Yamaha YZ250 service manual repair 2002 YZ 250

LIT-11626-16-39 YZ250FR 5UL-28199-10 OWNER’S SERVICE MANUAL Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

YZ250FR OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-16-39 Downloaded from www.Manualslib.com manuals search engine

EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. NOTE: As improvements are made on this model, some data in this manual may become out- dated. If you have any questions, please consult your Yamaha dealer. WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTE- NANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELI- ABILITY OF THIS MACHINE. Downloaded from www.Manualslib.com manuals search engine

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IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding. 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its character- istics. 2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. 3. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with gog- gles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine. 4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident. 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refu- eling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. SAFETY INFORMATION Downloaded from www.Manualslib.com manuals search engine

6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA- TION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and color- less. Carbon monoxide is a dangerous gas which can cause unconscious- ness or can be lethal. 8. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over. 9. THE ENGINE, EXHAUST PIPE, MUF- FLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair. 10. PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. Downloaded from www.Manualslib.com manuals search engine

EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc ....................... minimum 88 kg (194 lb) for the class 250 cc ....................... minimum 98 kg (216 lb) for the class 500 cc ....................... minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight. Downloaded from www.Manualslib.com manuals search engine

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: EC082000 FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; “General information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”. 2. The table of contents is at the beginning of the manual. Look over the general lay- out of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description. Downloaded from www.Manualslib.com manuals search engine

EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., ● Bearings Pitting/damage → Replace. EC084002 HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs. 2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 3. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces- sary removal job. 6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi- tion to the exploded diagram and job instruction chart. Downloaded from www.Manualslib.com manuals search engine

Yamaha YZ250 service manual repair 2002 YZ 250

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