Yamaha YZ250F 2016 Motocross Bike Manuals

Yamaha YZ250F 2016 Motocross Bike Manuals

Manuals and User Guides for Yamaha YZ250F 2016 Motocross Bike. We have 1 Yamaha YZ250F 2016 Motocross Bike manual available for free PDF download: Owner's Service Manual

Yamaha YZ250F 2016 Owner's Service Manual

Yamaha YZ250F 2016 Owner's Service Manual (356 pages)

Brand: Yamaha | Category: Motorcycle | Size: 11.79 MB

Table of Contents

Table of Contents

11
- Important Manual Information
  6
- Safety Information
  7
- How to Use this Manual
  8
- General Information
  13
  - Location of Important Labels
    15
  - Description
    18
  - Identification
    19
    
    Vehicle Identification Number
    19
    
    Engine Serial Number
    19
  - Included Parts
    20
    
    Sidestand
    20
    
    Spark Plug Wrench
    20
    
    Nipple Wrench
    20
    
    Handlebar Protector
    20
    
    Fuel Hose Joint Cover
    20
    
    Coupler for Connecting Optional Part
    20
  - Important Information
    22
    
    Preparation for Removal and Disassembly
    22
    
    Replacement Parts
    22
    
    Gaskets, Oil Seals and O-Rings
    23
    
    Lock Washers/Plates and Cotter Pins
    23
    
    Bearings and Oil Seals
    23
    
    Circlips
    23
  - Basic Service Information
    24
    
    Electrical System
    24
  - Special Tools
    27
  - Control Functions
    32
    
    Engine Stop Switch
    32
    
    Clutch Lever
    32
    
    Shift Pedal
    32
    
    Kickstarter Lever
    32
    
    Throttle Grip
    32
    
    Front Brake Lever
    32
    
    Rear Brake Pedal
    33
    
    Starter Knob/Idle Adjusting Screw
    33
    
    Fuel Tank Cap
    33
  - Starting and Break-In
    34
    
    Fuel
    34
    
    Starting a Cold Engine
    34
    
    Starting a Warm Engine
    35
    
    Break-In Procedures
    35
  - Maintenance after Break-In
    36
    
    Major Maintenance
    36
  - Torque-Check Points
    37
  - Cleaning and Storage
    39
    
    Cleaning
    39
    
    Storage
    39
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  51
- Tightening Torques
  52
- Lubrication Points and Lubricant Types
  59
  - Engine
    59
- Chassis
  61
  - Lubrication System Chart and Diagrams
    64
    
    Lubrication Diagrams
    64
  - Cable Routing Diagram
    72
Periodic Checks and Adjustments

83
- Maintenance Intervals
  
  85
- Pre-Operation Inspection and Maintenance
  
  91
  - General Inspection and Maintenance
    91
- Engine
  
  92
  - Checking the Coolant Level
    92
    
    Checking the Cooling System
    92
    
    Changing the Coolant
    92
    
    Checking the Radiator Cap
    93
    
    Checking the Radiator Cap Valve Opening Pressure
    93
    
    Checking the Coolant Circulatory System for Leaks
    94
    
    Adjusting the Clutch Lever Position
    94
    
    Adjusting the Clutch Lever Free Play
    94
    
    Adjusting the Throttle Grip Free Play
    95
    
    Lubricating the Throttle Cable
    96
    
    Cleaning the Air Filter Element
    96
    
    Checking the Throttle Body Joint
    97
    
    Checking the Breather Hoses
    97
    
    Checking the Exhaust System
    97
    
    Checking the Fuel Line
    98
    
    Checking the Engine Oil Level
    98
    
    Changing the Engine Oil
    99
    
    Adjusting the Engine Idling Speed
    100
    
    Adjusting the Valve Clearance
    101
- Chassis
  
  106
  - Bleeding the Brake System
    106
  - Checking the Brake Hose
    107
  - Adjusting the Front Brake
    107
  - Adjusting the Rear Brake
    108
  - Checking the Front Brake Pads
    108
  - Checking the Rear Brake Pads
    110
  - Checking the Rear Brake Pad Insulator
    111
  - Checking the Brake Fluid Level
    111
  - Adjusting the Drive Chain Slack
    112
  - Checking the Front Fork Legs
    113
  - Checking the Front Fork Protector Guide
    113
  - Cleaning the Front Fork Oil Seal and Dust Seal
    113
  - Air Bleeding from Front Fork
    113
  - Adjusting the Front Fork Legs
    114
  - Checking the Swingarm Operation
    115
  - Checking the Rear Suspension
    115
  - Adjusting the Rear Shock Absorber Assembly
    115
  - Checking the Tires
    117
  - Checking and Tightening the Spokes
    117
  - Checking the Wheels
    118
  - Checking the Wheel Bearings
    118
  - Checking and Adjusting the Steering Head
    118
  - Lubricating the Levers
    119
  - Lubricating the Pedal
    119
- Electrical System
  
  120
  - Checking the Spark Plug
    120
  - Checking the Ignition Timing
    120
Chassis

123
- General Chassis
  
  125
  - Removing the Left Side Cover
    126
  - Removing the Seat
    126
  - Removing the Number Plate
    126
- Front Wheel
  
  127
  - Removing the Front Wheel
    128
  - Checking the Front Wheel
    128
  - Disassembling the Front Wheel
    129
  - Assembling the Front Wheel
    129
  - Installing the Front Wheel
    130
- Rear Wheel
  
  131
  - Removing the Rear Wheel
    132
  - Checking the Rear Wheel
    132
  - Disassembling the Rear Wheel
    132
  - Checking and Replacing the Rear Wheel Sprocket
    132
  - Assembling the Rear Wheel
    133
  - Installing the Rear Wheel
    133
- Front Brake
  
  135
- Rear Brake
  
  145
- Handlebar
  
  157
  - Removing the Handlebar
    157
  - Checking the Handlebar
    157
  - Installing the Handlebar
    157
- Front Fork
  
  161
  - Removing the Front Fork Legs
    163
  - Disassembling the Front Fork Legs
    163
  - Checking the Front Fork Legs
    164
  - Assembling the Front Fork Legs
    165
  - Installing the Front Fork Legs
    171
- Steering Head
  
  173
  - Removing the Lower Bracket
    174
  - Checking the Steering Head
    174
  - Installing the Steering Head
    174
- Rear Shock Absorber Assembly
  
  177
- Swingarm
  
  184
  - Removing the Swingarm
    185
  - Removing the Bearing
    185
  - Checking the Swingarm
    185
  - Installing the Swingarm
    186
- Chain Drive
  
  187
  - Removing the Drive Chain
    188
  - Checking the Drive Chain
    188
  - Checking the Drive Sprocket
    189
  - Checking the Rear Wheel Sprocket
    189
  - Installing the Drive Chain
    189
Engine

191
- Engine Removal
  
  194
  - Removing the Silencer
    199
  - Removing the Exhaust Pipe 2
    199
  - Removing the Drive Sprocket
    199
  - Removing the Engine
    200
  - Checking the Silencer and Exhaust Pipe
    200
  - Changing the Silencer Fiber
    200
  - Installing the Engine
    201
  - Installing the Brake Pedal
    202
  - Installing the Drive Sprocket
    202
  - Installing the Exhaust Pipe and Muffler
    203
- Camshaft
  
  204
  - Removing the Camshaft
    206
  - Checking the Camshaft
    207
  - Checking the Timing Chain and Camshaft Sprocket
    208
  - Checking the Timing Chain Tensioners
    208
  - Checking the Decompression System
    209
  - Installing the Camshafts
    209
- Cylinder Head
  
  211
- Valves and Valve Springs
  
  216
  - Removing the Valves
    216
  - Checking the Valves and Valve Guides
    217
  - Checking the Valve Seats
    218
  - Checking the Valve Springs
    220
  - Checking the Valve Lifters
    221
  - Installing the Valves
    221
- Cylinder and Piston
  
  224
  - Removing the Piston
    224
  - Checking the Cylinder and Piston
    224
  - Checking the Piston Rings
    225
  - Checking the Piston Pin
    226
  - Installing the Piston and Cylinder
    226
- Clutch
  
  229
  - Removing the Clutch
    231
  - Checking the Friction Plates
    231
  - Checking the Clutch Plates
    231
  - Checking the Clutch Springs
    231
  - Checking the Clutch Housing
    232
  - Checking the Clutch Boss
    232
  - Checking the Pressure Plate
    232
  - Checking the Push Lever Shaft
    232
  - Checking the Clutch Push Rods
    232
  - Checking the Primary Drive Gear
    232
  - Checking the Primary Driven Gear
    233
  - Installing the Oil Seal
    233
  - Installing the Right Crankcase Cover
    233
  - Installing the Clutch
    234
  - Installing the Kickstarter Lever
    236
- Kickstater
  
  238
- Shift Shaft
  
  240
  - Removing the Shift Guide and Shift Lever Assembly
    242
  - Removing the Segment
    242
  - Checking the Shift Shaft
    242
  - Checking the Shift Guide and Shift Lever Assembly
    242
  - Checking the Stopper Lever
    242
  - Installing the Stopper Lever
    243
  - Installing the Segment
    243
  - Installing the Shift Guide and Shift Lever Assembly
    243
  - Installing the Shift Shaft
    244
  - Installing the Shift Pedal
    244
- Oil Pump and Balancer Gear
  
  246
- Ac Magneto
  
  251
  - Removing the Ac Magneto
    252
  - Checking the Ac Magneto
    252
  - Checking the Woodruff Key
    252
  - Installing the Ac Magneto
    252
- Crankcase
  
  254
  - Disassembling the Crankcase
    257
  - Removing the Crankcase Bearing
    257
  - Checking the Timing Chain, Timing Chain Guide, Oil Strainer
    257
  - Checking the Crankcase
    257
  - Installing the Oil Seal
    258
  - Assembling the Crankcase
    258
- Crankshaft Assembly and Balancer Shaft
  
  259
- Transmission
  
  262
  - Removing the Transmission
    263
  - Checking the Shift Forks
    263
  - Checking the Shift Drum Assembly
    264
  - Checking the Transmission
    264
  - Installing the Transmission
    264
  - Cooling System
    267
    
    Water Pump
    273
Fuel System

275
- Fuel Tank
  
  276
  - Checking the Fuel Pump Body
    277
  - Installing the Fuel Pump
    277
  - Removing the Fuel Pump
    277
  - Removing the Fuel Tank
    277
  - Checking the Fuel Pressure
    278
  - Installing the Fuel Tank
    278
  - Checking and Replacing the Protector
    279
  - Checking the Damper
    279
- Throttle Body
  
  280
  - Checking the Injector
    283
  - Checking the Throttle Body
    283
  - Checking the Throttle Body Joint
    283
  - Adjusting the Throttle Position Sensor
    284
Electrical System

285
- Ignition System
  
  288
  - Circuit Diagram
    288
  - Troubleshooting
    290
- Charging System
  
  292
  - Circuit Diagram
    292
  - Troubleshooting
    294
- Fuel Injection System
  
  296
  - Circuit Diagram
    296
  - Yamaha Diagnostic Tool
    298
  - Troubleshooting Details
    299
- Fuel Pump System
  
  318
  - Circuit Diagram
    318
  - Troubleshooting
    320
- Electrical Components
  
  322
  - Checking the Switches
    324
  - Checking the Ignition Spark Gap
    327
  - Checking the Spark Plug Cap
    327
  - Checking the Ignition Coil
    327
  - Checking the Crankshaft Position Sensor
    328
  - Checking the Ecu
    329
  - Checking the Stator Coil
    329
  - Checking the Rectifier/Regulator
    329
  - Checking the Coolant Temperature Sensor
    330
  - Checking the Throttle Position Sensor
    330
  - Checking the Throttle Position Sensor Input Voltage
    331
  - Checking the Intake Air Pressure Sensor
    332
  - Checking the Intake Air Temperature Sensor
    332
  - Checking the Neutral Switch
    332
  - Checking the Fuel Injector
    333
Troubleshooting

335
- General Information
  335
- Troubleshooting
  
  336
  - General Information
    336
  - Incorrect Engine Idling Speed
    336
  - Starting Failures
    336
  - Clutch Drags
    337
  - Clutch Slips
    337
  - Jumps out of Gear
    337
  - Overheating
    337
  - Poor Medium-And-High-Speed Performance
    337
  - Shift Pedal Does Not Move
    337
  - Shifting Is Difficult
    337
  - Faulty Front Fork Legs
    338
  - Front Fork Oil Leaking
    338
  - Overcooling
    338
  - Poor Braking Performance
    338
  - Unstable Handling
    338
- List of Self-Diagnostic and Fail-Safe Actions
  
  339
Tuning

343
- Chassis
  344
- Drive and Rear Wheel Sprockets Setting Parts
  344
- Selection of the Secondary Reduction Ratio (Sprocket)
  344
- Change in Amount and Characteristics of Fork Oil
  345
- Front Fork Setting
  345
- Tire Pressure
  345
- Choosing Set Length
  346
- Front Fork Setting Parts
  346
- Rear Suspension Setting
  346
- Setting of Spring after Replacement
  346
- Setting of Spring after Replacement
  347
- Rear Shock Absorber Setting Parts
  348
- Suspension Setting (Front Fork)
  349
- Suspension Setting (Rear Shock Absorber)
  350

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