2004 YAMAHA YZ250LC lock

EC085002
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 7are designed as
thumb tabs to indicate the chapter’s number and
content.
1
General information
2Specifications
3Regular inspection and adjustments
4Engine
5Chassis
6Electrical
7Tuning
Illustrated symbols 8to rare used to identify
the specifications appearing in the text.
8
With engine mounted
9Special tool
0Filling fluid
qLubricant
wTightening
eSpecified value, Service limit
rResistance (Ω), Voltage (V), Electric current (A)
Illustrated symbols tto oin the exploded dia-
grams indicate grade of lubricant and location of
lubrication point.
t
Apply transmission oil
yApply engine mixing oil
uApply molybdenum disulfide oil
iApply lightweight lithium-soap base grease
oApply molybdenum disulfide grease
Illustrated symbols pto ain the exploded dia-
grams indicate where to apply a locking agent
and where to install new parts.
p
Apply locking agent (LOCTITER)
aUse new one
GEN
INFO
12
3
5
74
6
8
90
qw
er
tyu
io
pa
SPEC
INSP
ADJENG
CHASELEC
TUN
5XF-9-30-0 4/4/03 5:41 PM Page 14

1-4
IMPORTANT INFORMATION
GEN
INFO
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing (s) 1and oil seal (s) 2
with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil seal(s),
apply a light coating of light-weight lithium
base grease to the seal lip(s). Oil the bear-
ings liberally when installing.
cC
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
5XF-9-30-1 4/22/03 8:54 AM Page 8

1-15
MISE EN MARCHE ET RODAGE
STARTEN UND EINFAHREN
AVVIAMENTO E RODAGGIO
GEN
INFO
fF
9Après le rodage ou avant chaque
course, il faut vérifier toutes les
fixations et serrages comme indiqué
dans “POINTS DE VERIFICA-
TION DE COUPLE DE SERRA-
GE”.
Serrer toutes ces fixations comme
requis.
9Après avoir remplacé les pièces sui-
vantes, un nouveau rodage est
nécessaire.
CYLINDRE ET VILEBREQUIN:
Une heure environ de rodage est
nécessaire.
PISTON, SEGMENT ET
PIGNONS:
Ces pièces exigent 30 minutes envi-
ron de rodage à miaccélération ou
moins. Surveiller attentivement
l’état du moteur pendant la
marche.
dD
9Nach dem Einfahren und vor
jedem Rennen müssen Sie gemäß
„ANZUGSMOMENTE-PRÜFPUNK-
TE“ die gesamte Maschine auf
lockere Befestigungselemente
überprüfen. Alle Befestigungsele-
mente wie erforderlich festziehen.
9Wenn eines der folgenden Teile
erneuert wurde, dann muß die
Maschine wiederum eingefahren
werden.
ZYLINDER UND KURBELWELLE:
Etwa eine Stunde Einfahrzeit ist
erforderlich.
KOLBEN, KOLBENRING UND
ZAHNRÄDER:
Diese Teile erfordern eine Einfahr-
zeit von etwa 30 Minuten bei Halb-
gas oder weniger. Bei laufendem
Motor sorgfältig die Betriebsbe-
dingungen kontrollieren.
iI
9Dopo il rodaggio o prima di ciascu-
na gara, si deve controllare tutto il
veicolo per eventuali accessori e
dispositivi di fissaggio allentati
come da “PUNTI DI CONTROL-
LO DELLA COPPIA”.
Serrare tutti i dispositivi di fissag-
gio che lo richiedono.
9Quando sono state sostituite alcune
delle parti che seguono, devono
essere rodate.
CILINDRO E ALBERO A GOMI-
TI:
È necessaria circa un’ora di funzio-
namento di rodaggio.
PISTONE, FASCIA ELASTICA E
INGRANAGGI:
Queste parti richiedono circa 30
minuti di funzionamento di rodag-
gio con la valvola a farfalla aperta a
metà o meno. Osservare attenta-
mente le condizioni del motore
durante il funzionamento.
5XF-9-30-1 4/22/03 8:54 AM Page 35

1-17
CLEANING AND STORAGE
GEN
INFO
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will enhance
its appearance, maintain good overall perfor-
mance, and extend the life of many components.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
cC
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been hosed
off, wash all surfaces with warm water and a
mild detergent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel and
lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery clean-
er to keep the cover pliable and glossy.
8. Automotive wax may be applied to all paint-
ed or chromed surfaces. Avoid combination
cleaner-waxes, as they may contain abra-
sives.
9. After completing the above, start the engine
and allow it to idle for several minutes.
5XF-9-30-1 4/22/03 8:54 AM Page 40

1-18
CLEANING AND STORAGE
GEN
INFO
EC1B2001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be taken
to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as fol-
lows:
1. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed metal
surfaces with a film of light oil. Do not apply
oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the machine
is stored.
5XF-9-30-1 4/22/03 8:54 AM Page 42

2-9
MAINTENANCE SPECIFICATIONSSPEC
17
14
105
20
22
40
21
0.7
7.2
7.2
11
5.1
0.7
2.9
2.9
2.9
6.5
1.4
4.3
4.3
3.6
2.9
22
22
17
2.2
13
4.3
75
17
8.7
10
19
7.2M 8 × 1.25
M 8 × 1.25
M24 × 1.0
M 8 × 1.25
M28 × 1.0
M51 × 1.5
M30 × 1.0
M12 × 1.25
M 5 × 0.8
M 6 × 1.0
M 6 × 1.0
M 8 × 1.25
M 6 × 1.0
M 4 × 0.7
M 6 × 1.0
M 6 × 1.0
M 5 × 0.8
M 6 × 1.0
M 4 × 0.7
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M10 × 1.25
M10 × 1.25
M 8 × 1.25
M10 × 1.0
M10 × 1.0
M 8 × 1.25
M16 × 1.5
M 8 × 1.25
M 6 × 1.0
M 6 × 1.0
M 8 × 1.25
M 6 × 1.0 Handle crown and outer tube
Under bracket and outer tube
Handle crown and steering shaft
Handlebar holder (upper)
Steering ring nut
Front fork and cap bolt
Front fork and base valve
Cap bolt and damper rod (front fork)
Bleed screw (front fork) and cap bolt
Front fork and protector
Front fork and brake hose holder
Front fork and hose cover
Front fork and hose cover
Throttle cable cap
Grip cap upper and lower
Clutch lever (nut)
Clutch lever holder
Front brake master cylinder and bracket
Front brake master cylinder cap
Brake lever mounting (bolt)
Brake lever mounting (nut)
Brake lever position locknut
Cable guide (front brake hose) and under bracket
Front brake hose union bolt (master cylinder)
Front brake hose union bolt (caliper)
Front brake caliper and front fork
Brake caliper (front and rear) and pad pin plug
Brake caliper (front and rear) and pad pin
Brake caliper (front and rear) and bleed screw
Front wheel axle and nut
Front wheel axle holder
Front brake disc and wheel hub
Rear brake disc and wheel hub
Brake pedal mounting
Rear brake master cylinder and framePart to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
4
4
1
4
1
2
2
2
2
6
2
1
1
2
2
1
2
2
2
1
1
1
1
1
1
2
2
2
2
1
4
6
6
1
223
20
145
28
30
55
29
1
10
10
16
7
1
4
4
4
9
2
6
6
5
4
30
30
23
3
18
6
105
23
12
14
26
102.3
2.0
14.5
2.8
3.0
5.5
2.9
0.1
1.0
1.0
1.6
0.7
0.1
0.4
0.4
0.4
0.9
0.2
0.6
0.6
0.5
0.4
3.0
3.0
2.3
0.3
1.8
0.6
10.5
2.3
1.2
1.4
2.6
1.0
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the ring nut wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
Refer to NOTE.
5XF-9-30-2 5/15/03 3:54 PM Page 10

2-10
MAINTENANCE SPECIFICATIONSSPEC
M 4 × 0.7
M10 × 1.25
M10 × 1.25
M20 × 1.5
M 8 × 1.25
–
M 6 × 1.0
M 6 × 1.0
M 8 × 1.25
M 8 × 1.25
M10 × 1.25
M10 × 1.25
M10 × 1.25
M16 × 1.5
M14 × 1.5
M14 × 1.5
M14 × 1.5
M10 × 1.25
M10 × 1.25
M 8 × 1.25
M 8 × 1.25
M 5 ×0.8
M 4 ×0.7
M 8 × 1.25
M 6 × 1.0
M 5 ×0.8
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 8 × 1.25
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0
M 6 × 1.0 Rear brake master cylinder cap
Rear brake hose union bolt (caliper)
Rear brake hose union bolt (master cylinder)
Rear wheel axle and nut
Driven sprocket and wheel hub
Nipple (spoke)
Disc cover and rear brake caliper
Protector and rear brake caliper
Chain puller adjust bolt and locknut
Engine mounting:
Engine bracket and frame
Engine and frame (front)
Engine and frame (upper)
Engine and frame (lower)
Pivot shaft and nut
Relay arm and swingarm
Relay arm and connecting rod
Connecting rod and frame
Rear shock absorber and frame
Rear shock absorber and relay arm
Rear frame and frame (upper)
Rear frame and frame (lower)
Swingarm and brake hose holder
Swingarm and patch
Drive chain tensioner mounting
Chain support and swingarm
Seal guard and swingarm
Fuel tank mounting
Fuel tank and fuel cock
Fuel tank and seat set bracket
Fuel tank and hooking screw (fitting band)
Fuel tank and fuel tank bracket
Seat mounting
Side cover mounting
Air scoop mounting
Front fender mounting
Rear fender mounting (front)
Rear fender mounting (rear)
Number platePart to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
2
1
1
1
6
72
2
2
2
2
1
1
1
1
1
1
1
1
1
1
2
4
4
2
3
4
2
2
1
1
4
2
2
6
4
2
2
12
30
30
125
42
3
7
7
16
34
64
64
64
85
80
80
80
56
53
32
29
1
2
19
7
6
10
7
7
7
7
19
7
4
7
7
12
70.2
3.0
3.0
12.5
4.2
0.3
0.7
0.7
1.6
3.4
6.4
6.4
6.4
8.5
8.0
8.0
8.0
5.6
5.3
3.2
2.9
0.1
0.2
1.9
0.7
0.6
1.0
0.7
0.7
0.7
0.7
1.9
0.7
0.4
0.7
0.7
1.2
0.71.4
22
22
90
30
2.2
5.1
5.1
11
24
46
46
46
61
58
58
58
40
38
23
21
0.7
1.4
13
5.1
4.3
7.2
5.1
5.1
5.1
5.1
13
5.1
2.9
5.1
5.1
8.7
5.1
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
5XF-9-30-2 5/15/03 3:54 PM Page 11

3-3
WARTUNGSINTERVALLE
INSP
ADJ
NachNach Nach
BenennungNach demjedemjedem jedem Wie
BemerunenEinfahren
Rennendritten fünftenErforderlich
Rennen Rennen
RÄDER, REIFEN
Reifendruck, Felgenschlag,
Reifenverschleiß und Speichen
66
auf Lockerung prüfen
Ketternrad-Befestigungsschraube
66nachziehen
Lager prüfen
6
Lager erneuern6
Schmieren6
GASDREHGRIFF, GASSEIL
Seilzugführung und Anschlüsse
66prüfen
Schmieren
66
Lithium-Fett
Yamaha Seilzug-
Schmiermittel oder
Motoröl SAE 10W-30
5XF-9-30-3A 4/21/03 2:09 PM Page 10