Yamaha YZ250M User Manual

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

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

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

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

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

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 .

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

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

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

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

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,

A3

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

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

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

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

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

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

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

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

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

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

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

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,

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

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

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

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

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

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

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

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

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

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

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

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,

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

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

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

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

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

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

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–

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

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

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

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

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

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

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

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

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

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,

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–

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