Yamaha YZ250G2 2016 - User Manual

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2016

OWNER’S SERVICE MANUAL

YZ250G2

YZ250XG

1SS-28199-14LIT-11626-29-29

YZ250G2 YZ250XG 2016

Read this manual carefully before operating this vehicle.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2015.06–0.3 × 1

(E)

1SS-28199-14_Hyoshi.indd 1 2015/05/28 15:36:27

Main Page

Important Manual Information4
Safety Information5
Manual Format7
Illustrated Symbols9
Table of Contents11
General Information12
Specifications12
Regular Inspection and Adjustments12
Engine13
Chassis13
Electrical13
Tuning14
General Information15
Location of Important Labels15
Consumer Information17
Vehicle Identification Number17
Engine Serial Number17
Included Parts18
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
Kickstarter Lever25
Clutch Lever25
Throttle Grip25
Rear Brake Pedal26
Break-In Procedures28
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 Cooling System65
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
Bleeding the Hydraulic Brake System71
Adjusting the Front Brake71
Adjusting the Rear Brake72
Checking the Brake Fluid Level76
Adjusting the Drive Chain Slack79
Checking the Front Fork79
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
Removing the Side Cover94
Removing the Radiator97
Checking the Radiator98
Installing the Radiator98
Disassembling the Carburetor101
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
Removing the Primary Drive Gear129
Installing the Stopper Lever133
Installing the Shift Shaft134
Installing the Primary Drive Gear135
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
Removing the Drive Sprocket149
Installing the Engine149
Installing the Drive Sprocket150
Crankcase and Crankshaft151
Removing the Crankshaft151
Disassembling the Crankcase153
Checking the Crankcase154
Checking the Crankshaft154
Installing the Crankshaft155
Removing the Transmission159
Installing the Transmission160
Removing the Front Wheel163
Removing the Rear Wheel165
Checking the Brake Disc167
Installing the Front Wheel167
Installing the Rear Wheel168
Removing the Rear Brake172
Disassembling the Brake Caliper173
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
Installing the Swingarm214
Removing the Rear Shock Absorber217
Removing the Bearing219
Checking the Rear Shock Absorber220
Installing the Rear Shock Absorber221
Electrical Components223
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
Tire Pressure243

Brand	Yamaha
Model	YZ250G2 2016
Category	Offroad Vehicle
Language	English

Yamaha YZ250G2 2016 - User Manual

Table of Contents

Yamaha YZ250G2 2016 Specifications

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