Yamaha yz250s 2004 Manuals

Manuals and User Guides for Yamaha yz250s 2004. We have 1 Yamaha yz250s 2004 manual available for free PDF download: Owner's Service Manual

YAMAHA yz250s 2004 Owner's Service Manual

YAMAHA yz250s 2004 Owner's Service Manual (579 pages)

YZ series

Brand: YAMAHA | Category: Motorcycle | Size: 15.16 MB

Table of Contents

Important Notice
6
Safety Information
6
Wichtige Hinweise
7
F.I.M. Machine Weights
10
Description
12
Chapitre
13
Renseignements Generaux
13
- How to Read Descriptions
  14
- Manual Format
  14
- Illustrated Symbols
  16
- Index
  18
- Table of Contents
  20
Description
26
Engine
26
- General Information
  26
- Informazioni Generali
  27
Chapter 1

28
- Machine Identification
  28
  - Engine Serial Number
    28
  - Frame Serial Number
    28
  - Vehicle Identification Number
    28
  - Identificazione del Veicolo
    29
- Identification de la Machine
  29
- Preparation for Removal and Disassembly
  30
- Important Information
  30
- Informations Importantes
  31
- Silencieux
  31
  - All Replacement Parts
    32
  - Bearings and Oil Seals
    32
  - Gaskets, Oil Seals and O-Rings
    32
  - Lock Washers/Plates and Cotter Pins
    32
  - Circlips
    34
  - Checking of Connections
    36
  - Controllo Dei Collegamenti
    37
- Verification des Connexions
  37
- Special Tools
  38
- Outils Speciaux
  40
- Utensili Speciali
  44
- Control Functions
  46
  - "Engine Stop" Button
    46
  - Clutch Lever
    46
  - Kick Starter
    46
- Fonctions des Commandes
  47
  - Front Brake Lever
    48
  - Fuel Cock
    48
  - Rear Brake Pedal
    48
  - Starter Knob (Choke)
    48
  - Funzioni Dei Comandi
    49
    
    Detachable Sidestand
    50
    
    Valve Joint
    50
- Fuel and Engine Mixing Oil
  52
- Essence Et Huile de Melange du Moteur
  53
- Starting and Break-In
  54
  - Starting a Cold Engine
    54
  - Starting a Warm Engine
    54
- Mise en Marche Et Rodage
  55
- Break-In Procedures
  56
- Starten und Einfahren
  57
- Avviamento E Rodaggio
  57
- Torque-Check Points
  60
- Points de Verification de Couple de Serrage
  61
- Cleaning and Storage
  64
- Nettoyage Et Rangement
  65
Chapter 2

68
- General Specifications
  68
- Chassis
  69
- Maintenance Specifications
  70
- General Torque Specifications
  79
- Definition of Units
  79
- Caracteristiques Generales
  80
- Carburateur Et
  81
- Caracteristiques D'entretien
  82
- Specifications Generales de Couple
  91
- Definition des Unites
  91
- Moteur
  91
- Technische Daten
  92
- Allgemeine Technische Daten
  92
- Wartungsdaten
  94
- Allgemeine Anzugsdaten
  103
- Definition der Einheiten
  103
  - Coppia
    115
  - Definizione Delle Unità
    115
- Cable Routing Diagram
  116
  - Diagramma del Passaggio
    117
    
    Schema de Cheminement des Cables
    117
    
    Kabelführungsübersichtplan
    117
Chapter 3

124
- Maintenance Intervals
  124
  - Regular Inspection and Adjustments
    124
  - Intervalli DI Manutenzione
    133
  - Revisione Eregolazioni Regolari
    133
    
    Engine
    136
    
    General Inspection and Maintenance
    136
    
    Pre-Operation Inspection and Maintenance
    136
- Chassis
  136
  - Ispezione E Manutenzione Prima del Funzionamento
    139
    
    Engine
    140
    
    Coolant Level Inspection
    140
    
    Coolant Replacement
    140
- Motore
  141
  - Radiator Cap Inspection
    144
  - Radiator Cap Opening Pressure Inspection
    146
  - Coolant System Inspection
    146
  - Clutch Adjustment
    148
  - Throttle Cable Adjustment
    150
  - Throttle Lubrication
    150
  - Air Filter Cleaning
    152
  - Transmission Oil Level Check
    154
  - Transmission Oil Replacement
    156
  - Pilot Air Screw Adjustment
    158
  - Idle Speed Adjustment
    160
  - Muffler Inspection
    160
  - Silencer Fiber Replacement
    160
  - Silencer Fiber Replacement
    162
  - Chassis
    164
  - Brake System Air Bleeding
    164
- Telaio
  165
  - Partie Cycle
    165
  - Front Brake Adjustment
    166
  - Reare Brake Adjustment
    168
  - Front Brake Pad Inspection and Replacement
    168
  - Rear Brake Pad Inspection and Replacement
    172
  - Front Wheel and Rear Wheel
    172
- Roue Avant Et Roue Arriere
  173
  - Rear Brake Pad Insulator Inspection
    176
  - Brake Fluid Level Inspection
    176
  - Sprockets Inspection
    178
  - Drive Chain Inspection
    178
  - Drive Chain Slack Adjustment
    180
  - Front Fork Inspection
    182
  - Front Fork Oil Seal and Dust Seal Cleaning
    184
  - Front Fork Rebound Damping Force Adjustment
    184
  - Standart Position
    184
  - Front Fork Compression Damping Force Adjustment
    186
  - Rear Shock Absorber Inspection
    188
- Bras Oscillant
  189
- Rear Shock Absorber Spring Preload Adjustment
  190
- Amortisseur Arriere
  191
- Electrical
  206
- Spark Plug Inspection
  206
- Parte Elettrica
  207
- Moteur
  207
- Ignition Timing Check
  208
Chapter 4

212
- Seat, Fuel Tank and Side Covers
  212
- Seat, Fuel Tank and Side Covers Removal
  212
- Sitz, Kraftstofftank und Seitendeckel
  213
- Side Cover Removal Points
  214
- Seitendeckel
  215
- Exhaust Pipe and Silencer
  216
- Exhaust Pipe and Silencer Removal
  216
- Auspuffrohr und Schalldämpfer
  217
- Tubo DI Scarico E Silenziatore
  217
- Radiator
  218
- Radiator Removal
  218
- Kühler
  219
  - Radiator Handling Note
    220
  - Panel Removal Points
    220
  - Radiator Inspection
    220
  - Radiator Assembly and Installation
    222
- Carburetor and Reed Valve
  224
- Carburetor and Reed Valve Removal
  224
- Vergaser und Zungenventil
  225
  - Carburetor Disassembly
    226
  - Carburetor and Reed Valve Handling Note
    228
  - Throttle Valve Removal Points
    228
  - Pilot Air Screw Removal Points
    228
  - Carburetor Inspection
    230
  - Needle Valve Inspection
    230
  - Throttle Valve Inspection
    230
  - Jet Needle Inspection
    232
  - Float Height Inspection
    232
  - Float Inspection
    234
  - Reed Valve Inspection
    234
  - Reed Valve Assembly and Installation
    234
  - Carburetor Assembly and Installation
    236
  - Carburetor Installation
    242
- Cylinder Head, Cylinder and Piston
  244
- Zylinderkopf, Zylinder und Kolben
  245
  - Piston and Power Valve
    246
  - Piston and Power Valve Removal
    246
  - Push Rod Removal Points
    248
  - Piston and Piston Ring Removal Points
    248
  - Cylinder Head Inspection
    250
  - Cylinder Inspection
    252
  - Piston Inspection
    252
  - Piston Pin and Small End Bearing Inspection
    254
  - Piston Ring Inspection
    256
  - Piston Clearance Inspection
    258
  - Combination of Piston and Cylinder Inspection
    258
  - Power Valve Inspection
    260
  - Power Valve Hole on Cylinder Inspection
    260
  - Power Valve Assembly and Installation
    262
  - Piston Ring and Piston Assembly and Installation
    266
  - Cylinder Head and Cylinder Assembly and Installation
    268
- Clutch and Primary Driven Gear
  274
- Primärabtriebszahnrad
  279
  - Friction Plate Inspection
    280
  - Clutch Plate Inspection
    280
  - Push Lever Axle Inspection
    280
  - Push Rod Inspection
    280
  - Clutch Assembly and Installation
    282
  - Primary Drive Gear Removal
    288
- Kick Axle, Shift Shaft and Primary Drive Gear
  288
- Kickstarterwelle, Schaltwelle
  289
- YPVS Governor
  306
- YPVS Governor Removal
  306
- Ypvs Regler
  307
  - Governor Removal Points
    308
  - Governor Groove Inspection
    308
  - Bearing Inspection
    308
  - Governor Assembly and Installation
    308
- Water Pump
  312
  - Water Pump Disassembly
    312
  - Impeller Shaft Removal Points
    314
  - Oil Seal Removal Points
    314
  - Impeller Shaft Inspection
    314
  - Impeller Shaft Gear Inspection
    316
  - Oil Seal Inspection
    316
  - Oil Seal Assembly and Installation
    316
  - Impeller Shaft Assembly and Installation
    318
- CDI Magneto
  320
- CDI Magneto Removal
  320
- Laterali
  321
  - Rotor Removal Points
    322
  - CDI Magneto Inspection
    322
  - Woodruff Key Inspection
    322
  - CDI Magneto Assembly and Installation
    322
- Engine Removal
  328
- Silenziatore
  329
- Radiatore
  329
- Lamella
  329
  - Drive Sprocket Removal Points
    332
  - Engine Removal Points
    332
  - Engine Installation
    334
  - Brake Pedal Assembly and Installation
    334
  - Drive Sprocket Assembly and Installation
    334
- Crankcase and Crankshaft
  338
- Crankcase and Crankshaft Removal
  338
- Pistone
  339
  - Segment Removal Points
    340
  - Crankcase Removal Points
    340
  - Crankshaft Removal Points
    342
  - Crankshaft Bearing Removal Points
    342
  - Crankcase Inspection
    342
  - Crankshaft Inspection
    344
  - Crankshaft Bearing Assembly and Installation
    344
  - Crankshaft Assembly and Installation
    346
- Transmission, Shift Cam and Shift Fork
  352
- Transmission, Shift Cam and Shift Fork Removal
  352
- Trasmissione, Camma del
  353
- Cambio
  357
- Front Wheel Removal
  362
Chapter 5

362
- Front Wheel and Rear Wheel
  362
- Telaio
  363
- Ruota Anteriore E Ruota
  363
- Partie Cycle
  363
- Motor
  363
- Fahrgestell
  363
  - Rear Wheel
    364
  - Rear Wheel Removal
    364
- Posteriore
  365
  - Ruota Anteriore E Ruota Posteriore
    365
  - Rear Wheel Removal Points
    366
  - Wheel Bearing Removal Points
    366
  - Wheel Axle Removal Points
    368
  - Brake Disc Removal Points
    368
  - Front Wheel Assembly and Installation
    370
  - Rear Wheel Assembly and Installation
    374
  - Front Brake Removal
    380
- Front Brake and Rear Brake
  380
- Freno Anteriore E Freno
  381
  - Rear Brake
    382
  - Rear Brake Removal
    382
  - Freno Posteriore
    383
  - Caliper Disassembly
    384
  - Master Cylinder Disassembly
    386
  - Brake Fluid Removal Points
    388
  - Caliper Piston Removal Points
    388
  - Piston Seal Kit Removal Points
    390
  - Master Cylinder Inspection
    390
  - Caliper Inspection
    392
  - Brake Hose Inspection
    392
  - Caliper Piston Assembly and Installation
    392
  - Front Caliper Assembly and Installation
    394
  - Rear Caliper Assembly and Installation
    396
- Posteriore
  399
- Front Fork
  414
- Front Fork Removal
  414
- Forcella Anteriore
  415
  - Fourche Avant
    415
  - Front Fork Disassembly
    416
  - Front Fork Handling Note
    418
  - Cap Bolt Removal Points
    418
  - Inner Tube Removal Points
    420
  - Damper Rod Removal Points
    420
  - Damper Rod Inspection
    420
  - Base Valve Inspection
    422
  - Fork Spring Inspection
    422
  - Inner Tube Inspection
    422
  - Outer Tube Inspection
    422
  - Cap Bolt Inspection
    424
  - Front Fork Assembly
    424
  - Front Fork Installation
    436
- Handlebar
  440
- Handlebar Removal
  440
- Manubrio
  441
  - Throttle Disassembly
    442
  - Master Cylinder Removal Points
    444
  - Handlebar Inspection
    444
  - Throttle Assembly
    444
  - Handlebar Assembly and Installation
    446
- Steering
  454
- Steering Removal
  454
- Sterzo
  455
  - Ring Nut Removal Points
    456
  - Bearing (Lower) Removal Points
    456
  - Ball Race Removal Points
    456
  - Steering Shaft Inspection
    456
  - Bearing and Ball Race Inspection
    458
  - Under Bracket Assembly and Installation
    458
- Swingarm
  464
- Swingarm Removal
  464
- Forcellone Oscillante
  465
  - Frein Avant Et Frein Arriere
    465
  - Swingarm Disassembly
    466
  - Bearing Removal Points
    468
  - Swingarm Inspection
    468
  - Relay Arm Inspection
    468
  - Connecting Rod Inspection
    468
  - Bearing and Oil Seal Assembly and Installation
    470
  - Swingarm Assembly and Installation
    472
- Rear Shock Absorber
  478
- Rear Shock Absorber Removal
  478
- Ammortizzatore Posteriore
  479
- Et Couvercles Lateraux
  479
Chapter 6

490
- Electrical Components and Wiring Diagram
  490
  - Elektrische Einrichtungen
    491
  - Ignition System
    492
  - Inspection Steps
    492
  - Spark Gap Test
    496
  - Couplers and Leads Connection Inspection
    496
  - "Engine Stop" Button Inspection
    496
- Ignition System
  496
  - Ignition Coil Inspection
    498
  - Ignition System
    498
  - Magneto CDI
    499
  - CDI Unit Inspection
    500
- Solenoid Valve System
  502
- Systeme D'electrovanne
  503
- Spezialwerkzeuge
  504
  - Utensili Speciali
    505
    
    Solenoid Valve Operation
    506
    
    Solenoid Valve Coil Inspection
    506
    
    TPS (Throttle Position Sensor) System
    508
    
    TPS Coil Inspection
    512
- Tps (Throttle Position Sensor)
  513
- System
  513
  - Vergaser und Zungenventil
    513
  - TPS Replacement and Adjustment
    514
  - TPS Input Voltage Inspection
    518
  - Setting
    520
CHAPTER 7 Tuning

520
- Carburetor Setting
  520
- Atmospheric Conditions and Carburetor Setting
  520
- Engine
  520
  - Test Run
    522
  - Effects of Setting Parts in Relation to Throttle Valve Opening
    524
  - Main Jet Adjustment
    524
  - Powet Jet Adjustment
    524
  - Pilot Jet Adjustment
    526
  - Jet Needle Groove Position Adjustment
    526
  - Jet Needle Adjustment(for USA, CDN, ZA, aus and NZ)
    530
  - Jet Needle Adjustment (for Europe)
    532
  - Relationship with Throttle Opening
    534
  - Carburetor Setting Parts
    536
  - Road Condition and Examples of Carburetor Setting
    538
  - Examples of Carburetor Setting Depending on Symptom
    538
  - Change of the Heat Range of Spark Plugs
    546
  - Selection of the Secondary Reduction Ratio (Sprocket)
    548
  - Fahrgestell
    549
  - Partie Cycle
    549
- Telaio
  549
  - Drive and Driven Sprockets Setting Parts
    550
  - Tire Pressure
    550
  - Front Fork Setting
    552
  - Spring Preload Adjustment
    554
  - Setting of Spring after Replacement
    554
  - Front Fork Setting Parts
    558
  - Adjustment Washer
    558
  - Rear Suspension Setting
    560
  - Choosing Set Length
    560
  - Rear Shock Absorber Setting Parts
    566
  - Rear Shock Spring
    566
  - Extent of Adjustment (Spring Length)
    566
  - Suspension Setting
    568

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