Yamaha YZ250 2018 - User Manual

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1SS-28199-16LIT-11626-31-12

Read this manual carefully before operating this vehicle.

YZ250J2

YZ250XJ

OWNER’S SERVICE MANUAL

YZ250

YZ250X

2018

PRINTED IN JAPAN

2017.04-0.7×1 !

(E)

PRINTED ON RECYCLED PAPER

2018

YZ250J2 YZ250XJ

1SS-28199-16_cover.indd 1-3 2017/03/31 10:45:40

Main Page

Important Manual Information4
Safety Information5
How to Use this Manual7
Manual Format7
Illustrated Symbols9
Table of Contents11
General Information12
Specifications12
Regular Inspection and Adjustments12
Engine13
Chassis13
Electrical13
Tuning14
Consumer Information17
Vehicle Identification Number17
Engine Serial Number17
Included Parts18
Nipple Wrench18
Preparation for Removal and Disassembly19
All Replacement Parts19
Gaskets, Oil Seals and O-Rings19
Lock Washers/Plates and Cotter Pins20
Bearings and Oil Seals20
Checking of Connection21
Special Tools22
Control Functions25
Rear Brake Pedal26
Starter Knob (Choke)26
Starting and Break-In27
Break-In Procedures28
Torque-Check Points29
Maintenance after Break-In30
Major Maintenance30
Cleaning and Storage31
Specifications General Specifications32
Maintenance Specifications35
Tightening Torques41
General Torque Specifications46
Definition of Units47
Cable Routing Diagram48
Maintenance Intervals59
Pre-Operation Inspection and Maintenance62
General Inspection and Maintenance62
Checking the Coolant Level63
Changing the Coolant63
Checking the Radiator Cap Opening Pressure64
Checking the Cooling System65
Adjusting the Clutch Lever Position65
Adjusting the Clutch Lever Free Play65
Adjusting the Throttle Grip Free Play66
Cleaning the Air Filter Element67
Checking the Transmission Oil Level68
Changing the Transmission Oil69
Adjusting the Engine Idling Speed70
Checking the Exhaust Pipe70
Bleeding the Hydraulic Brake System71
Adjusting the Front Brake71
Adjusting the Rear Brake72
Checking the Rear Brake Pad Insulator75
Checking the Brake Fluid Level76
Adjusting the Drive Chain Slack79
Checking the Front Fork79
Checking the Front Fork Protector Guide80
Cleaning the Front Fork Oil Seal and Dust Seal80
Checking the Tire Pressure84
Checking and Tightening the Spokes85
Checking the Wheels85
Checking and Adjusting the Steering Head85
Checking the Spark Plug90
Checking the Ignition Timing90
Seat, Fuel Tank and Side Covers92
Removing the Side Cover94
Removing the Number Plate94
Exhaust Pipe and Silencer95
Changing the Silencer Fiber96
Removing the Radiator97
Checking the Radiator98
Installing the Radiator98
Carburetor and Reed Valve100
Disassembling the Carburetor101
Handling Note102
Checking the Carburetor102
Checking the Jet Needle103
Checking the Reed Valve104
Assembling the Carburetor105
Installing the Carburetor107
Cylinder Head, Cylinder and Piston109
Removing the Cylinder Head and Cylinder109
Checking the Cylinder Head113
Checking the Cylinder114
Checking the Piston115
Checking the Piston Ring116
Checking the Piston Clearance116
Removing the Clutch123
Kick Shaft and Shift Shaft129
Removing the Primary Drive Gear129
Installing the Segment133
Installing the Shift Guide and Shift Lever Assembly133
Installing the Stopper Lever133
Installing the Kick Shaft Assembly134
Installing the Shift Shaft134
Installing the Kick Idle Gear135
Installing the Primary Drive Gear135
Ypvs Governor137
Checking the Bearing138
Disassembling the Water Pump140
Installing the Oil Seal142
CDI Magneto144
Removing the Rotor145
Checking the Woodruff Key145
Engine Removal147
Removing the Engine147
Handling Note149
Removing the Drive Sprocket149
Installing the Engine149
Installing the Brake Pedal150
Installing the Drive Sprocket150
Crankcase and Crankshaft151
Removing the Crankshaft151
Removing the Segment153
Disassembling the Crankcase153
Removing the Crankcase Bearing153
Checking the Crankcase154
Checking the Crankshaft154
Installing the Crankshaft155
Transmission, Shift Cam and Shift Fork158
Removing the Transmission159
Installing the Transmission160
Front Wheel and Rear Wheel163
Removing the Front Wheel163
Removing the Rear Wheel165
Checking the Brake Disc167
Installing the Front Wheel167
Installing the Rear Wheel168
Front Brake and Rear Brake171
Installing the Brake Caliper Piston177
Checking the Brake Hose177
Installing the Front Brake Caliper178
Installing the Rear Brake Caliper178
Installing the Front Brake Master Cylinder180
Installing the Rear Brake Master Cylinder181
Removing the Front Fork185
Installing the Front Fork196
Removing the Handlebar198
Checking the Handlebar200
Installing the Handlebar201
Checking the Steering Stem207
Removing the Swingarm210
Disassembling the Swingarm211
Installing the Swingarm214
Removing the Rear Shock Absorber217
Notes on Disposal (Yamaha Dealers Only)219
Removing the Bearing219
Checking the Rear Shock Absorber220
Installing the Bearing220
Installing the Rear Shock Absorber221
Electrical Components and Wiring Diagram223
Wiring Diagram224
Color Code224
Ignition System225
Inspection Steps225
Spark Gap Test226
Checking the Ignition Coil226
Checking the Spark Plug Cap227
Checking the Neutral Switch228
Checking the CDI Unit228
Solenoid Valve System229
Throttle Position Sensor System231
Checking the Throttle Position Sensor Input Voltage234
Carburetor Setting Parts239
Selection of the Secondary Reduction Ratio (Sprocket)243
Drive and Rear Wheel Sprockets Setting Parts243
Tire Pressure243
Front Fork Setting244
Change in Amount and Characteristics of Fork Oil244
Setting of Spring after Replacement244
Suspension Setting (Front Fork)248
Suspension Setting (Rear Shock Absorber)249

Brand	Yamaha
Model	YZ250 2018
Category	Motorcycle
Language	English

Yamaha YZ250 2018 - User Manual

Table of Contents

Yamaha YZ250 2018 Specifications

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