maintenance YAMAHA YZ250LC 2004 User Guide

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

2-11
MAINTENANCE SPECIFICATIONSSPEC
EC212300
ELECTRICAL
Part to be tightened Thread size Q’tyT ightening torqueNm m•kg ft•lb
Stator M 6 ×1.0 3 8 0.8 5.8
Rotor M12 ×1.25 1 56 5.6 40
Ignition coil M 6 ×1.0 2 7 0.7 5.1
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.) 0.18 mm (0.007 in)…
Advancer type Electrical…
CDI:
Magneto-model (stator)/Manufacturer 5CU-02/YAMAHA…
Source coil 1 resistance (color) 720~1,080 Ωat 20°C (68°F)…
(Black-Black/Red)
Source coil 2 resistance (color) 44~66 Ωat 20°C (68°F)…
(Green/Blue-Green/White)
Pickup coil resistance (color) 248~372 Ωat 20°C (68°F)…
(White/Blue-White/Red)
CDI unit-model/Manufacturer 5NX-01/YAMAHA…
Ignition coil:
Model/Manufacturer 4MX-00/YAMAHA…
Minimum spark gap 6 mm (0.24 in)…
Primary winding resistance 0.20~0.30 Ωat 20°C (68°F)…
Secondary winding resistance 9.5~14.3 kΩat 20°C (68°F)…
Spark plug cap:
Resistance 4~6 kΩat 20°C (68°F)…
5XF-9-30-2 5/15/03 3:54 PM Page 12

INSP
ADJ
3-1
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
EC310013
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the required
maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining
and lubricating your machine, consult your Yamaha dealer.
Item Remarks
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
Inspect crack
Inspect carbon deposits
and eliminate them
Check ring end gap
Inspect carbon deposits
and eliminate them
Check gasket
Inspect score marks
Inspect wear
Inspect carbon deposits
and eliminate them
Inspect housing, friction
plate, clutch plate and
spring
Yamalube 4 (10W-30) or
SAE 10W-30 SE motor oil
Inspect wear
Use chain lube
Chain slack: 40~50 mm
(1.6~2.0 in) PISTON
Inspect and clean
Replace
PISTON RING
Inspect
Replace
PISTON PIN, SMALL END BEARING
Inspect
Replace
CYLINDER HEAD
Inspect and clean
Retighten
CYLINDER
Inspect and clean
Replace
YPVS
Inspect and clean
CLUTCH
Inspect and adjust
Replace
TRANSMISSION
Replace oil
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
ROTOR NUT
Retighten
MUFFLER
Inspect
Clean
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Lubricate, slack, alignment
Replace
5XF-9-30-3A 4/21/03 2:09 PM Page 2

INSP
ADJ
3-2
MAINTENANCE INTERVALS
3
Item Remarks
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolantEvery two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
RetightenAND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricateUse foam air-filter oil or
Replaceequivalent oil
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper bolts,

master cylinder bolts and union bolts
Replace pads
Replace brake fluidEvery one year
FRONT FORKS
Inspect and adjust
Replace oilSuspension oil “01”
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL
Clean and lubeLithium base grease
REAR SHOCK ABSORBER
(After
Inspect and adjustrain ride)
Lube Molybdenum disulfide grease
Retighten
CHAIN GUARD AND ROLLERS
Inspect
SWINGARM
Inspect, lube and retightenMolybdenum disulfide grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retightenMolybdenum disulfide grease
STEERING HEAD
Inspect free play and retighten
Clean and lubeLithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,

tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
LubricateLithium base grease
THROTTLE, CONTROL CABLE
Check routing and connectionYamaha cable lube or
LubricateSAE 10W-30 motor oil
After
break-
inEvery
raceEvery
thirdEvery
fifthAs re-
quired
5XF-9-30-3A 4/21/03 2:09 PM Page 3

3-4
PRE-OPERATION INSPECTION AND MAINTENANCE
INSP
ADJ
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EC321000
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Coolant Check that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P3-5~9
Fuel Check that a fresh mixture of oil and gasoline is filled in
the fuel tank. Check the fuel line for leakage.P1-12
Transmission oil Check that the oil level is correct. Check the crankcase
for leakage.P3-12~14
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly.P3-9
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and P3-10~11
housing, if necessary.
Brakes Check the play of front brake and effect of front and
rear brake.P3-17~23
Chain Check chain slack and alignment. Check that the chain
is lubricated properly.P3-24~26
Wheels Check for excessive wear and tire pressure. Check for
loose spokes and have no excessive play.P3-34~35
Steering Check that the handlebar can be turned smoothly and
have no excessive play.P3-35~36
Front forks and Check that they operate smoothly and there is no oil
rear shock absorber leakage.P3-26~33
Cables (wires) Check that the clutch and throttle cables move smooth-
ly. Check that they are not caught when the handlebars —
are turned or when the front forks travel up and down.
Muffler Check that the muffler is tightly mounted and has no
cracks.P3-15~16
Sprocket Check that the driven sprocket tightening bolt is
not loose.P3-24
Lubrication Check for smooth operation. Lubricate if necessary. P3-37
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P1-16
Lead connectors Check that the CDI magneto, CDI unit, and ignition coil
are connected tightly.P1-6
Settings Is the machine set suitably for the condition of the
racing course and weather or by taking into account the
P7-1~24
results of test runs before racing? Are inspection and
maintenance completely done?
5XF-9-30-3A 4/21/03 2:09 PM Page 14

INSP
ADJ
3-11
AIR FILTER CLEANING
3. Install:
9Throttle cable cap
9Cap cover
EC35G041
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and dam-
age.
cC
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:
9Seat
9Fitting bolt 1
9Washer 2
9Air filter element 3
9Filter guide 4
2. Clean:
9Air filter element
Clean them with solvent.
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
cC
Do not twist the element when squeezing
the element.
1 Nm (0.1 m•kg, 0.7 ft•lb)
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5-53
CHASSWINGARM
EC573000
REMOVAL POINTS
EC573201
Bearing
1. Remove:
9Bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC574010
INSPECTION
Wash the bearings, bushes, collars, and covers in
a solvent.
EC574111
Swingarm
1. Inspect:
9Bearing 1
9Bush 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and bush as a set.
2. Inspect:
9Oil seal 3
Damage Replace.
EC574211
Relay arm
1. Inspect:
9Bearing (polylube bearing) 1
9Collar 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and collar as a set.
2. Inspect:
9Bearing (polylube bearing) 1
Loss of solid lubrication Replace.
9Oil seal 3
Damage Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the needle
bearings, used in this model, maintenance free.
With polylube bearings, no grease nipple and
regular lubrication is necessary. However,
grease should be applied to all oil seals and col-
lars when removed or installed.
5XF-9-30-5D 5/6/03 6:37 PM Page 6

5-54
CHASSWINGARM
EC575000
ASSEMBLY AND INSTALLATION
EC575202
Bearing and oil seal
1. Install:
9Bearing 1
9Oil seal 2
To swingarm.
NOTE:
9Apply the molybdenum disulfide grease on the
bearing when installing.
9Install the bearing by pressing it on the side hav-
ing the manufacture's marks or numbers.
9First install the outer and then the inner bear-
ings to a specified depth from inside.
Installed depth of bearings:
Outer a a
: Zero mm (Zero in)
Inner b b
: 8.5 mm (0.33 in)
EC574311
Connecting rod
1. Inspect:
9Bearing (polylube bearing) 1
9Collar 2
Free play exists/Unsmooth revolution/Rust 
Replace bearing and collar as a set.
2. Inspect:
9Bearing (polylube bearing) 1
Loss of solid lubrication Replace.
9Oil seal 3
Damage Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the needle
bearings, used in this model, maintenance free.
With polylube bearings, no grease nipple and
regular lubrication is necessary. However,
grease should be applied to all oil seals and col-
lars when removed or installed.
5XF-9-30-5D 5/6/03 6:37 PM Page 8