SERVICE MANUAL
YFM250RX
4D3-28197-10 LIT-11616-21-22
2008
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
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 checking or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the machine.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title : This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title : This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
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 is provided for removal and disassembly jobs.
2. Numbers 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
. The meanings of the symbol marks are given on the next page.
4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements are given in addition
to the exploded diagram and the job instruction chart.
GEN
INFO
CHAS
EBS00006
SYMBOLS
The following symbols are not relevant to every
machine.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Engine
Carburetor
Chassis
Electrical
Troubleshooting
Symbols to indicate the following
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Torque
Wear limit, clearance
Engine speed
Electrical data (Ω, V, A)
Symbols to in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply brake fluid
Apply wheel bearing grease
Apply lithium-soap-based grease
Apply molybdenum disulfide grease
Apply silicone grease
Symbols to in the exploded diagrams
indicate where to apply a locking agent and
when to install a new part .
Apply the locking agent (LOCTITE
®
)
Replace
EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION
GEN
INFO
1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS
CHK
ADJ
3
ENGINE
ENG
4
CARBURETOR
CARB
5
CHASSIS
CHAS
6
ELECTRICAL
ELEC
7
TROUBLESHOOTING
TRBL
SHTG
8
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . 1-2
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . 2-19
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-19
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2
SEAT, FENDERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SEAT, FRONT FENDER AND HEADLIGHTS . . . . . . . . . . . . . . . . . . 3-4
FOOT PROTECTORS AND ENGINE SKID PLATE . . . . . . . . . . . . . . 3-5
REAR FENDER AND AIR FILLTER CASE. . . . . . . . . . . . . . . . . . . . . 3-6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE ENGINE IDLING SPEED. . . . . . . . . . . . . . . . . . . . 3-11
ADJUSTING THE THROTTLE LEVER FREE PLAY . . . . . . . . . . . . . 3-12
ADJUSTING THE SPEED LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-17
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ADJUSTING THE CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 3-23
CLEANING THE SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
ADJUSTING THE BRAKE LEVER (For adjustment type model) . . . . 3-26
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 3-28
CHECKING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 3-29
CHECKING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . 3-30
ADJUSTING THE REAR BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . 3-31
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-32
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
ADJUSTING THE DRIVE CHAIN SLACK. . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3-36
ADJUSTING THE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
CHECKING THE FRONT AND REAR SHOCK ABSORBERS . . . . . . 3-38
ADJUSTING THE FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 3-39
ADJUSTING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 3-40
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . 3-43
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-44
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 3-45
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . 3-53
REPLACING A HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
CHAPTER 4
ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
MUFFLER AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
INSTALLING THE EXHAUST PIPE AND MUFFLER . . . . . . . . . . . . . 4-2
LEADS, CABLES AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ENGINE MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
CHECKING THE TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . 4-11
CHECKING THE TIMING CHAIN TENSIONERS . . . . . . . . . . . . . . . . 4-11
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
ROCKER ARM, CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-16
CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . 4-19
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . 4-23
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
REMOVING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . 4-32
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
CHECKING THE PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
INSTALLING THE PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . 4-37
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . 4-46
CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-46
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
OIL PUMP AND BLANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . . . . . 4-50
REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP. . . . 4-53
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
CHECKING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . 4-54
ASSENBLING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . 4-56
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
PICKUP COIL ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . 4-60
REMOVING THE PICKUPCOIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-62
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-63
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . 4-64
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4-69
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
REMOVING THE CRANKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . 4-73
REMOVING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . . . 4-73
CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET
AND TIMING CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
INSTALLING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
INSTALLING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . 4-75
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . 4-81
CHECKING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
INSTALLING THE SHIFT FORKS AND SHIFT DRUM
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
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2009-2010 Yamaha YFM250 Raptor 250 Service Repair Manual ( 09 10 )
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Description
This Service Repair Manual is the ultimate resource for maintaining and repairing the Yamaha YFM250 Raptor 250 for the years 2009 and 2010. It is a comprehensive guide featuring high-quality diagrams and step-by-step instructions covering everything from the front bumper to the rear. Whether you are a professional mechanic or a DIY enthusiast, this manual is indispensable.
The manual covers the following models:
- 2009 Yamaha YFM250 Raptor
- 2010 Yamaha YFM250 Raptor
Key areas covered in the Service Repair Manual include:
- General information
- Specifications
- Periodic checks and adjustments
- Chassis
- Engine
- Fuel system
- Electrical system
- Troubleshooting
This manual is available in a printable file format, compatible with all versions of Windows and Mac. It is an essential tool for anyone looking to save on maintenance and repair costs. The language used in the manual is English, and it requires Adobe Reader for access.
