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Yamaha YZ250F Service Manual Repair 2004 YZ 250F
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🏷️ Basic Information Identification Make: Yamaha Model: YZ250F Year: 2004 Type: Off-Road Motorcycle (Motocross) Codes Vin Prefix: JY 👋 Introduction Market Position Positioning: The 2004 Yamaha YZ250F was a dominant...
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ250F
Year:
2004
Type:
Off-Road Motorcycle (Motocross)
Codes
Vin Prefix:
JY
👋 Introduction
Market Position
Positioning:
The 2004 Yamaha YZ250F was a dominant force in the 250cc four-stroke motocross class, known for its potent engine and advanced suspension.
Competitive Analysis
Competitors:
Competed directly with models such as the Honda CRF250R, Kawasaki KX250F, and Suzuki RM-Z250.
Key Features
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve, single-cylinder.
Suspension Type:
Industry-leading Kayaba SSS (Speed Sensitive System) front forks and rear shock absorber.
Transmission Type:
Constant mesh, 5-speed.
Frame Type:
Aluminum alloy, dual-beam perimeter frame.
📋 Manual Details
Coverage Areas
Engine:
Complete tear down and rebuild
Maintenance:
Scheduled maintenance, inspections
Troubleshooting:
Diagnosis and repair of common issues
Chassis:
Suspension, frame, wheels, brakes
Electrical:
Ignition, lighting, wiring diagrams
Bodywork:
Plastics, seat, fuel tank removal/installation
Page Count
Pages:
297
Manual Type
Type:
Factory Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Cylinder head, piston, crankshaft, connecting rod, valve train, oil pump, cooling system.
Fuel System:
Carburetor (Keihin FCR MX), fuel tank, fuel lines, petcock.
Ignition System:
CDI, spark plug, ignition coil, timing.
Cooling System:
Radiator, coolant lines, thermostat, fan (if applicable, though unlikely for this model).
Lubrication System:
Engine oil system, oil filter, oil passages.
Exhaust System:
Exhaust pipe, muffler, packing.
Transmission:
Clutch assembly, gear shifting mechanism, internal gears, oil.
Drivetrain:
Drive chain, sprockets.
Suspension Front:
Kayaba (KYB) SSS (Speed Sensitive System) forks, seals, oil, adjustments.
Suspension Rear:
Kayaba (KYB) shock absorber, linkage, bearings, adjustments.
Brakes Front:
Hydraulic disc brake, caliper, master cylinder, brake pads, brake lines, rotor.
Brakes Rear:
Hydraulic disc brake, caliper, master cylinder, brake pads, brake lines, rotor.
Wheels And Tires:
Spoke wheels, hubs, bearings, tire removal/installation, pressure.
Steering:
Handlebars, steering stem, steering bearings, fork guards.
Electrical System:
Wiring harness, connectors, lighting (headlight, taillight, brake light), battery (if applicable, though this is kick-start only).
Frame And Body:
Frame inspection, subframe, fuel tank, seat, fenders, plastics.
Procedures Included
Engine Rebuild:
Complete engine disassembly, inspection of components, replacement of wear items (piston rings, gaskets), reassembly, valve adjustment.
Suspension Service:
Fork seal replacement, fork oil change and level adjustment, shock absorber servicing.
Carburetor Tuning:
Carburetor cleaning, jetting adjustments for altitude and temperature, idle speed adjustment.
Clutch Service:
Clutch adjustment, clutch plate replacement.
Brake Bleeding:
Hydraulic brake system bleeding procedure.
Chain And Sprocket Maintenance:
Chain cleaning, lubrication, adjustment of tension, sprocket inspection and replacement.
Troubleshooting Guides:
Systematic approach to diagnosing common problems like starting issues, poor performance, unusual noises.
Technical Depth
Depth:
Comprehensive - suitable for professional mechanics and experienced DIY enthusiasts. Covers full teardowns and rebuilds.
Torque Specifications:
Detailed torque values for all critical fasteners.
Diagnostic Procedures:
Includes procedures for identifying faults in ignition, fuel, and mechanical systems.
Visual Aids:
Includes pictures and part diagrams to aid in identification and reassembly.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text
Print Quality
Quality:
High resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Navigation
Navigation:
Clickable chapters and internal links
⚙️ Engine Specifications
Primary Engine
Engine Type:
249cc liquid-cooled, DOHC, four-stroke, four-valve, single-cylinder.
Bore X Stroke:
77.0 mm x 53.6 mm
Compression Ratio:
12.5:1
Carburetion:
Keihin FCR MX40 with throttle position sensor (TPS)
Ignition:
Digital CDI
Starting System:
Kick starter
Performance
Horsepower:
Approx. 40-42 HP (at crankshaft, estimated)
Torque:
N/A (Manufacturer does not typically publish torque figures for motocross bikes)
Fuel System
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
8.0 liters (2.1 US gal)
🔧 Transmission
Standard
Transmission:
Constant mesh, 5-speed
Features
Clutch:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain, Sprockets (e.g., 14T front / 50T rear - typical configuration)
📐 Dimensions
Exterior
Length:
2170 mm (85.4 in)
Width:
825 mm (32.5 in)
Height:
1280 mm (50.4 in)
Wheelbase:
1475 mm (58.1 in)
Ground Clearance:
355 mm (14.0 in)
Seat Height:
970 mm (38.2 in)
Weights
Dry Weight:
97 kg (213.8 lbs)
Wet Weight:
N/A (Typically not officially published for MX bikes)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not subject to automotive crash test ratings like NHTSA or IIHS)
Active Features
Braking System:
Powerful hydraulic disc brakes front and rear.
Suspension Design:
High-performance Kayaba SSS suspension provides excellent control and stability.
Passive Features
Frame Construction:
Robust aluminum frame designed for durability and handling.
Ergonomics:
Designed for rider control and confidence in aggressive riding conditions.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle focused on performance, not comfort/infotainment)
Driver Assistance
Assistance Features:
N/A (Motorcycle focused on rider input)
Connectivity
Connectivity Features:
N/A (Motorcycle focused on performance, not connectivity)
Engine Management
Tps Sensor:
Throttle Position Sensor (TPS) on the Keihin FCR carburetor for optimized fuel delivery.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10-15 hours of riding or as per manual recommendations (e.g., after significant race events).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Inspection:
Regularly, replace as needed based on condition.
Valve Clearance Check:
Every 20-30 hours of riding (critical for performance).
Piston Ring Replacement:
Recommended around 50-100 hours of use, depending on riding style and maintenance.
Suspension Service:
Fork oil and seal replacement every 20-40 hours; shock service as needed.
Fluid Specifications
Engine Oil Type:
Yamalube (or equivalent) 10W-40, API SG, JASO MA or MA2, high-performance 4-stroke motorcycle oil.
Engine Oil Capacity:
1.00 liter (1.06 US qt) without filter change; 1.10 liter (1.16 US qt) with filter change.
Transmission Oil Type:
Yamalube (or equivalent) 10W-30, API SG, JASO MA or MA2, high-performance 4-stroke motorcycle oil.
Transmission Oil Capacity:
0.70 liter (0.74 US qt)
Fork Oil Type:
Kayaba Suspension Fluid (or equivalent) 01 (SAE 2.5W equivalent) - 750 ml per fork leg.
Coolant Type:
High-quality, pre-mixed permanent type antifreeze coolant (50/50 mixture of ethylene glycol and distilled water).
Known Issues
Common Wear Items:
Piston rings, valve seats, clutch plates, wheel bearings, steering bearings, suspension seals are typical wear items on high-performance motocross bikes.
Carburetor Performance:
Proper jetting and cleaning are crucial for optimal performance; sensitivity to altitude and temperature changes.
Valve Train Wear:
Regular valve clearance checks are essential to prevent premature wear and performance degradation.
📚 Vehicle History
Brand Heritage
Yamaha Motorsports:
Yamaha has a long and storied history in professional motocross and off-road racing, dating back to the 1960s.
Model Evolution
Yz250F Progression:
The YZ250F has undergone continuous development, with the 2004 model representing a significant advancement with its introduction of the Kayaba SSS suspension, which set a new industry standard.
Production
Manufacturing Location:
Japan (typically)
Production Years:
2001 - Present (with continuous updates)
🏆 Awards & Recognition
Recognitions
Motocross Magazine Reviews:
The 2004 YZ250F was consistently praised by motocross publications for its powerful engine, class-leading suspension, and sharp handling.
Industry Impact:
The introduction of Kayaba SSS suspension on this model significantly influenced subsequent motocross suspension development across the industry.