User manual YAMAHA YZ250F-2004

[. . . ] Please take the time to read this manual thoroughly, so as to enjoy all your YZF-R7's advantages. The owner's service manual does not only instruct you in how to operate, inspect and basic maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help to keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. [. . . ] · bearing 2 Damage/wear Replace. CHECKING THE PUSH RODS AND BALL 1. Check: · push rod #1 1 · push rod #2 2 · ball 3 Damage/wear Replace the pull rods and ball as a set. Check: · push rod bearing 4 Damage/wear Replace. CHECKING THE BACK TORQUE LIMITER 1. Check: · back torque limiter outer boss splines Damage/pitting/wear Replace the back torque limiter outer boss. 4 - 44 CLUTCH ENG 2. Check: · back torque limiter clutch wwwwwwwwwwwwwwwwwwwwwwwwwww a. Install the back torque limiter bearing and back torque limiter outer boss onto the back torque limiter inner boss and hold the back torque limiter inner boss. When turning the back torque limiter outer boss clockwise Å, the back torque limiter inner boss and back torque limiter outer boss should engage, otherwise the back torque limiter is faulty and must be replaced. When turning the back torque limiter outer boss counterclockwise i, it should turn freely, otherwise the back torque limiter is faulty and must be replaced. vvvvvvvvvvvvvvvvvvvvvvvvvvv CHECKING THE STARTER CLUTCH 1. Check: · starter clutch gear · starter clutch idle gear Chips/pitting/roughness/wear Replace the defective part(-s). 2. Check: · starter clutch operation wwwwwwwwwwwwwwwwwwwwwwwwwww a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. Check: · oil/water pump assembly driven sprocket 1 · oil pump housing 2 Cracks/damage/wear Replace the defective part(-s). 2. Measure: · inner rotor-to-outer rotor tip clearance a · outer rotor-to-oil pump housing clearance b Out of specification Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor-to-outer rotor tip clearance 0. 09 ~ 0. 15 mm (0. 004 ~ 0. 006 in) Outer rotor-to-oil pump housing clearance 0. 03 ~ 0. 08 mm (0. 001 ~ 0. 003 in) 4 - 53 OIL PAN AND OIL PUMP ENG 3. Check: · oil pump operation Unsmooth Repair or replace the defective part(-s). Refer to "WATER PUMP" in chapter 5. EB411410 CHECKING THE RELIEF VALVE 1. Check: · relief valve body 1 · relief valve 2 · spring 3 · O-ring 4 Damage/wear Replace the defective part(-s). EB411421 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: · oil delivery pipe 1 · oil pipe 2 Damage Replace. Obstruction Wash and blow out with compressed air. EB411430 CHECKING THE OIL STRAINER 1. Contaminants Clean with engine oil. EB411701 ASSEMBLING THE OIL PUMP 1. Lubricate: · inner rotor · outer rotor · impeller shaft (with the recommended lubricant) Recommended lubricant Engine oil 4 - 54 OIL PAN AND OIL PUMP ENG 2. Check: · oil pump operation Refer to "CHECKING THE OIL PUMP". EB411710 INSTALLING THE OIL PUMP 1. Install: · oil pump 1 12 Nm (1. 2 m · kg, 8. 7 ft · lb) NOTE: Install the oil/water pump assembly drive chain onto the oil/water pump assembly driven sprocket. EB411720 INSTALLING THE OIL STRAINER 1. [. . . ] During this time, the warning light lights up for 0. 5 second once every second. Test coupler adapter method Within one second after the engine stop switch is turned to " ", the ignition coil for the selected cylinder is operated once every second for the next five seconds. During this time, the warning light lights up for 0. 5 second once every second. ELEC ­ + Tachometer display (0 ~ 10, 000 r/min) 13 Ignition coil for cylinder #1 14 Ignition coil for cylinder #2 15 Ignition coil for cylinder #3 16 Ignition coil for cylinder #4 8 - 37 ELECTRICAL CONTROL SYSTEM Diagnosis code 17 18 19 20 21 22 23 24 Inspected item Injector 1 for cylinder #1 Injector 1 for cylinder #2 Injector 1 for cylinder #3 Injector 1 for cylinder #4 Injector 2 for cylinder #1 Injector 2 for cylinder #2 Injector 2 for cylinder #3 Injector 2 for cylinder #4 System response CO, diagnosis switch box method Before selecting a code, disconnect the fuel pump coupler from the wire harness. Within one second after the MODE switch is released, the main relay is turned on, and the selected injector is operated once every second for the next five seconds. [. . . ]