Yamaha YZ250M User Manual

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Summary of Contents

Page 1 - CANADA,U.S.A.,SOUTH AFRICA

A2YZ250M(5HC1)CANADA,U.S.A.,SOUTH AFRICAYZ250(5HC2)EUROPEYZ250(5HC3)JAPANYZ250M(5HC4)OCEANIA205HC–100E1

Page 2

B7FIG. 5 RADIATOR. HOSE1 4SR–1240A–10 RADIATOR ASSY 1 1 1 12 91A20–05065 TUBE, FLEXIBLE VINYL 1 1 1 13 90467–09006 CLIP 1 1 1 14 4SR–12461–10 RADIATOR

Page 3 - FOREWORD

B8FIG. 6 INTAKE1 4XL–13610–00 REED VALVE ASSY 1 1 1 12 4XL–13613–00 .REED, VALVE 2 2 2 23 4XL–13616–00 .STOPPER, REED VALVE 2 2 2 24 98507–03008 .SCRE

Page 4 - MODEL LABEL

B9FIG. 7 CARBURETOR1 5HC–14101–00 CARBURETOR ASSY 1 1 1 15HC–14101–10 CARBURETOR ASSY 1 12 4JT–14171–00 .PLUNGER, STARTER 1 1 1 13 4SR–14985–00 .FLOAT

Page 5 - FIG. 1 CYLINDER HEAD

B10FIG. 7 CARBURETOR10 4SR–14916–CJ .NEEDLE (N3CJ) 1 1 1 1 AP4SR–14916–EG .NEEDLE (N3EG) 1 1 1 1 AP4SR–14916–EH .NEEDLE (N3EH) 1 1 1 1 AP4SR–14916–EW

Page 6

B11FIG. 7 CARBURETOR23 4MX–14943–95 .JET, MAIN (#188) 1 1 1 1 AP4MX–14943–45 .JET, MAIN (#190) 1 1 1 1 AP24 4MX–14194–00 .RING 1 1 1 125 98502–04012 .

Page 7 - FIG. 2 GOVERNOR

B12FIG. 8 EXHAUST1 5CU–14610–00 EXHAUST PIPE ASSY 1 1 1 1 12 93210–53638 O–RING 2 2 2 23 90507–20052 SPRING, TENSION 2 2 2 24 5CU–14771–00 STAY, MUFFL

Page 8 - FIG. 3 CRANKSHAFT. PISTON

B13FIG. 9 CRANKCASE1 5CU–15111–01 CRANKCASE 1 1 1 1 12 5CU–15121–01 CRANKCASE 2 1 1 1 13 91317–06050 BOLT 7 7 7 74 91317–06060 BOLT 1 1 1 15 91317–060

Page 9 - FIG. 4 WATER PUMP

B14FIG. 10 CRANKCASE COVER 11 5CU–15411–00 COVER, CRANKCASE 1 1 1 1 12 5CU–15451–00 GASKET, CRANKCASE COVER 1 1 1 1 13 98507–06030 SCREW, PAN HEAD 5 5

Page 10 - FIG. 5 RADIATOR. HOSE

B15FIG. 11 STARTER1 5CU–15601–01 KICK SHAFT ASSY 1 1 1 12 90201–20685 .WASHER, PLATE (0.5T) 1 1 1 13 93410–20038 .CIRCLIP 1 1 1 14 90501–16107 .SPRING

Page 11 - FIG. 6 INTAKE

C2FIG. 12 CLUTCH1 5DJ–16111–00 GEAR, PRIMARY DRIVE 1 1 1 12 90387–2513A COLLAR 1 1 1 13 5CU–11956–00 GEAR, GOVERNOR DRIVE 1 1 1 14 90201–105P3 WASHER,

Page 13

C3FIG. 12 CLUTCH28 90430–05242 GASKET 1 1 1 1PART NO. DESCRIPTION REMARKSREF.NO.5HC15HC25HC35HC4

Page 14

C4FIG. 13 TRANSMISSION1 5BE–17411–00 AXLE, MAIN 1 1 1 12 93306–20540 BEARING 1 1 1 13 5BE–17151–00 GEAR, 5TH PINION 1 1 1 14 90201–253K0 WASHER, PLATE

Page 15 - FIG. 8 EXHAUST

C5FIG. 13 TRANSMISSION28 9383E–14210 SPROCKET, DRIVE (14T) 1 1 1 1 STD9383E–13144 SPROCKET,DRIVE 13T(2141746130) 1 1 1 1 AP29 90215–21256 WASHER, LOCK

Page 16 - FIG. 9 CRANKCASE

C6FIG. 14 SHIFT CAM. FORK1 5CU–18541–00 CAM, SHIFT 1 1 1 12 93306–90504 BEARING 1 1 1 13 5DH–18562–00 PLATE, STOPPER 2 2 2 2 24 90105–06553 BOLT, W AS

Page 17 - FIG. 10 CRANKCASE COVER 1

C7FIG. 15 SHIFT SHAFT1 5CU–18101–00 SHIFT SHAFT ASSY 1 1 1 12 5CU–18122–00 LEVER, SHIFT 2 1 1 1 13 90387–124F4 COLLAR 1 1 1 14 90201–12575 WASHER, PLA

Page 18 - FIG. 11 STARTER

C8FIG. 16 FRAME1 5HC–21110–00–P0 FRAME COMP. 1 1 1 1 DPBMC2 5HC–21190–00–P0 REAR FRAME COMP. 1 1 1 1 DPBMC3 90110–08096 BOLT, HEXAGON SOCKET HEAD 2 2

Page 19 - FIG. 12 CLUTCH

C9FIG. 17 FENDER1 5HD–21511–00 FENDER, FRONT 1 1 1 12 3JD–21748–00 COLLAR 4 4 4 43 90119–06096 BOLT, WITH WASHER 4 4 4 44 99241–00080 EMBLEM, YAMAHA 1

Page 20

C10FIG. 18 SIDE COVER1 4SS–21711–00 COVER, SIDE 1 1 1 1 12 95827–06016 BOLT, FLANGE 1 1 1 13 90387–06009 COLLAR 1 1 1 14 95827–06016 BOLT, FLANGE 1 1

Page 21 - FIG. 13 TRANSMISSION

C11FIG. 19 REAR ARM1 5CU–22110–00 REAR ARM COMP. 1 1 1 12 90151–04048 SCREW, COUNTERSUNK 4 4 4 43 5ET–22355–00 PATCH 2 2 2 24 93317–22262 BEARING 4 4

Page 22

C12FIG. 19 REAR ARM28 90109–147F2 BOLT 1 1 1 129 90109–142F4 BOLT 2 2 2 230 90201–164H4 WASHER, PLATE 2 2 2 231 90201–14740 WASHER, PLATE 3 3 3 332 90

Page 23 - FIG. 14 SHIFT CAM. FORK

FOREWORDA4This Parts Catalogueis related to theparts forthemodel(s)inthebelowframe. When you areorderingreplacementparts,pleaserefertothisParts Catalo

Page 24 - FIG. 15 SHIFT SHAFT

C13FIG. 20 REAR SUSPENSION1 5HC–22210–00 SHOCK ABSORBER ASSY, REAR 1 FOR USA5HC–22210–10 SHOCK ABSORBER ASSY, REAR 15HC–22210–20 SHOCK ABSORBER ASSY,

Page 25 - FIG. 16 FRAME

C14FIG. 20 REAR SUSPENSION19 90105–105A2 BOLT, WASHER BASED 1 1 1 120 90201–112U6 WASHER, PLATE 1 1 1 1PART NO. DESCRIPTION REMARKSREF.NO.5HC15HC25HC3

Page 26 - FIG. 17 FENDER

C15FIG. 21 STEERING1 93332–00081 BEARING 1 1 1 12 93332–00068 BEARING 1 1 1 13 4EW–23416–00 COVER, BALL RACE 2 1 1 1 14 90179–28650 NUT 1 1 1 15 5HC–2

Page 27 - FIG. 18 SIDE COVER

D2FIG. 22 FRONT FORK1 5HC–23102–00 FRONT FORK ASSY (L.H) 1 15HC–23102–10 FRONT FORK ASSY (L.H) 15HC–23102–20 FRONT FORK ASSY (L.H) 12 5HD–23136–L0 .TU

Page 28 - FIG. 19 REAR ARM

D3FIG. 22 FRONT FORK21 5HC–23103–20 FRONT FORK ASSY (R.H) 122 5HD–23136–L0 .TUBE, OUTER (RIGHT) 1 1 1 123 5BF–23110–L0 .INNER TUBE COMP.1 1 1 1 124 5E

Page 29

D4FIG. 22 FRONT FORK45 4SS–23346–L0 BOLT 1 2 2 2 246 5DH–2314J–00 PROTECTER COMP., 2 1 1 1 147 5DH–2314H–00 PROTECTER COMP., 1 1 1 1 148 3SP–23356–L0

Page 30 - FIG. 20 REAR SUSPENSION

D5FIG. 23 FUEL TANK1 5CU–24110–00 FUEL TANK COMP. 1 1 1 12 1UY–24610–00 CAP ASSY 1 1 1 13 90445–09220 HOSE 1 1 1 14 3XJ–24380–00 PIPE JOINT ASSY 1 1 1

Page 31

D6FIG. 24 SEAT1 5DH–24770–00 SEMI–DOUBLE SEAT ASSY 1 1 1 12 5DH–24731–00 .COVER, SEAT 1 1 1 13 4SS–24728–00 .BRACKET, SEAT 2 2 2 24 97007–06012 .BOLT

Page 32 - FIG. 21 STEERING

D7FIG. 25 FRONT WHEEL1 4SS–25111–00 HUB, FRONT 1 1 1 12 93306–90403 BEARING 2 2 2 23 5DH–25117–00 SPACER, BEARING 1 1 1 14 93102–26468 OIL SEAL 2 2 2

Page 33 - FIG. 22 FRONT FORK

D8FIG. 26 FRONT BRAKE CALIPER1 4XM–2582T–00 DISC, BRAKE 1 1 1 12 90149–06327 SCREW 6 6 6 63 5DH–2580T–00 CALIPER ASSY (LEFT) 1 1 15DH–2580T–10 CALIPER

Page 34

MODEL LABELA5(1) A label called “Model Label” is affixed in the location as indicated in (3) below.When using this parts catalogue, please be sure to

Page 35

D9FIG. 27 REAR WHEEL1 5ET–25311–00 HUB, REAR 1 1 1 12 5ET–25317–00 SPACER, BEARING 1 1 1 13 93306–27205 BEARING 1 1 1 14 93306–07202 BEARING 1 1 1 15

Page 36 - FIG. 23 FUEL TANK

D10FIG. 27 REAR WHEEL19 90480–08608 GROMMET 1 1 1 120 5ET–25383–00 COLLAR, WHEEL 2 2 2 221 5ET–25388–00 PULLER, CHAIN 1 1 1 1 122 5ET–25389–00 PULLER,

Page 37 - FIG. 24 SEAT

D11FIG. 28 REAR BRAKE CALIPER1 5DH–2582W–00 DISC, REAR BRAKE 2 1 1 1 12 90109–065G4 BOLT 6 6 6 63 5ET–2580W–00 CALIPER ASSY, REAR 2 1 1 1 14 5ET–W0057

Page 38 - FIG. 25 FRONT WHEEL

D12FIG. 29 STEERING HANDLE. CABLE1 4XM–26111–00 HANDLEBAR 1 1 1 12 4GY–26241–00 GRIP (LEFT) 1 1 1 13 4XM–26240–00 GRIP ASSY 1 1 1 14 4GY–26242–00 .GRI

Page 39 - FIG. 26 FRONT BRAKE CALIPER

D13FIG. 30 FRONT MASTER CYLINDER1 5ET–25872–00 HOSE, BRAKE 1 1 1 1 12 90201–10118 WASHER, PLATE 4 4 4 43 90401–10168 BOLT, UNION 2 2 2 24 4SS–W2587–01

Page 40 - FIG. 27 REAR WHEEL

D14FIG. 31 STAND. FOOTREST1 4XM–27200–00 PEDAL, BRAKE 1 1 1 12 4SS–27217–00 BOLT 1 1 1 13 93210–11073 O–RING 2 2 2 24 91401–20012 PIN, COTTER 1 1 1 15

Page 41

D15FIG. 32 REAR MASTER CYLINDER1 3SP–2583V–00 RR. MASTER CYLINDER ASSY. 1 1 1 12 4SS–W0042–50 .CYLINDER KIT, MASTER 1 1 1 13 93210–15620 .O–RING 1 1 1

Page 42 - FIG. 28 REAR BRAKE CALIPER

E2FIG. 33 GENERATOR1 5CU–85560–00 BASE ASSY 1 1 1 12 5CU–85550–10 ROTOR ASSY 1 1 1 13 90149–06011 SCREW 3 3 3 34 90179–10394 NUT 1 1 1 15 90201–10591

Page 43 - PART NO. DESCRIPTION REMARKS

E3FIG. 34 HANDLE SWITCH. LEVER1 5HD–82911–00 HOLDER, LEVER 1 1 1 1 12 38V–82913–00 HOLDER, LEVER LOWER 1 1 1 1 13 5HD–83912–00 LEVER 1 1 1 1 14 90109–

Page 44 - FIG. 30 FRONT MASTER CYLINDER

E4FIG. 35 ELECTRICAL 11 5HC–85540–00 C.D.I. UNIT ASSY 1 1 1 12 5CU–85546–00 BAND 1 1 1 13 5BE–82310–00 IGNITION COIL ASSY 1 1 1 14 95027–06016 BOLT, F

Page 45 - FIG. 31 STAND. FOOTREST

B2FIG. 1 CYLINDER HEAD1 5CU–11111–00 HEAD, CYLINDER 1 1 1 1 12 94702–00326 PLUG, SPARK (NGK BR8EG) 1 1 1 13 90116–08394 BOLT, STUD 6 6 6 64 93604–0807

Page 46 - FIG. 32 REAR MASTER CYLINDER

E5FIG. 36 ALTERNATE (CHASSIS)1 5ET–22212–20 SPRING (K=APPROX.4.6) 1 1 1 1 AP5ET–22212–00 SPRING (K=APPROX.4.8) 1 1 1 1 AP5ET–22212–10 SPRING (K=APPROX

Page 47 - FIG. 33 GENERATOR

E6FIG. 37 OPTIONAL PARTS 11 5CU–11630–00 PISTON ASSY (STD) 1 1 1 12 5CU–11631–00–A0 .PISTON (STD) 1 1 1 15CU–11631–00–B0 .PISTON (STD) 1 1 1 15CU–1163

Page 48 - FIG. 34 HANDLE SWITCH. LEVER

NUMERICAL INDEXPARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.M14SS–W0041–00 D – 134SS–W0042–50 D – 155DH–W0045–0

Page 49 - FIG. 35 ELECTRICAL 1

NUMERICAL INDEXPARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.M23V6–22358–00 D – 54EW–22474–00 C – 133JE–22475–00

Page 50 - FIG. 36 ALTERNATE (CHASSIS)

NUMERICAL INDEXPARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.PARTNO.GRIDNO.M390201–164H4 C – 11C–1290201–167P7 B – 1590201–202

Page 51 - FIG. 37 OPTIONAL PARTS 1

CONTENTSENGINECYLINDER HEAD B2...GOVERNOR B4...CRANKSHAFT. PISTON B5...

Page 52

B3FIG. 1 CYLINDER HEAD28 98907–05012 SCREW, BIND 2 2 2 229 93104–08040 OIL SEAL 1 1 1 130 4SS–11832–00 LEVER, LINK 1 1 1 131 90508–155B8 SPRING, TORSI

Page 53

B4FIG. 2 GOVERNOR1 4JY–11915–01 PLATE, THRUST 1 1 1 1 12 98907–05012 SCREW, BIND 1 1 1 13 90105–05002 BOLT, W ASHER BASED 1 1 1 14 90201–057H5 WASHER,

Page 54

B5FIG. 3 CRANKSHAFT. PISTON1 5CU–11631–00–A0 PISTON (STD) 1 1 1 1 UR5CU–11631–00–B0 PISTON (STD) 1 1 1 1 UR5CU–11631–00–C0 PISTON (STD) 1 1 1 1 UR5CU–

Page 55 - CONTENTS

B6FIG. 4 WATER PUMP1 5CU–12459–00 GEAR, IMPELLER SHAFT 1 1 1 12 5DJ–12451–00 IMPELLER, WATER PUMP 1 1 1 13 90201–08512 WASHER, PLATE 1 1 1 14 93109–11

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