radiator cap tester adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Repair.
Radiator 1
Radiator hose joint 2
Coolant leakage → Repair or replace.
Radiator hose 3
Swelling → Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side
using the adjuster 2.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknuts 1.
Adjust the free play by changing their
tightening position.
Tighten the locknuts.

3 - 18
INSP
ADJ
ENGINE IDLING SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it
up.
2. Adjust:
Engine idling speed
Adjustment steps:
Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.
Turn the throttle stop screw 1 until the
specified engine idling speed.
NOTE:
Using a digital engine tachometer for idle
speed adjustment, detect the engine idling
speed by bringing the sensing element c of
the engine tachometer close to the ignition
coil 2.
To increase idle speed → Turn the throt-
tle stop screw 1 in a.
To decrease idle speed → Turn the throt-
tle stop screw 1 out b.
Engine idling speed:
1,900 ~ 2,100 r/min
c2
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT
NOTE:
The valve clearance should be adjusted
when the engine is cool to the touch.
The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove:
Seat
Fuel tank
Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section in the CHAP-
TER 4.
2. Drain:
Coolant
Refer to “COOLANT REPLACEMENT”
section.
ENGINE IDLING SPEED ADJUSTMENT/
VALVE CLEARANCE INSPECTION AND ADJUSTMENT

4 - 5
ENG

RADIATOR
EC450001
RADIATOR
Extent of removal:
1
Radiator removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Radiator guard 2
2 Radiator hose clamp 8 Only loosening.
3 Radiator hose 1 1
4 Left radiator 1
5 Radiator hose 3 1
6 Right radiator 1
7 Radiator hose 2 1
8 Radiator hose 4 1
9 Radiator breather hose 1
10 Radiator pipe 1
1

4 - 56
ENG
OIL FILTER ELEMENT, WATER PUMP AND RIGHT
CRANKCASE COVER
OIL FILTER ELEMENT, WATER PUMP AND RIGHT
CRANKCASE COVER
Extent of removal:1 Oil filter element removal2 Water pump removal
3 Right crankcase cover removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER ELEMENT, WATER
PUMP AND RIGHT CRANK-
CASE COVER REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Radiator hose 3 Disconnect at water pump side.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
Brake pedal Refer to “ENGINE REMOVAL” section.
Right engine guard
1 Oil filter element cover 1
2 Oil filter element 1
13

4 - 58
ENG
OIL FILTER ELEMENT, WATER PUMP AND RIGHT
CRANKCASE COVER
REMOVAL POINTS
Impeller shaft
1. Remove:
Impeller 1
Washer 2
Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discolora-
tion of coolant, or milky transmission oil.
1. Remove:
Bearing 1
2. Remove:
Oil seal 1
INSPECTION
Oil delivery pipe
1. Inspect:
Oil delivery pipe 1
Bend/damage → Replace.
Clogged → Blow.