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Yamaha YZ250 YZ 250 2004 2-STROKE Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Model Variant: YZ250 Year: 2004 Category: Motocross Motorcycle Codes Engine Code: 13W Chassis Code: 4JT 👋 Introduction Market Position Segment: High-performance motocross...
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ250
Model Variant:
YZ250
Year:
2004
Category:
Motocross Motorcycle
Codes
Engine Code:
13W
Chassis Code:
4JT
👋 Introduction
Market Position
Segment:
High-performance motocross motorcycle
Target Audience:
Motocross racers, off-road enthusiasts, and DIY mechanics
Competitive Analysis
Key Competitors 2004:
Honda CR250R, KTM 250 SX, Suzuki RM250, Kawasaki KX250
Key Features
Engine Type:
Liquid-cooled, 2-stroke, Reed valve, 249cc
Suspension Front Type:
Upside-down telescopic fork
Suspension Rear Type:
Swingarm, Monocross
Braking System:
Dual hydraulic disc brakes
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Specific Systems Covered:
Engine, Transmission, Chassis, Electrical, Suspension, Brakes, Fuel System, Cooling System, Lubrication System, Ignition System, Bodywork, Troubleshooting
Page Count
Estimated Pages:
300+
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Comprehensive disassembly, inspection, assembly, and tuning of the 2-stroke engine components including piston, cylinder, crankshaft, connecting rod, and bearings.
Engine Lubrication:
Details on the automatic oil injection system, oil pump, and lubrication points.
Cooling System:
Information on the liquid cooling system, radiator, water pump, and coolant specifications.
Fuel System:
Carburetor (Mikuni TMX) specifications, jetting, adjustments, and fuel delivery system.
Ignition System:
CDI ignition system, spark plug specifications, and troubleshooting.
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, and lubrication.
Chassis Frame:
Frame inspection, suspension mounting points, and general chassis maintenance.
Suspension Front:
KYB USD (Upside Down) forks, including disassembly, fork seal replacement, oil levels, and damping adjustments.
Suspension Rear:
Monoshock rear suspension (KYB), linkage system maintenance, shock absorber servicing, and spring preload adjustments.
Brakes Front:
Hydraulic disc brake system, caliper maintenance, pad replacement, fluid bleeding, and rotor specifications.
Brakes Rear:
Hydraulic disc brake system, caliper maintenance, pad replacement, fluid bleeding, and rotor specifications.
Electrical System:
Wiring diagrams, lighting system, ignition coil, battery maintenance, and troubleshooting electrical faults.
Bodywork Plastics:
Removal and installation of fenders, tank shrouds, seat, and other body panels.
Procedures Included
Routine Maintenance:
Oil changes, air filter cleaning, chain adjustment, spark plug replacement, general inspection.
Engine Rebuild:
Complete engine overhaul, including top-end and bottom-end rebuilds.
Suspension Service:
Fork seal replacement, fork oil changes, shock absorber rebuilds.
Brake Maintenance:
Brake pad replacement, brake fluid flush, caliper servicing.
Carburetor Tuning:
Jetting adjustments, idle speed setting, and mixture screw calibration.
Troubleshooting Guides:
Diagnostic flowcharts and step-by-step guides for common problems.
Wiring Diagrams:
Detailed electrical schematics for easy fault finding.
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to full engine and chassis overhauls.
Diagnostics:
Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues.
Specifications And Tolerances:
Precise measurements, clearances, and torque specifications for all components.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality:
High-resolution, clear diagrams and text
Print Quality
Illustration Detail:
Detailed, step-by-step illustrations and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, Reed valve
Displacement:
249 cc
Bore X Stroke:
66.4 mm x 72.0 mm
Compression Ratio:
9.3:1 (at 1100 rpm)
Carburetor:
Mikuni TMX38, Flat-slide
Ignition:
Digital CDI
Starting System:
Kick starter
Performance
Horsepower:
Approx. 50-52 hp (manufacturer claimed, varies by tuning)
Torque:
Not officially published, estimated range.
Fuel System
Fuel Type:
Unleaded gasoline (min. 91 octane recommended)
Fuel Tank Capacity:
8.0 L (2.1 US gal)
Oil Injection:
Automatic, separate reservoir
Premix Ratio:
N/A (uses oil injection)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch:
Wet, multi-disc, manual
Features
Gear Ratios:
Provided in manual: 1st: 2.333, 2nd: 1.750, 3rd: 1.400, 4th: 1.150, 5th: 0.960
Final Drive:
Chain drive, 520 O-ring chain
📐 Dimensions
Exterior
Length:
2,165 mm (85.2 in)
Width:
825 mm (32.5 in)
Height:
1,270 mm (50.0 in)
Wheelbase:
1,470 mm (57.9 in)
Ground Clearance:
340 mm (13.4 in)
Seat Height:
990 mm (39.0 in)
Weights
Dry Weight:
98 kg (216 lbs)
Wet Weight:
Approximately 105 kg (231 lbs), with fluids.
Front Tire:
80/100-21 51M
Rear Tire:
110/90-19 62M
🛡️ Safety Features
Ratings
Safety Classification:
Not Applicable (Motocross Vehicle)
Active Features
Braking System:
Powerful dual disc hydraulic brakes for excellent stopping power.
Suspension:
High-performance KYB suspension provides stability and control over rough terrain.
Passive Features
Frame Construction:
Durable aluminum frame for strength and rigidity.
💡 Technology Features
Infotainment
Infotainment System:
Not Applicable (Motocross Motorcycle)
Driver Assistance
Assistance Features:
Not Applicable (Motocross Motorcycle)
Connectivity
Connectivity Features:
Not Applicable (Motocross Motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual for specific intervals based on riding conditions, typically after extended use or periodically.
Air Filter Cleaning:
After every few rides or as needed based on dust conditions.
Chain Lubrication Adjustment:
Regularly, based on mileage and riding conditions.
Spark Plug Replacement:
Refer to manual, typically every 30-50 hours of use or as needed.
Top End Rebuild:
Recommended at 50-100 hours of hard use, or based on compression loss.
Fluid Specifications
Engine Oil Type:
Yamalube 2-Stroke Injector Oil (or equivalent high-quality 2-stroke oil for injection systems)
Transmission Oil Type:
Yamalube Hypoid Gear Oil SAE 80 or equivalent motorcycle transmission oil
Coolant Type:
Permanent type anti-freeze coolant (50% mixture with distilled water)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Fork Oil Type:
Specific KYB fork oil (e.g., KYB 01M or equivalent, manual specifies viscosity/weight)
Known Issues
Typical Wear Items:
Piston rings, piston, clutch plates, brake pads, swingarm bearings, wheel bearings.
Common Problems:
Potential for overheating if cooling system is not maintained; carburetor jetting sensitivity to altitude and temperature; wear on the reed valve assembly.
📚 Vehicle History
Brand Heritage
Yamaha Motorsports:
Yamaha has a long and illustrious history in professional motorsports, particularly in motocross, with iconic models like the YZ series.
Model Evolution
Yz250 Development:
The YZ250 has been a dominant force in the 250cc class for decades, undergoing continuous refinement in engine performance, suspension technology, and chassis design.
2004 Updates:
The 2004 model featured refinements to the suspension (longer travel KYB forks), improved frame rigidity, and revised styling.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motocross Awards:
The YZ250 series has consistently received praise and accolades in motocross publications and industry awards for its performance and reliability.