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Yamaha YZ250R Manuals
Manuals and User Guides for Yamaha YZ250R. We have
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Yamaha YZ250R manuals available for free PDF download: Owner's Service Manual, Service Manual
YAMAHA YZ250R Owner's Service Manual (587 pages)
YZ Series
Brand:
YAMAHA
| Category:
Motorcycle
| Size: 16.24 MB
Table of Contents
Important Notice
6
Safety Information
6
Wichtige Hinweise
7
FIM Machine Weights
10
Description
12
How to Use this Manual
12
Chapitre
13
Renseignements Generaux
13
How to Read Descriptions
14
Illustrated Symbols
16
Index
18
Table of Contents
20
Chapter 7
26
Description
26
Engine
26
General Information
26
Vehicle Views
26
Informazioni Generali
27
Chapter 1
28
Engine Serial Number
28
Frame Serial Number
28
Machine Identification
28
Vehicle Identification Number
28
Identification de la Machine
29
Important Information
30
Preparation for Removal and Disassembly
30
Informations Importantes
31
Informazioni Importanti
31
Wichtige Informationen
31
All Replacement Parts
32
Bearings and Oil Seals
32
Gaskets, Oil Seals and O-Rings
32
Lock Washers/Plates and Cotter Pins
32
Circlips
34
Checking of Connection
36
Controllo Dei Collegamenti
37
Verification des Connexions
37
Special Tools
38
Outils Speciaux
40
Utensili Speciali
44
"Engine Stop" Button
46
Clutch Lever
46
Control Functions
46
Shift Pedal
46
Fonctions des Commandes
47
Front Brake Lever
48
Fuel Cock
48
Rear Brake Pedal
48
Starter Knob (Choke)
48
Funzioni Dei Comandi
49
Detachable Sidestand
50
Nipple Wrench
50
Set Pin
50
Valve Joint
50
Fuel and Engine Mixing Oil
52
Essence Et Huile de Melange du Moteur
53
Starting a Cold Engine
54
Starting a Warm Engine
54
Starting and Break-In
54
Mise en Marche Et Rodage
55
Break-In Procedure
56
Starten und Einfahren
57
Torque-Check Points
60
Points de Verification de Couple de Serrage
61
Cleaning and Storage
64
Nettoyage Et Rangement
65
Storage
66
Chapter 2
68
General Specifications
68
Chassis
69
Engine Specifications
70
Maintenance Specifications
70
Chassis Specifications
74
Electrical Specifications
78
Definition of Units
79
General Torque Specifications
79
Caracteristiques Generales
80
Caracteristiques D'entretien
82
Moteur
82
Definition des Unites
91
Moteur
91
Specifications Generales de Couple
91
Allgemeine Technische Daten
92
Technische Daten
92
Wartungsdaten
94
Allgemeine Anzugsdaten
103
Definition der Einheiten
103
Motor
104
Specifiche
104
Specifiche Generali
104
Specifiche DI Manutenzione
106
Alla Coppia
115
Definizione Delle Unità
115
Cable Routing Diagram
116
Diagramma del Passaggio Dei Cavi
117
Schema de Cheminement des Cables
117
Kabelführungsübersichtplan
117
Regular Inspection and Adjustments
126
Chapter 3
126
Maintenance Intervals
126
Revisione Eregolazioni Regolari
135
Intervalli DI Manutenzione
135
Pre-Operation Inspection and Maintenance
138
General Inspection and Maintenance
138
Engine
138
Chassis
138
Ispezione E Manutenzione Prima del Funzionamento
141
Engine Coolant Level Inspection
142
Coolant Replacement
142
Motore
143
Coolant Replacement
144
Radiator Cap Inspection
146
Handling Notes of Coolant
146
Radiator Cap Opening Pressure Inspection
148
Cooling System Inspection
148
Clutch Adjustment
150
Throttle Cable Adjustment
152
Throttle Lubrication
152
Air Filter Cleaning
154
Transmission Oil Level Check
156
Transmission Oil Replacement
158
Pilot Air Screw Adjustment
160
Idle Speed Adjustment
162
Muffler Inspection
162
Silencer Fiber Replacement
162
Silencer Fiber Replacement
164
Chassis
166
Brake System Air Bleeding
166
Telaio
167
Partie Cycle
167
Front Brake Adjustment
168
Rear Brake Adjustment
170
Pedal Height Adjustment Steps
170
Front Brake Pad Inspection and Replacement
170
Rear Brake Pad Inspection and Replacement
174
Front Wheel and Rear Wheel
174
Roue Avant Et Roue Arriere
175
Brake Fluid Level Inspection
178
Rear Brake Pad Insulator Inspection
178
Drive Chain Inspection
180
Sprockets Indpection
180
Drive Chain Slack Adjustment
182
Front Fork Inspection
184
Front Fork Internal Pressure Relieving
186
Front Fork Oil Seal and Dust Seal Cleaning
186
Front Fork Rebound Damping Force Adjustment
186
Front Fork Compression Damping Force Adjustment
188
Fourche Avant
189
Rear Shock Absorber Inspection
190
Rear Shock Absorber Spring Preload Adjustment
192
Rear Shock Absorber Rebound Damping Force Adjustment
194
Rear Shock Absorber Low Compression Damping Force Adjustment
196
Rear Shock Absorber High Compression Damping Force Adjustment
198
Spokes Inspection and Tightening
200
Tire Pressure Check
200
Wheel Inspection
200
Steering Head Inspection and Adjustment
202
Lubrication
206
Electrical Parts
208
Spark Plug Inspection
208
Parte Elettrica
209
Ignition Timing Check
210
Chapter 4
214
Engine
214
Seat, Fuel Tank and Side Covers
214
Motor
215
Sitz, Kraftstofftank und Seitendeckel
215
Side Cover Removal
216
Seitendeckel
217
Exhaust Pipe and Silencer
218
Tubo DI Scarico E Silenziatore
219
Radiator
220
Kühler
221
Radiator Handling Note
222
Radiator Inspection
222
Radiator Installation
224
Carburetor and Reed Valve
226
Vergaser und Zungenventil
227
Carburetor Disassembly
228
Pilot Air Screw Removal
230
Throttle Valve Removal
230
Carburetor Inspection
232
Needle Valve Inspection
232
Throttle Valve Inspection
232
Float Height
234
Jet Needle Inspection
234
Float Inspection
236
Reed Valve Inspection
236
Reed Valve Installation
236
Carburetor Installation
238
Carburetor and Reed Valve
242
Cylinder Head, Cylinder and Piston
248
Zylinderkopf, Zylinder und
249
Piston and Power Valve Removal
250
Push Rod Removal
252
Piston and Piston Ring Removal
252
Cylinder Head Inspection
254
Cylinder Inspection
256
Piston Inspection
256
Piston Pin and Small End Bearing Inspection
258
Piston Ring Inspection
260
Piston Clearance
262
Combination of Piston and Cylinder
262
Kolben
263
Power Valve Inspection
264
Power Valve Hole on Cylinder
264
Power Valve Installation
266
Piston Ring and Piston Installation
270
Cylinder Head and Cylinder Installation
272
Clutch and Primary Driven Gear
278
Clutch Plate and Friction Plate Removal
278
Primary Driven Gear, Push Rod and Push Lever Axle Removal
280
Clutch Boss Removal
282
Clutch Housing and Boss Inspection
282
Clutch Spring Inspection
282
Primary Driven Gear Inspection
282
Primärabtriebszahnrad
283
Clutch Plate Inspection
284
Friction Plate Inspection
284
Push Lever Axle Installation
284
Push Rod Inspection
284
Clutch Installation
286
Kick Axle, Shift Shaft and Primary Driven Gear
292
Primary Driven Gear Removal
292
Kickstarterwelle, Schaltwelle
293
Kick Axle and Shift Shaft Removal
294
Kick Axle and Ratchet Wheel Inspection
296
Kick Axle Assembly Removal
296
Primary Drive Gear Removal
296
Shift Guide and Shift Lever Assembly Removal
296
Kick Gear, Kick Idle Gear and Ratchet Wheel Inspection
298
Shift Guide and Shift Lever Assembly Inspection
298
Shift Shaft Inspection
298
Stopper Lever Inspection
298
Shift Guide and Shift Lever Assembly Installation
300
Stopper Lever Installation
300
Kick Axle Assembly Installation
302
Shift Shaft Installation
302
Kick Idle Gear Installation
304
Primary Drive Gear Installation
306
Und Primärantriebszahnrad
307
YPVS Governor Removal
310
Regolatore Ypvs
311
Regulateur Ypvs
311
Ypvs Regler
311
Bearing Inspection
312
Governor Groove Inspection
312
Governor Installation
312
Governor Removal
312
Wasserpumpe
315
Water Pump Disassembly
316
Pompe a Eau
317
Impeller Shaft Inspection
318
Impeller Shaft Removal
318
Oil Seal Removal
318
Impeller Shaft Gear Inspection
320
Oil Seal Inspection
320
Oil Seal Installation
320
Impeller Shaft Installation
322
CDI Magneto Removal
324
Magnete CDI
325
Magneto CDI
325
CDI Magneto Inspection
326
CDI Magneto Installation
326
Rotor Removal
326
Woodruff Key Inspection
326
Engine Removal
332
Depose du Moteur
333
Rimozione del Motore
335
Drive Sprocket Removal
336
Engine Removal Steps
336
Brake Pedal Installation
338
Engine Installation
338
Drive Sprocket Installation
340
Crankcase and Crankshaft Removal
342
Carter Et Vilebrequin
343
Kurbelgehäuse und
343
Crankcase Removal
344
Segment Removal
344
Crankcase Inspection
346
Crankshaft Bearing Removal
346
Crankshaft Removal
346
Kurbelwelle
347
Crankshaft Bearing Installation
348
Crankshaft Inspection
348
Crankshaft Installation
350
To Install Oil Seal
350
Transmission, Shift Cam and Shift Fork Removal
356
Getriebe, Schaltnocke und
357
Gears Inspection
358
Transmission Removal
358
Schaltgabel
359
Shift Fork, Shift Cam and Segment Inspection
360
Transmission Installation
360
Chassis Works
366
Front Wheel Removal
366
Front Wheel and Rear Wheel
366
Motor
367
Fahrgestell
367
Rear Wheel Removal
368
Ruota Anteriore E Ruota Posteriore
369
Rear Wheel Bearing Removal
370
Rear Wheel Inspection
370
Wheel Axle Inspection
372
Brake Disc Inspection
372
Front Wheel Installation
374
Rear Wheel Installation
378
Front Brake Removal
384
Front Brake and Rear Brake
384
Vorderradbremse und
385
Frein Avant Et Frein Arriere
385
Rear Brake Removal
386
Hinterradbremse
387
Freno Posteriore
387
Caliper Disassembly
388
Master Cylinder Disassembly
390
Brake Fluid
392
Caliper Piston Removal
392
Piston Seal Kit Removal
394
Master Cylinder Inspection
394
Caliper Inspection
396
Brake Hose Inspection
396
Caliper Piston Installation
396
Front Caliper Installation
398
Rear Caliper Installation
400
Master Cylinder Kit Installation
402
Front Master Cylinder Installation
404
Rear Master Cylinder Installation
406
Front Brake Hose Installation
408
Rear Brake Hose Installation
410
Brake Fluid Filling
412
Front Fork Removal
416
Vorderradgabel
417
Fourche Avant
417
Front Fork Disassembly
418
Forcella Anteriore
419
Front Fork Handling Notes
420
Cap Bolt Removal
420
Inner Tube Removal
422
Damper Rod Removal
422
Damper Rod Inspection
422
Base Valve Inspection
424
Fork Spring Inspection
424
Inner Tube Inspection
424
Outer Tube Inspection
424
Cap Bolt Inspection
426
Front Fork Assembly
426
Front Fork Installation
438
Handlebar Removal
442
Throttle Disassembly
444
Master Cylinder Removal
446
Handlebar Inspection
446
Throttle Assembly
446
Handlebar Installation
448
Steering Removal
456
Ring Nut Removal
458
Bearing (Lower) Removal
458
Ball Race Removal
458
Steering Shaft Inspection
458
Bearing and Ball Race
460
Under Bracket Installation
460
Swingarm Removal
466
Bras Oscillant
467
Swingarm Disassembly
468
Forcellone Oscillante
469
Swingarm Inspection
470
Relay Arm Inspection
470
Connecting Rod Inspection
472
Bearing and Oil Seal Installation
472
Swingarm Installation
474
Rear Shock Absorber Removal
482
Ammortizzatore Posteriore
483
Et Couvercles Lateraux
483
Silenziatore
483
Telaio
483
Rear Shock Absorber Disposal
484
Rear Shock Absorber Handling Note
484
Rear Shock Absorber: Inspection
486
Spring (Rear Shock Absorber) Installation
488
Rear Shock Absorber Installation
490
Electrical Components Diagram
494
Wiring Diagram
494
Composants Electriques
495
Elektrische Einrichtungen
495
Et Schema de Cablage
495
Ignition System Inspection Steps
496
Systeme D'allumage
497
"Engine Stop" Button Inspection
500
Couplers and Leads Connection Inspection
500
Spark Gap Test
500
Ignition Coil Inspection
502
CDI Magneto Inspection
504
Spark Plug Cap Inspection
504
Magneto CDI
505
CDI Unit Inspection
506
Solenoid Valve System Inspection Steps
508
Systeme D'electrovanne
509
Magnetventilsystem
510
Spezialwerkzeuge
510
Utensili Speciali
511
Couplers and Leads Connection Check
512
Solenoid Valve Operation
512
Solenoid Valve Coil Inspection
512
Solenoid Valve System
512
TPS (Throttle Position Sensor) System Inspection Steps
514
Tps-System
516
Sistema Tps (Sensore DI Posizione Dell'acceleratore)
517
TPS Coil Inspection
518
Vergaser und Zungenventil
519
TPS Replacement and Adjustment
520
TPS Input Voltage Inspection
526
Atmospheric Conditions and Carburetor Setting
528
Carburetor Setting
528
Tuning
528
Messa a Punto
529
Motore
529
Test Run (Carburetor)
530
Effects of Setting Parts in Relation to Throttle Valve Opening
532
Main Jet Adjustment
532
Power Jet Adjustment
532
Jet Needle Groove Position Adjustment
534
Pilot Jet Adjustment
534
Jet Needle Adjustment (for USA, CDN, ZA, aus and NZ)
538
Jet Needle Adjustment (for Europe)
540
Relationship with Throttle Opening
542
Carburetor Setting Parts
544
Examples of Carburetor Setting Depending on Symptom
546
Road Condition and Examples of Carburetor Setting
546
Change of the Heat Range of Spark Plugs
554
Selection of the Secondary Reduction Ratio (Sprocket)
556
Fahrgestell
557
Partie Cycle
557
Telaio
557
Drive and Driven Sprockets Setting Parts
558
Tire Pressure
558
Change in Level and Characteristics of Fork Oil
560
Front Fork Setting
560
Fourche Avant
561
Setting of Spring after Replacement
562
Spring Preload Adjustment
562
Front Fork Setting Parts
566
Choosing Set Length
568
Rear Suspension Setting
568
To Set the Spring after Replacement
570
Rear Shock Absorber Setting Parts
574
Suspension Setting
576
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Yamaha YZ250R Service Manual (270 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 9.8 MB
Table of Contents
Important Notice
6
Table of Contents
13
Chapter 1 General Information
16
Description
16
Machine Identification
17
Important Information
18
Checking of Connection
21
Special Tools
22
Control Functions
24
Fuel and Engine Mixing Oil
27
Starting and Break-In
28
Torque-Check Points
31
Cleaning and Storage
32
Chapter 2 Specifications
34
General Specifications
34
Maintenance Specifications
36
General Torque Specifications
45
Definition of Units
45
Cable Routing Diagram
46
Chapter 3 Regular Inspection and Adjustments
51
Maintenance Intervals
51
Pre-Operation Inspection and Maintenance
54
Engine
55
Silencer Fiber Replacement
66
Chassis
67
Rear Brake Adjustment
69
Rear Shock Absorber Inspection
79
Electrical
88
Chapter 4
91
Seat, Fuel Tank and Side Covers
91
Exhaust Pipe and Silencer
93
Radiator
94
Carburetor and Reed Valve
97
Cylinder Head, Cylinder and Piston
108
Clutch and Primary Driven Gear
123
Kick Axle, Shift Shaft and Primary Drive Gear
130
Kick Axle and Shift Shaft
131
Ypvs Governor
139
Water Pump
142
CDI Magneto
146
Engine Removal
150
Crankcase and Crankshaft
155
Transmission, Shift Cam and Shift Fork
162
Chapter 5 Chassis
167
Front Wheel and Rear Wheel
167
Rear Wheel
168
Front Brake and Rear Brake
175
Rear Brake
176
Caliper Disassembly
177
Front Fork
191
Front Fork Disassembly
192
Handlebar
204
Steering
211
Swingarm
216
Rear Shock Absorber
224
Chapter 6
230
Electrical Components and Wiring Diagram
230
Ignition System
231
Solenoid Valve System
236
Tps (Throttle Position Sensor) System
238
Chapter 7 Tuning
244
Engine
244
Chassis
256
Suspension Setting
266
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