2004 YAMAHA YZ250F ABS

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CHAS
DIRECTION
LENKKOPF
STERZO
Lager und Laufring
1. Die Lager und Laufringe in Lö-
sungsmittel waschen.
2. Kontrollieren:
Lager 1
Laufring
Pitting/Beschädigung →
Lager und Laufringe im Satz
erneuern.
Die Lager in die Laufringe
einbauen. Die Lager mit
dem Finger drehen. Bei
Schwergängigkeit die Lager
und Laufringe im Satz
erneuern.
ZUSAMMENBAU UND MONTAGE
Untere Gabelbrücke
1. Montieren:
Unteres Lager 1
HINWEIS:
Lithiumfett auf die Staubschutz-
ringlippe und am inneren Lager-Um-
fang auftragen.
2. Montieren:
Laufring
Oberes Lager 1
Lagerschutzkappe 2
HINWEIS:
Lithiumfett auf Lager und Lager-
schutzkappen-Lippe auftragen.
3. Montieren:
Untere Gabelbrücke 1
HINWEIS:
Lithiumfett auf das Lager und den
Abschnitt a und den Gewindeteil der
Lenkwelle auftragen. Roulement et cage à billes
1. Nettoyer les roulements et les
cages à billes dans du solvant.
2. Contrôler:
Roulement 1
Cage à billes
Piqûres/endommagements →
Remplacer les roulements et les
cages à billes.
Monter les billes dans les cages
à billes. Faire tourner les billes
à la main. Si les billes accro-
chent ou ne tournent pas en
douceur dans les cages à billes,
remplacer le jeu complet de
billes et de cages à billes.
REMONTAGE ET MONTAGE
Té inférieur
1. Monter:
Roulement inférieur 1
N.B.:
Appliquer de la graisse à base de savon
au lithium sur la lèvre du joint antipous-
sière et sur la circonférence interne du
roulement.
2. Monter:
Cage à billes
Roulement supérieur 1
Couvercle de cage à billes 2
N.B.:
Appliquer de la graisse de base de savon
au lithium sur le roulement et la lèvre de
couvercle de cage à billes.
3. Monter:
Té inférieur 1
N.B.:
Appliquer de la graisse à base de savon
au lithium sur le roulement et sur la par-
tie a et le filetage de la colonne de
direction.Cuscinetto e pista
1. Lavare i cuscinetti e le piste con
un solvente.
2. Ispezionare:
Cuscinetto 1
Pista
Vaiolature/danno → Sostituire
in blocco i cuscinetti e le corse.
Installare il cuscinetto nelle
corse. Provare manualmente la
rotazione del cuscinetto. Se il
cuscinetto si blocca o non si
muove agevolmente nelle
corse, sostituire in blocco il
cuscinetto e le corse.
MONTAGGIO ED INSTALLA-
ZIONE
Staffa inferiore
1. Installare:
Cuscinetto inferiore 1
NOTA:
Applicare grasso a base di sapone di litio
sul labbro del parapolvere e sulla circon-
ferenza interna del cuscinetto.
2. Installare:
Pista
Cuscinetto superiore 1
Coperchio pista 2
NOTA:
Applicare grasso a base di sapone di litio
sul cuscinetto e al labbro del coperchio
della corsa.
3. Installare:
Staffa inferiore 1
NOTA:
Applicare grasso a base di sapone di litio
sul cuscinetto e sulla zona a e sulla
filettatura del cannotto di sterzo.

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CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNINGSupport the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear brake caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

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CHASSWINGARM
8. Install:
Bolt (connecting rod) 1
Washer 2
Nut (connecting rod) 3
NOTE:
Apply the molybdenum disulfide grease on
the bolt.
Do not tighten the nut yet.
9. Install:
Bolt (rear shock absorber-relay arm) 1
Nut (rear shock absorber-relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..53 Nm (5.3 m · kg, 38 ft · lb)
10. Tighten:
Nut (connecting rod) 1
T R..80 Nm (8.0 m · kg, 58 ft · lb)
11. Tighten:
Nut (relay arm) 1
T R..80 Nm (8.0 m · kg, 58 ft · lb)
12. Install:
Cap 1
NOTE:
Install the right cap with its mark a facing for-
ward.

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CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
Seat and fitting band Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
1 Clamp (air filter joint) 1 Only loosening.
2 Rear frame 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Lower spring guide 1
1
2

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CHAS
AMORTISSEUR ARRIERE
FEDERBEIN
AMMORTIZZATORE POSTERIORE
FEDERBEIN
Demontage-Arbeiten:1 Federbein demontieren2 Federbein zerlegen
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
Vorbereitung für den AusbauFEDERBEIN DEMONTIEREN
Das Motorrad am Motor aufbocken.
WARNUNGDas Motorrad gegen Umfallen sichern.
Sitz und Paßband Siehe Abschnitt “SITZBANK, KRAFTSTOFFTANK
UND SEITENABDECKUNGEN” in KAPITEL 4.
Schalldämpfer Siehe Abschnitt “KRÜMMER UND SCHALLDÄMP-
FER” in KAPITEL 4.
1 Schlauchschelle (Luftfilteranschluß) 1 Nur lockern.
2 Rahmenhinterteil 1
3 Schraube (Umlenkhebel, Federbein) 1 Die Schwinge festhalten.
4 Schraube (Federbein, Rahmen) 1
5 Federbein 1
6 Sicherungsmutter 1 Nur lockern.
7 Einstellmutter 1 Nur lockern.
8 Unterer Federsitz 1
1
2
AMORTISSEUR ARRIERE
Organisation de la dépose:1 Dépose de l’amortisseur arrière2 Démontage de l’amortisseur arrière
Organisation de la dépose Ordre Nom de pièce QtéRemarques
Préparation pour la déposeDEPOSE DE L’AMORTISSEUR ARRIERE
Maintenir la machine en plaçant un support
approprié sous le moteur.
AVERTISSEMENT
Bien soutenir la machine afin qu’elle ne risque
pas de se renverser.
Selle et ruban d’ajustement Se référer à la section “SELLE, RESERVOIR DE CAR-
BURANT ET CACHES LATERAUX” du CHAPITRE 4.
Silencieux Se référer à la section “TUYAU D’ECHAPPEMENT ET
SILENCIEUX” du CHAPITRE 4.
1 Bride (raccord de filtre à air) 1 Desserrer uniquement.
2 Cadre arrière 1
3 Boulon (amortisseur arrière-bras de relais) 1 Tenir le bras oscillant.
4 Boulon (amortisseur arrière-cadre) 1
5 Amortisseur arrière 1
6 Contre-écrou 1 Desserrer uniquement.
7 Dispositif de réglage 1 Desserrer uniquement.
8 Guide de ressort inférieur 1
1
2
AMMORTIZZATORE POSTERIORE
Portata dello smontaggio:1 Rimozione ammortizzatore posteriore2 Smontaggio ammortizzatore posteriore
Portata dello smontaggio Ordine Denominazione QuantitàOsservazioni
Preparazione per la rimozioneRIMOZIONE AMMORTIZZATORE
POSTERIORE
Mantenere il veicolo posizionando un supporto
idoneo sotto al motore.
AVVERTENZASostenere saldamente il veicolo in modo che non ci siail rischio che si rovesci.
Sella e fascia di regolazione Fare riferimento al paragrafo “SELLA, SERBATOIO
CARBURANTE E CARENATURA LATERALE” nel
CAPITOLO 4.
Silenziatore Fare riferimento al paragrafo “TUBO DI SCARICO E
SILENZIATORE” nel CAPITOLO 4.
1 Morsetto (giunto filtro dell’aria) 1 Allentare soltanto.
2 Telaio posteriore 1
3 Bullone (ammortizzatore posteriore - leva di
rinvio)1 Sostenere il forcellone oscillante.
4 Bullone (ammortizzatore posteriore - telaio) 1
5 Ammortizzatore posteriore 1
6 Controdado 1 Allentare soltanto.
7 Registro 1 Allentare soltanto.
8 Guida molla inferiore 1
1
2

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CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
9 Upper spring guide 1
10 Spring (rear shock absorber) 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
2

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CHAS
HANDLING NOTE
WARNING
This rear shock absorber is provided with a
separate type tank filled with high-pressure
nitrogen gas. To prevent the danger of
explosion, read and understand the follow-
ing information before handling the shock
absorber.
The manufacturer can not be held respon-
sible for property damage or personal
injury that may result from improper han-
dling.
1. Never tamper or attempt to disassem-
ble the cylinder or the tank.
2. Never throw the rear shock absorber
into an open flame or other high heat.
The rear shock absorber may explode
as a result of nitrogen gas expansion
and/or damage to the hose.
3. Be careful not to damage any part of
the gas tank. A damaged gas tank will
impair the damping performance or
cause a malfunction.
4. Take care not to scratch the contact
surface of the piston rod with the cylin-
der; or oil could leak out.
5. Never attempt to remove the plug at
the bottom of the nitrogen gas tank. It
is very dangerous to remove the plug.
6. When scrapping the rear shock
absorber, follow the instructions on
disposal.
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve 1.
Wear eye protection to prevent eye damage
from escaping gas and/or metal chips.
WARNING
To dispose of a damaged or worn-out rear
shock absorber, take the unit to your
Yamaha dealer for this disposal procedure.
REAR SHOCK ABSORBER

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CHAS
EC583000
REMOVAL POINTS
EC583320
Bearing
1. Remove:
Stopper ring (upper bearing) 1
NOTE:
Press in the bearing while pressing its outer
race and remove the stopper ring.
2. Remove:
Upper bearing 1
NOTE:
Remove the bearing by pressing its outer race.
3. Remove:
Lower bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC584000
INSPECTION
Rear shock absorber
1. Inspect:
Damper rod 1
Bends/damage → Replace rear shock
absorber assembly.
Shock absorber 2
Oil leaks → Replace rear shock
absorber assembly.
Gas leaks → Replace rear shock
absorber assembly.
Spring 3
Damage → Replace spring.
Fatigue → Replace spring.
Move spring up and down.
Spring guide 4
Wear/damage → Replace spring guide.
Bearing 5
Free play exists/unsmooth revolution/
rust → Replace.
REAR SHOCK ABSORBER