drain bolt YAMAHA YZ250F 2002 Owners Manual

GEN
INFO

1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Decompression lever
3
Front brake lever
4
Throttle grip
5
Radiator cap
6
Fuel tank cap
7
Oil tank cap
8
Engine stop switch
9
Kickstarter crank
0
Fuel tank
A
Radiator
B
Coolant drain bolt
C
Rear brake pedal
D
Valve joint
E
Fuel cock
F
Cold starter knob
G
Hot starter knob (red)
H
Drive chain
I
Air filter
J
Shift pedal
K
Front fork
NOTE:


The machine you have purchased may differ
slightly from those shown in the following.

Designs and specifications are subject to
change without notice.

SPEC

2 - 10
MAINTENANCE SPECIFICATIONS
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 37 3.7 27
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
Decompression shaft M6
×
1.0 1 7 0.7 5.1
Decompression cable guide M6
×
1.0 1 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 3 0.3 2.2
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 delivery pipe 2 M6
×
1.0 1 10 1.0 7.2
Oil hose M6
×
1.0 3 10 1.0 7.2
Oil hose clamp—2 2 0.2 1.4
Oil strainer and frame M18
×
1.5 1 90 9.0 65
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 cover M5 × 0.8 1 4 0.4 2.9
Air filter joint M5 × 0.8 2 5 0.5 3.6
Air filter joint and air filter case M5 × 0.8 5 1 0.1 0.7
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

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 20 2.0 14
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 8 0.8 5.8
Clutch boss M16 × 1.0 1 60 6.0 43
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segument M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap 1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
Radiator cap
3. Check:
Coolant level a
Coolant level low → Add coolant.
1Radiator
1a
ENGINE/COOLANT LEVEL INSPECTION

3 - 6
INSP
ADJ
COOLANT REPLACEMENT
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
CAUTION:
Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
Coolant drain bolt 1
3. Remove:
Radiator cap
Drain the coolant completely.
4. Clean:
Cooling system
Thoroughly flush the cooling system
with clean tap water.
5. Install:
Copper washer
Coolant drain bolt
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. Fill:
Radiator
Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing anti-
corrosion for aluminum engine
Coolant 1 and water (soft water) 2
mixing ratio:
50 %/50 %
Coolant capacity:
0.9 L (0.79 Imp qt, 0.95 US qt)

3 - 16
INSP
ADJ
ENGINE OIL REPLACEMENT
4. Remove:
Oil tank cap 1
Frame oil drain bolt 2
Crankcase oil drain bolt 3
Oil filter element drain bolt 4
Drain the crankcase and oil tank
(frame) of its oil.
5. Remove:
Lower engine bracket
Oil hose clamp 1
Bolt (oil hose) 2
Oil hose 3
Oil strainer (frame) 4
6. Inspect:
Oil strainer (frame)
Clogged → Blow.
7. If the oil filter is to be replaced during this
oil change, remove the following parts
and reinstall them.
Replacement steps:
Remove the oil filter element cover 1 and
oil filter element 2.
Check the O-rings 3, if cracked or dam-
aged, replace them with a new one.
Install the oil filter element and oil filter ele-
ment cover.
T R..
Oil filter element cover:
10 Nm (1.0 m • kg, 7.2 ft • lb)

3 - 17
INSP
ADJ
ENGINE OIL REPLACEMENT
8. Install:
Copper washer 1
Oil strainer (frame) 2
Oil hose 3
Bolt (oil hose) 4
Oil hose clamp 5
Lower engine bracket
9. Install:
Copper washer
Oil filter element drain bolt
Crankcase oil drain bolt
Frame oil drain bolt
10. Fill:
Engine oil
11. Check:
Oil leakage
12. Install:
Oil tank cap
13. Check:
Engine oil level
Oil quantity:
Total amount:
1.7 L (1.50 Imp qt, 1.80 US qt)
Periodic oil change:
1.5 L (1.32 Imp qt, 1.59 US qt)
With oil filter replacement:
1.6 L (1.41 Imp qt, 1.69 US qt)
T R..90 Nm (9.0 m · kg, 65 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)

3 - 28
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
Loosen the pad pin 2.
Remove the brake hose holder 3 and
brake caliper 4 from the front fork.
Remove the pad pin and brake pads 5.
Connect the transparent hose 6 to the
bleed screw 7 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
Install the brake pads 8 and pad pin.
NOTE:
Install the brake pads with their projec-
tions a into the brake caliper recesses b.
Temporarily tighten the pad pin at this
point.
Install the brake hose holder 9 and brake
caliper 0 and tighten the pad pin A.
NOTE:
Fit the brake hose holder cut c over the
projection d on the front fork and clamp the
brake hose.
T R..
Bolt (brake caliper):
23 Nm (2.3 m • kg, 17 ft • lb)
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)

3 - 30
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
Remove the pad pin 6 and brake pads 7.
Connect the transparent hose 8 to the
bleed screw 9 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
Install the brake pad 0 and pad pin A.
NOTE:
Install the brake pads with their projec-
tions a into the brake caliper recesses b.
Temporarily tighten the pad pin at this
point.
Install the brake caliper B and rear wheel
C.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.
Tighten the pad pin D.
T R..
Pad pin:
18 Nm (1.8 m • kg, 13 ft • lb)
Install the pad pin plug E and protector F.
T R..
Pad pin plug:
3 Nm (0.3 m • kg, 2.2 ft • lb)
Bolt (protector):
7 Nm (0.7 m • kg, 5.1 ft • lb)

5 - 10
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:1 Brake hose removal2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid.
WARNING
Support the machine securely so there is nodanger of it falling over.
Refer to “REMOVAL POINTS”.
1 Brake hose cover 1
2 Brake hose holder 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Brake caliper 1
9 Brake lever 1
10 Brake master cylinder bracket 1
11 Brake master cylinder 1
2
3
1
3
2