2005 YAMAHA YZ250F radiator

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ..................................4-1
EXHAUST PIPE AND SILENCER .............4-3
RADIATOR ................................................4-5
CARBURETOR ..........................................4-8
CAMSHAFTS ...........................................4-21
CYLINDER HEAD ....................................4-30
VALVES AND VALVE SPRINGS ............4-33
CYLINDER AND PISTON ........................4-42
CLUTCH ...................................................4-49
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER .......4-56
BALANCER .............................................4-63
OIL PUMP ................................................4-66
KICK SHAFT AND SHIFT SHAFT ..........4-71
CDI MAGNETO ........................................4-78
ENGINE REMOVAL .................................4-82
CRANKCASE AND CRANKSHAFT ........4-87
TRANSMISSION, SHIFT CAM
AND SHIFT FORK ...................................4-96
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT BRAKE AND REAR BRAKE .....5-10
FRONT FORK ..........................................5-26
HANDLEBAR ...........................................5-42
STEERING ...............................................5-48
SWINGARM .............................................5-53
REAR SHOCK ABSORBER ....................5-61

KAPITEL 4
MOTOR
SITZBANK,
KRAFTSTOFFTANK UND
SEITENABDECKUNGEN............ 4-1
AUSPUFFKRÜMMER
UND SCHALLDÄMPFER............ 4-3
KÜHLER...................................... 4-5
VERGASER................................. 4-8
NOCKENWELLEN.................... 4-21
ZYLINDERKOPF....................... 4-30
VENTILE
UND VENTILFEDERN............... 4-33
ZYLINDER UND KOLBEN........ 4-42
KUPPLUNG............................... 4-49
ÖLFILTER, WASSERPUMPE
UND KURBELGEHÄUSEDECKEL
RECHTS.................................... 4-56
AUSGLEICHSWELLE............... 4-63
ÖLPUMPE................................. 4-66
KICKHEBELWELLE
UND SCHALTWELLE............... 4-71
LICHTMASCHINE..................... 4-78
MOTOR DEMONTIEREN.......... 4-82
KURBELGEHÄUSE
UND KURBELWELLE............... 4-87
GETRIEBE, SCHALTWALZE
UND SCHALTGABELN............ 4-96
KAPITEL 5
FAHRWERK
VORDER- UND HINTERRAD..... 5-1
VORDER- UND
HINTERRADBREMSEN............ 5-10
TELESKOPGABEL................... 5-26
LENKER.................................... 5-42
LENKUNG................................. 5-48
SCHWINGE............................... 5-53
FEDERBEIN.............................. 5-61
CHAPITRE 4
MOTEUR
SELLE, RESERVOIR
DE CARBURANT
ET CACHES LATERAUX............. 4-1
TUBE D’ECHAPPEMENT
ET SILENCIEUX............................ 4-3
RADIATEUR................................... 4-5
CARBURATEUR............................ 4-8
ARBRES A CAMES...................... 4-21
CULASSE....................................... 4-30
SOUPAPES ET RESSORTS
DE SOUPAPES.............................. 4-33
CYLINDRE ET PISTON.............. 4-42
EMBRAYAGE............................... 4-49
ELEMENT DE FILTRE
A HUILE, POMPE A EAU
ET COUVERCLE DE CARTER
DROIT............................................ 4-56
BALANCIER................................. 4-63
POMPE A HUILE......................... 4-66
ARBRE DE KICK ET AXE
DE SELECTEUR.......................... 4-71
VOLANT MAGNETIQUE
CDI.................................................. 4-78
DEPOSE DU MOTEUR............... 4-82
CARTER MOTEUR
ET VILEBREQUIN...................... 4-87
BOITE DE VITESSES,
TAMBOUR ET FOURCHETTES
DE SELECTION........................... 4-96
CHAPITRE 5
CHASSIS
ROUE AVANT ET ROUE
ARRIERE......................................... 5-1
FREIN AVANT ET FREIN
ARRIERE....................................... 5-10
FOURCHE..................................... 5-26
GUIDON......................................... 5-42
DIRECTION.................................. 5-48
BRAS OSCILLANT...................... 5-53
AMORTISSEUR ARRIERE........ 5-61
CAPITOLO 4
MOTORE
SELLA, SERBATOIO
CARBURANTE
E FIANCHETTI.............................. 4-1
TUBO DI SCARICO
E SILENZIATORE......................... 4-3
RADIATORE................................... 4-5
CARBURATORE............................ 4-8
ALBERI A CAMME..................... 4-21
TESTATA....................................... 4-30
VALVOLE E MOLLE
VALVOLE...................................... 4-33
CILINDRO E PISTONE............... 4-42
FRIZIONE...................................... 4-49
ELEMENTO FILTRO OLIO,
POMPA DELL’ACQUA
E COPERCHIO CARTER
DESTRO......................................... 4-56
EQUILIBRATORE....................... 4-63
POMPA DELL’OLIO................... 4-66
ALBERO PEDALE E ALBERO
DEL CAMBIO............................... 4-71
MAGNETE CDI............................ 4-78
RIMOZIONE DEL MOTORE..... 4-82
CARTER E ALBERO
MOTORE....................................... 4-87
TRASMISSIONE, CAMMA
DEL CAMBIO E FORCELLA
DEL CAMBIO............................... 4-96
CAPITOLO 5
PARTE CICLISTICA
RUOTA ANTERIORE
E POSTERIORE.............................. 5-1
FRENO ANTERIORE
E POSTERIORE............................ 5-10
FORCELLA ANTERIORE.......... 5-26
MANUBRIO................................... 5-42
STERZO......................................... 5-48
FORCELLONE
OSCILLANTE............................... 5-53
AMMORTIZZATORE
POSTERIORE............................... 5-61

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Engine stop switch
8Kickstarter crank
9Fuel tank
0Radiator
ACoolant drain bolt
BRear brake pedal
CValve joint
DFuel cock
ECold starter knob
FDrive chain
GAir filter
HShift pedal
IDipstick
JFront forkNOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.

GEN
INFO
ALLGEMEINE
ANGABEN
FAHRZEUGBESCHREI-
BUNG
1Kupplungshebel
2Warmstarthebel
3Handbremshebel
4Gasdrehgriff
5Kühlerverschlußdeckel
6Tankverschluß
7Motorstoppschalter
8Kickstarterhebel
9Kraftstofftank
0Kühler
AKühlflüssigkeits-Ablaßschraube
BFußbremshebel
CVentilverbindung
DKraftstoffhahn
EChokehebel
FAntriebskette
GLuftfilter
HFußschalthebel
IMeßstab
JTeleskopgabel
HINWEIS:
Die Abbildungen in vorliegender
Anleitung können leicht vom
eigentlichen Modell abweichen
und dienen daher lediglich zur
Bezugnahme.
Änderungen an Design und techni-
schen Daten jederzeit vorbehalten.
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1Levier d’embrayage
2Levier de démarrage à chaud
3Levier de frein avant
4Poignée des gaz
5Bouchon de radiateur
6Bouchon du réservoir de carburant
7Coupe-circuit du moteur
8Pédale de kick
9Réservoir de carburant
0Radiateur
ABoulon de vidange du liquide de refroi-
dissement
BPédale de frein arrière
CJoint de robinet
DRobinet de carburant
ECommande de départ à froid
FChaîne de transmission
GFiltre à air
HSélecteur
IJauge
JFourche
N.B.:
Votre moto diffère peut-être partielle-
ment de celle montrée sur ces photos.
La conception et les caractéristiques
peuvent être modifiées sans préavis.
INFORMAZIONI
GENERALI
DESCRIZIONE
1Leva della frizione
2Leva starter per partenze a caldo
3Leva del freno anteriore
4Manopola acceleratore
5Coperchio del radiatore
6Tappo serbatoio carburante
7Interruttore di arresto motore
8Leva avviamento a pedale
9Serbatoio del carburante
0Radiatore
ABullone di scarico refrigerante
BPedale del freno posteriore
CGiunto della valvola
DRubinetto del carburante
EManopola starter per partenze a freddo
FCatena di trasmissione
GFiltro aria
HPedale del cambio
IAstina di misurazione
JForcella anteriore
NOTA:
È possibile che alcune delle caratteri-
stiche del mezzo acquistato non corri-
spondano a quanto mostrato in
seguito.
Il design e i dati tecnici sono soggetti a
variazioni senza preavviso.
DESCRIPTION
FAHRZEUGBESCHREIBUNG
DESCRIZIONE
1 - 1
1

GEN
INFO
1 - 7
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1135-A, 90890-01135 Crankcase separating tool
These tool is used to remove the crankshaft from
either case.YU-1135-A 90890-01135
YM-1189, 90890-01189 Flywheel puller
This tool is used to remove the flywheel magneto.YM-1189 90890-01189
YU-1235, 90890-01235 Rotor holding tool
This tool is used when loosening or tightening the fly-
wheel magneto securing nut.YU-1235 90890-01235
YU-3097, 90890-01252
YU-1256Dial gauge and stand
Stand
These tools are used to check each part for runout or
bent.YU-3097
YU-125690890-01252
YU-90050, 90890-01274
YU-90050, 90890-01275
YU-91044, 90890-04081
YU-90063, 90890-01278Crankshaft installing tool
Crankshaft installing pot
Crankshaft installing bolt
Spacer (crankshaft installer)
Adapter (M12)
These tools are used to install the crankshaft.YU-90050
YU-90063
YU-9104490890-01274
90890-01275
90890-01278
90890-04081
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.YU-1304 90890-01304
YU-24460-01, 90890-01325
YU-33984, 90890-01352Radiator cap tester
Radiator cap tester adapter
These tools are used for checking the cooling sys-
tem.YU-24460-01
YU-3398490890-01325
90890-01352

GEN
INFO
ATTREZZI SPECIALI
Sono necessari attrezzi speciali idonei per una messa a punto e un assemblaggio completi e accurati. L’uti-
lizzo di attrezzi speciali corretti previene i danni causati dall’impiego di attrezzi impropri o di tecniche
improvvisate. La forma e i numeri parte utilizzati per gli attrezzi speciali differiscono da Stato a Stato, per cui
se ne indicano due tipi. Fare riferimento all’elenco indicato per evitare ordini errati.
NOTA:
Per USA e Canada, utilizzare numeri parte che iniziano con le sigle “YM-”, “YU-”, o “ACC-”.
Per gli altri Stati, utilizzare numeri parte che iniziano con la serie di numeri “90890-”.
Numero parte Nome dell’attrezzo/Impiego Figura
YU-1135-A, 90890-01135 Separatore per il carter
Questo attrezzo è utilizzato per togliere l’albero motore dal
carter.YU-1135-A 90890-01135
YM-1189, 90890-01189 Estrattore del volano
Questo attrezzo è utilizzato per togliere il magnete volano.YM-1189 90890-01189
YU-1235, 90890-01235 Attrezzo di bloccaggio rotore
Questo attrezzo è utilizzato quando si allenta o si serra il
dado di sicurezza del magnete volano.YU-1235 90890-01235
YU-3097, 90890-01252
YU-1256Comparatore e cavalletto
Cavalletto
Questi attrezzi sono utilizzati per controllare che ogni
componente non sia scentrato o piegato.YU-3097
YU-125690890-01252
YU-90050, 90890-01274
YU-90050, 90890-01275
YU-91044, 90890-04081
YU-90063, 90890-01278Attrezzo installatore dell’albero motore
Installatore per albero motore
Bullone installatore per albero motore
Distanziatore (installatore per albero motore)
Adattatore (M12)
Questi attrezzi sono utilizzati per installare l’albero
motore.YU-90050
YU-90063
YU-9104490890-01274
90890-01275
90890-01278
90890-04081
YU-1304, 90890-01304 Kit estrattore dello spinotto
Questo attrezzo è utilizzato per togliere gli spinotti.YU-1304 90890-01304
YU-24460-01, 90890-01325
YU-33984, 90890-01352Tester del coperchio radiatore
Adattatore del tester del coperchio radiatore
Questi attrezzi sono utilizzati per controllare il sistema di
raffreddamento.YU-24460-01
YU-3398490890-01325
90890-01352
ATTREZZI SPECIALI
1 - 7

SPEC
2 - 9 Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 107.8 mm (4.2 in) ----
Height 220 mm (8.7 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 10 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil hose clamp—220.21.4
Oil strainer and frame M14 × 1.5 1 70 7.0 50
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Air filter element M6 × 1.0 1 2 0.2 1.4
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
MAINTENANCE SPECIFICATIONS