YAMAHA YZ250F(D) Motocross Bike Manuals

Manuals and User Guides for YAMAHA YZ250F(D) Motocross Bike. We have 1 YAMAHA YZ250F(D) Motocross Bike manual available for free PDF download: Owner's Service Manual

YAMAHA YZ250F(D) Owner's Service Manual (199 pages)

YZ Series

Brand: YAMAHA | Category: Motorcycle | Size: 12.3 MB

Safety Information
6
How to Use the Manual
7
Illustrated Symbols
8
Table of Contents
9
General Information
10
Location of Important Labels
11
Location of Important Labels
14
Vehicle View and Parts Identification
15
Description
15
Engine
15
Vehicle Identification Number
16
Included Items
16
Engine Serial Number
16
Preparation for Removal and Disassembly
16
Consumer Information
16
Included Parts
16
Important Information
16
Checking of Connection
17
Special Tools
18
Control Functions
22
Clutch Lever
22
Throttle Grip
22
Shift Pedal
22
Starting and Break-In
23
Restarting an Engine after a Fall
23
Torque-Check Points
25
Cleaning and Storage
26
Specifications
27
Chassis
28
Maintenance Specifications
29
Tightening Torques
36
Electrical
36
Lubrication Diagrams
42
Cable Routing Diagram
44
Maintenance Intervals
51
Regular Inspection and Adjustments
51
Pre-Operation Inspection and Maintenance
55
Checking the Coolant Level
56
Changing the Coolant
56
Checking the Radiator Cap
56
Checking Radiator Cap Opening Pressure
56
Engine Maintenance
56
Checking the Cooling System
57
Adjusting the Clutch Lever Position
57
Adjusting the Clutch Lever Free Play
57
Adjusting the Throttle Grip Free Play
57
Cleaning the Air Filter Element
58
Lubricating the Throttle
58
Adjusting the Hot Starter Lever Free Play
58
Checking the Engine Oil Level
59
Changing the Engine Oil
59
Checking the Oil Pressure
60
Adjusting the Pilot Screw
60
Adjusting the Engine Idling Speed
60
Adjusting the Valve Clearance
61
Specifications
61
Adjustments
62
Intake
63
Exhaust
63
Engine
63
Chassis
64
Bleeding the Hydraulic Brake System
64
Adjusting the Brakes
64
Checking and Replacing the Front Brake Pads
65
Checking and Replacing the Rear Brake Pads
65
Checking the Rear Brake Pad Insulator
66
Checking the Brake Fluid Level
66
Checking the Sprocket
67
Checking the Drive Chain
67
Adjusting the Drive Chain Slack
67
Checking the Front Fork
68
Relieving the Fron Fork Internal Pressure
68
Cleaning the Front Fork Oil Seal and Dust Seal
68
Adjusting the Front Fork Rebound Damping Force
68
Adjusting the Front Fork Compression Damping Force
69
Checking the Rear Shock Absorber
69
Adjusting the Rear Shock Absorber Spring Preload
69
Adjusting the Rear Shock Absorber Rebound Damping Force
69
Adjusting the Rear Shock Absorber Low Compression Damping Force
70
Adjusting the Rear Shock Absorber High Compression Damping Force
70
Checking the Tire Pressure
70
Checking and Tightening the Spokes
70
Checking the Wheels
71
Checking and Adjusting the Steering Head
71
Lubrication
73
Electrical Components Maintenance
74
Checking the Spark Plug
74
Checking the Ignition Timing
74
Seat, Fuel Tank and Side Covers
75
Removing the Side Cover
76
Removing the Number Plate
76
Exhaust Pipe and Silencer Removal
77
Silencer Disassembly
78
Checking the Silencer and Exhaust Pipe
79
Changing the Silencer Fiber
79
Installing the Silencer and Exhaust Pipe
80
Radiator Removal
81
Checking the Radiator
82
Radiator Installation
82
Carburetor Removal
83
Carburetor Disassembly
84
Removing the Pilot Screw
86
Checking the Needle Valve
86
Checking the Carburetor
86
Measuring and Adjusting the Float Height
86
Carburetor Assembly
87
Checking the Starter Plunger
87
Checking the Accelerator Pump
87
Adjusting the Accelerator Pump Timing
89
Installing the Carburetor
89
Camshafts
90
Removing the Cylinder Head Cover
90
Removing the Camshafts
91
Checking the Camshaft
92
Checking the Camshaft Sprocket
93
Checking the Decompression System
93
Checking the Timing Chain Tensioner
93
Installing the Camshaft
93
Cylinder Head Removal
95
Checking the Cylinder Head
96
Installing the Cylinder Head
96
Valves and Valve Springs Removal
97
Removing the Valve Lifter and Valve Cotter
98
Checking the Valve Springs
100
Checking the Valve Lifters
100
Installing the Valves
100
Cylinder and Piston Removal
101
Removing the Piston and Piston Ring
102
Checking the Cylinder and Piston
102
Checking the Piston Ring
102
Cylinder Installation
104
Clutch Removal
105
Removing the Clutch Boss
107
Checking the Clutch Springs
107
Checking the Clutch Housing and Boss
107
Installing the Push Lever Shaft
107
Installing the Clutch
108
Oil Filter Element and Water Pump Removal
109
Removing the Impeller Shaft
111
Removing the Oil Seal
111
Checking the Oil Delivery Pipe
111
Checking/Installing the Oil Seal
111
Installing the Impeller Shaft
112
Installing the Right Crankcase Cover
112
Installing the Kickstarter Crank
112
Installing the Water Pump Housing
113
Installing the Oil Filter Element
113
Balancer Removal
114
Checking the Balancer Shaft
115
Balancer Installation
115
Oil Pump Removal
116
Oil Tank Removal
117
Checking the Oil Pump
118
Oil Pump Installation
118
Oil Tank Breather Hose
119
Kick Shaft and Shift Shaft Removal
120
Removing the Kick Shaft Assembly
122
Removing the Shift Guide and Shift Lever Assembly
122
Checking the Shift Shaft
122
Checking the Stopper Lever
122
Installing the Stopper Lever
123
Installing the Shift Guide and Shift Lever Assembly
123
Installing the Shift Shaft
123
Installing the Kick Shaft Assembly
123
Installing the Kick Idle Gear
124
CDI Magneto Removal
125
Removing the Rotor
126
Checking the CDI Magneto
126
Installing the CDI Magneto
126
Checking the Woodruff Key
126
Engine Removal
127
Removing the Drive Sprocket
129
Installing the Engine
129
Installing the Brake Pedal
129
Installing the Drive Sprocket
130
Installing the Neutral Switch
130
Crankshaft Removal
131
Crankcase and Crankshaft
131
Crankcase Bearing Removal
133
Disassembling the Crankcase
134
Removing the Crankshaft
134
Checking the Crankcase
134
Checking the Crankshaft
134
Checking the Oil Strainer
135
Checking the Oil Delivery
135
Installing the Crankcase Bearing
135
Installing the Crankshaft
135
Transmission, Shift Cam and Shift Fork Removal
137
Shift Cam and Shift Fork
137
Checking the Gears
138
Installing the Transmission
138
Checking the Shift Fork, Shift Cam and Segment
138
Front Wheel and Rear Wheel
140
Removing the Front Wheel
140
Removing the Rear Wheel
141
Removing the Wheel Bearing
142
Checking the Wheel Axle
142
Checking the Brake Disc
142
Installing the Front Wheel
142
Front Wheel and Rear Wheel
142
Installing the Rear Wheel
143
Removing the Front Brake
145
Front Brake and Rear Brake
145
Removing the Rear Brake
146
Disassembling the Brake Caliper
147
Disassembling the Brake Master Cylinder
148
Draining the Brake Fluid
149
Removing the Brake Caliper Piston
149
Removing the Brake Caliper Piston Seal Kit
149
Checking the Brake Master Cylinder
149
Checking the Brake Caliper
150
Installing the Brake Caliper Piston
150
Installing the Front Brake Caliper
150
Installing the Rear Brake Caliper
151
Installing the Brake Master Cylinder Kit
151
Installing the Front Brake Master Cylinder
152
Installing the Rear Brake Master Cylinder
152
Installing the Front Brake Hose
152
Installing the Rear Brake Hose
153
Filling the Brake Fluid
153
Front Fork Removal
155
Front Fork Disassembly
156
Removing the Damper Assembly
157
Removing the Adjuster
157
Removing the Inner Tube
157
Removing the Base Valve
157
Checking the Damper Assembly
158
Checking the Front Spring
158
Checking the Adjuster
158
Assembling the Front Fork
158
Installing the Front Fork
162
Handlebar Removal
163
Removing the Brake Master Cylinder
164
Installing the Handlebar
164
Removing the Grip
164
Steering Removal
167
Checking the Steering Stem
168
Checking the Bearing and Bearing Race (Steering)
168
Swingarm Removal
170
Swingarm Disassembly
171
Checking the Swingram
172
Checking the Relay Arm
172
Checking the Connecting Rod
172
Installing the Bearing and Oil Seal
172
Installing the Swingarm
173
Rear Shock Absorber Removal
175
Rear Shock Absorber Bearing Removal
176
Rear Shock Absorber Bearing Installation
177
Rear Shock Absorber Spring Installation
177
Installing the Rear Shock Absorber
177
Electrical Components and Wiring Diagram
180
Ignition System Inspection
181
Spark Gap Test
182
Checking the Engine Stop Switch
182
Checking the Ignition Coil
182
Checking the Couplers, Leads and Ignition Coil Connection
182
Checking the Neutral Switch
183
Throttle Position Sensor System Inspection
184
Checking the Throttle Position Sensor Coil
185
Changing and Adjusting the Throttle Position Sensor
185
Checking the Throttle Position Sensor Input Voltage
186
Engine Tuning
187
Carburetor Setting
187
Effect of Setting Parts in Relation to Throttle Valve Opening
187
Adjusting the Main Jet
187
Adjusting the Pilot Jet
188
Adjusting the Jet Needle Groove Position
188
Relationship with Throttle Opening
188
Adjusting the Jet Needle
188
Adjusting the Leak Jet (Accelerator Pump)
189
Carburetor Setting Parts
189
Specifications of Jet Needle
190
Examples of Carburetor Setting Depending on Symptom
190
Chassis Maintenance
192
Selection of the Secondary Reduction Ratio (Sprocket)
192
Drive and Rear Wheel Sprockets Setting Parts
192
Tire Pressure
192
Setting of Spring after Replacement
193
Front Fork Setting Parts
193
Rear Suspension Setting
193
Setting of Spring after Replacement (Rear)
194
Rear Shock Absorber Setting Parts
194
Suspension Setting (Front Fork)
195
Suspension Setting (Rear Shock Absorber)
196

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