2004 YAMAHA YZ250F key

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:

EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters;
“General information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and
“Tuning”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

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

4 - 78
ENGCDI MAGNETO
EC4L0000
CDI MAGNETO
Extent of removal:1 CDI magneto removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Bolt (left radiator) Refer to “RADIATOR” section.
Disconnect the CDI magneto lead.
Shift pedal Refer to “KICK SHAFT AND SHIFT
SHAFT” section.
1 Left crankcase cover 1
2 Nut (rotor) 1 Use special tool.
Refer to “REMOVAL POINTS”.
3 Rotor 1
4 Stator 1
5Woodruff key
1
1

4 - 79
ENGCDI MAGNETO
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:
Nut (rotor) 1
Washer 2
Use the rotor holding tool 3.
2. Remove:
Rotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YM-1189/90890-01189
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
Rotor inner surface a
Stator outer surface b
Damage → Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magneto and/
or stator.
EC4L4200
Woodruff key
1. Inspect:
Woodruff key 1
Damage → Replace.

4 - 80
ENGCDI MAGNETO
EC4L5000
ASSEMBLY AND INSTALLATION
CDI magneto
1. Install:
Stator 1
Screw (stator) 2
NOTE:
Apply the sealant on the grommet of the CDI
magneto lead.
Tighten the screws using the T30 bit.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portions of the crankshaft
and rotor.
When installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.
When installing the rotor, align the keyway c
of the rotor with the woodruff key.
3. Install:
Washer 1
Nut (rotor) 2
Use the rotor holding tool 3.
Rotor holding tool:
YU-1235/90890-01235
T R..56 Nm (5.6 m · kg, 40 ft · lb)