Yamaha YZ250M manuals

Yamaha YZ250M Service Manual (270 pages)

Brand: Yamaha | Category: Cars | Size: 10.44 MB |

English

Table of contents

OWNER’S SERVICE MANUAL

1

EC010000

3

INTRODUCTION

4

EC030002

5

SAFETY INFORMATION

6

TO THE NEW OWNER

8

PARTICULARLY IMPORTANT

9

INFORMATION

9

MANUAL FORMAT

10

ILLUSTRATED SYMBOLS

11

(Refer to the illustration)

11

EC090000

12

CONTENTS

13

CHAPTER 4

14

CHAPTER 5

14

CHAPTER 6

15

ELECTRICAL

15

CHAPTER 7

15

GENERAL INFORMATION

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

GENERAL SPECIFICATIONS

34

MAINTENANCE SPECIFICATIONS

36

DEFINITION OF UNITS

45

GENERAL TORQUE SPECIFICATIONS

45

CABLE ROUTING DIAGRAM

46

MAINTENANCE INTERVALS

51

EC320000

53

EC321000

53

1 Radiator

54

COOLANT REPLACEMENT

55

RADIATOR CAP INSPECTION

56

COOLING SYSTEM INSPECTION

57

3 Radiator cap

57

CLUTCH ADJUSTMENT

58

THROTTLE CABLE ADJUSTMENT/

59

THROTTLE LUBRICATION

59

AIR FILTER CLEANING

60

TRANSMISSION OIL LEVEL CHECK

61

2 Nm (0.2 m•kg, 1.4 ft•lb)

61

TRANSMISSION OIL REPLACEMENT

62

PILOT AIR SCREW ADJUSTMENT

63

SILENCER FIBER REPLACEMENT

64

EC360000

66

EC361030

66

FRONT BRAKE ADJUSTMENT

67

Standard

68

4.4 mm (0.17 in)

68

<Limit>

68

1.0 mm (0.04 in)

68

6.4 mm (0.25 in)

70

BRAKE FLUID LEVEL INSPECTION

72

SPROCKETS INSPECTION

73

DRIVE CHAIN INSPECTION

73

Limit: 242.9 mm (9.563 in)

73

DRIVE CHAIN SLACK ADJUSTMENT

74

FRONT FORK INSPECTION

75

ADJUSTMENT

77

EC36K000

78

FORCE ADJUSTMENT

80

DAMPING FORCE ADJUSTMENT

81

TIGHTENING/WHEEL INSPECTION

83

3 Nm (0.3 m•kg, 2.2 ft•lb)

83

STEERING HEAD INSPECTION AND

84

Ring nut wrench:

84

YU-33975/90890-01403

84

LUBRICATION

86

IGNITION TIMING CHECK

88

EC400000

90

EC4R0000

90

EXHAUST PIPE AND SILENCER

92

RADIATOR

93

CARBURETOR DISASSEMBLY

97

CARBURETOR AND REED VALVE

100

1 Nm (0.1 m•kg, 0.7 ft•lb)

101

10 Nm (1.0 m•kg, 7.2 ft•lb)

102

4 Nm (0.4 m•kg, 2.9 ft•lb)

105

CYLINDER HEAD AND CYLINDER

107

PISTON AND POWER VALVE

108

REMOVAL POINTS

109

INSPECTION

110

EC474201

111

EC474321

111

EC474402

112

EC474502

113

EC474700

114

EC474602

114

EC474841

115

EC474901

115

6 Nm (0.6 m•kg, 4.3 ft•lb)

116

42 Nm (4.2 m•kg, 30 ft•lb)

119

5 Nm (0.5 m•kg, 3.6 ft•lb)

120

25 Nm (2.5 m•kg, 18 ft•lb)

120

20 Nm (2.0 m•kg, 14 ft•lb)

121

34 Nm (3.4 m•kg, 24 ft•lb)

121

64 Nm (6.4 m•kg, 46 ft•lb)

121

Extent of removal: 1

122

75 Nm (7.5 m•kg, 54 ft•lb)

123

6 Nm (0.6 m•kg, 4.3ft•lb)

125

PRIMARY DRIVE GEAR

129

KICK AXLE AND SHIFT SHAFT

130

Shift shaft

132

Stopper lever

132

Kick idle gear

135

55 Nm (5.5 m•kg, 40 ft•lb)

136

30 Nm (3.0 m•kg, 22 ft•lb)

137

YPVS GOVERNOR

138

WATER PUMP

141

14 Nm (1.4 m•kg, 10 ft•lb)

144

CDI MAGNETO

145

8 Nm (0.8 m•kg, 5.8 ft•lb)

147

56 Nm (5.6 m•kg, 40 ft•lb)

147

ENGINE REMOVAL

149

ASSEMBLY AND INSTALLATION

152

CRANKCASE AND CRANKSHAFT

154

FRONT WHEEL

166

REAR WHEEL

167

FRONT WHEEL AND REAR WHEEL

168

12 Nm (1.2 m•kg, 8.7 ft•lb)

170

105 Nm (10.5 m•kg, 75 ft•lb)

171

23 Nm (2.3 m•kg, 17 ft•lb)

171

125 Nm (12.5 m•kg, 90 ft•lb)

174

16 Nm (1.6 m•kg, 11 ft•lb)

174

FRONT BRAKE

175

REAR BRAKE

176

CALIPER DISASSEMBLY

177

MASTER CYLINDER DISASSEMBLY

178

FRONT BRAKE AND REAR BRAKE

179

26 Nm (2.6 m•kg, 19 ft•lb)

186

7 Nm (0.7 m•kg, 5.1 ft•lb)

187

FRONT FORK

191

FRONT FORK DISASSEMBLY

192

Base valve

196

29 Nm (2.9 m•kg, 21 ft•lb)

199

HANDLEBAR

206

THROTTLE DISASSEMBLY

207

28 Nm (2.8 m•kg, 20 ft•lb)

209

9 Nm (0.9 m•kg, 6.5 ft•lb)

211

STEERING

213

145 Nm (14.5 m•kg, 105 ft•lb)

216

SWINGARM

218

SWINGARM DISASSEMBLY

219

9Collar 4

222

85 Nm (8.5 m•kg, 61 ft•lb)

223

80 Nm (8.0 m•kg, 58 ft•lb)

223

53 Nm (5.3 m•kg, 38 ft•lb)

224

19 Nm (1.9 m•kg, 13 ft•lb)

225

REAR SHOCK ABSORBER

226

32 Nm (3.2 m•kg, 23 ft•lb)

231

IGNITION SYSTEM

233

A For USA and CDN

234

B Except for USA and CDN

234

SOLENOID VALVE SYSTEM

238

EC690000

240

EC691001

240

HANDLING NOTE

241

EC693001

242

EC694000

245

Carburetor setting

246

EC713001

247

1 Throttle valve opening

248

2 Full-open

248

3 Full-closed

248

EC71R010

249

EC718001

249

EC716001

249

EC719081

251

EC71B011

253

EC71Q000

254

EC71D021

255

EC71C030

255

EC71M010

257

EC720000

258

EC71P002

258

EC72N000

259

EC721003

259

EC722011

260

EC723001

260

EC727030

261

EC72A001

261

∫ Rider weight

262

2 Standard

262

EC72P010

263

EC72B000

264

EC72C001

264

EC72G020

265

EC72Q011

267

EC72H010

268

Yamaha YZ250M User Manual (1 pages)

Brand: Yamaha | Category: Cars | Size: 0.06 MB |

English

Table of contents

Rekluse Motor Sports

1

Yamaha YZ250 2-Stroke

1

Suzuki RM250 2-Stroke

1

Yamaha YZ250M User Manual (55 pages)

Brand: Yamaha | Category: Cars | Size: 0.86 MB |

English

Table of contents

CANADA,U.S.A.,SOUTH AFRICA

1

FOREWORD

3

MODEL LABEL

4

FIG. 1 CYLINDER HEAD

5

FIG. 2 GOVERNOR

7

FIG. 3 CRANKSHAFT. PISTON

8

FIG. 4 WATER PUMP

9

FIG. 5 RADIATOR. HOSE

10

FIG. 6 INTAKE

11

FIG. 7 CARBURETOR

12

FIG. 8 EXHAUST

15

FIG. 9 CRANKCASE

16

FIG. 10 CRANKCASE COVER 1

17

FIG. 11 STARTER

18

FIG. 12 CLUTCH

19

FIG. 13 TRANSMISSION

21

FIG. 14 SHIFT CAM. FORK

23

FIG. 15 SHIFT SHAFT

24

FIG. 16 FRAME

25

FIG. 17 FENDER

26

FIG. 18 SIDE COVER

27

FIG. 19 REAR ARM

28

FIG. 20 REAR SUSPENSION

30

FIG. 21 STEERING

32

FIG. 22 FRONT FORK

33

FIG. 23 FUEL TANK

36

FIG. 24 SEAT

37

FIG. 25 FRONT WHEEL

38

FIG. 26 FRONT BRAKE CALIPER

39

FIG. 27 REAR WHEEL

40

FIG. 28 REAR BRAKE CALIPER

42

PART NO. DESCRIPTION REMARKS

43

FIG. 30 FRONT MASTER CYLINDER

44

FIG. 31 STAND. FOOTREST

45

FIG. 32 REAR MASTER CYLINDER

46

FIG. 33 GENERATOR

47

FIG. 34 HANDLE SWITCH. LEVER

48

FIG. 35 ELECTRICAL 1

49

FIG. 36 ALTERNATE (CHASSIS)

50

FIG. 37 OPTIONAL PARTS 1

51

CONTENTS

55

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