Yamaha YZ250Z 2010 Manuals

Manuals and User Guides for Yamaha YZ250Z 2010. We have 1 Yamaha YZ250Z 2010 manual available for free PDF download: Owner's Service Manual

Yamaha YZ250Z 2010 Owner's Service Manual

Yamaha YZ250Z 2010 Owner's Service Manual (193 pages)

Brand: Yamaha | Category: Motorcycle | Size: 7.37 MB

Table of Contents

Important Notice
6
How to Read Descriptions
8
Illustrated Symbols
8
Table of Contents
9
Contents
10
General Information
10
- General Information
  11
- Description
  11
- Machine Identification
  12
- Important Information
  12
- Vehicle Identification Number
  12
- Included Parts
  12
- All Replacement Parts
  13
- Gaskets, Oil Seals and O-Rings
  13
- Lock Washers/Plates and Cotter Pins
  13
- Checking of Connection
  13
- Special Tools
  14
- Clutch Lever
  18
- Engine Stop Switch
  18
- Starting and Break-In
  18
- Control Functions
  18
- Starting a Cold Engine
  19
- Starting a Warm Engine
  19
- Restarting an Engine after a Fall
  19
- The Engine Fails to Start
  19
- Break-In Procedures
  20
- Torque-Check Points
  21
- Cleaning and Storage
  22
- General Specifications
  23
- Chassis
  24
- Maintenance Specifications
  25
- Tightening Torques
  32
- General Torque Specifications
  37
- Definition of Units
  37
- Lubrication Diagrams
  38
- Cable Routing Diagram
  40
- Maintenance Intervals
  47
Regular Inspection and Adjustments
47
- Maintenance Intervals
  48
- General Inspection and Maintenance
  51
- Chassis
  51
- Pre-Operation Inspection and Maintenance
  51
- Checking the Coolant Level
  52
- Changing the Coolant
  52
- Checking Radiator Cap/Opening Pressure
  52
Engine
52
- Lubricating the Throttle
  53
- Checking the Cooling System
  53
- Adjusting the Throttle Cable Free Play
  53
- Adjusting the Clutch Cable Free Play
  53
- Cleaning the Air Filter Element
  54
- Adjusting the Hot Starter Lever Free Play
  54
- Checking the Engine Oil Level
  54
- Changing the Engine Oil
  55
- Adjusting the Engine Idling Speed
  56
- Adjusting the Pilot Screw
  56
- Checking the Oil Pressure
  56
- Adjusting the Valve Clearance
  57
- Intake
  59
- Exhaust
  59
- Bleeding the Hydraulic Brake System
  60
- Adjusting the Front Brake
  60
- Adjusting the Rear Brake
  60
Chassis
60
Electrical
69
- Seat, Fuel Tank and Side Covers
  70
- Removing the Seat, Fuel Tank and Side Covers
  70
- Removing the Side Cover
  71
- Removing the Number Plate
  71
- Installing the Air Scoop
  71
- Removing the Exhaust Pipe and Silencer
  72
- Installing the Silencer and Exhaust Pipe
  73
- Changing the Silencer Fiber
  73
- Checking the Silencer and Exhaust Pipe
  73
- Removing the Radiator
  74
- Handling Note
  75
- Checking the Radiator
  75
- Installing the Radiator
  75
- Removing the Carburetor
  76
- Disassembling the Carburetor
  77
- Checking the Throttle Valve
  79
- Checking the Carburetor
  79
- Checking the Needle Valve
  79
- Removing the Pilot Screw
  79
- Checking the Float
  80
- Checking the Starter Plunger
  80
- Checking the Accelerator Pump
  80
- Assembling the Carburetor
  80
- Adjusting the Accelerator Pump Timing
  82
- Installing the Carburetor
  82
- Camshafts
  83
- Removing the Cylinder Head Cover
  83
- Removing the Camshafts
  84
- Checking the Camshaft
  85
- Checking the Camshaft Sprocket
  86
- Checking the Decompression System
  86
- Checking the Timing Chain Tensioner
  86
- Installing the Camshaft
  86
- Removing the Cylinder Head
  88
- Checking the Cylinder Head
  89
- Installing the Cylinder Head
  89
- Removing the Valves and Valve Springs
  90
- Removing the Valve Lifter and Valve Cotter
  91
- Checking the Valve
  91
- Checking the Valve Springs
  92
- Checking the Valve Lifters
  93
- Installing the Valves
  93
- Removing the Cylinder and Piston
  94
- Checking the Cylinder and Piston
  95
- Checking the Piston Ring
  95
- Removing the Piston and Piston Ring
  95
- Checking the Piston Pin
  96
- Installing the Piston Ring and Piston
  96
- Installing the Cylinder
  96
- Removing the Clutch
  98
- Removing the Clutch Boss
  100
- Checking the Clutch Housing and Boss
  100
- Checking the Primary Driven Gear
  100
- Checking the Clutch Springs
  100
- Installing the Clutch
  101
- Removing the Oil Filter Element and Water Pump
  103
- Removing the Impeller Shaft
  105
- Removing the Oil Seal
  105
- Checking the Oil Delivery Pipe
  105
- Checking the Impeller Shaft
  105
- Installing the Oil Filter Element
  106
- Installing the Water Pump Housing
  106
- Installing the Kickstarter Crank
  106
- Installing the Right Crankcase Cover
  106
- Removing the Balancer
  107
- Checking the Primary Drive Gear, Balancer Shaft Drive Gear and Balancer Shaft Driven Gear
  108
- Checking the Balancer Shaft
  108
- Installing the Balancer
  108
- Removing the Oil Pump
  109
- Removing the Oil Tank
  111
- Installing the Oil Pump
  112
- Checking the Oil Pump
  112
- Removing the Kick Shaft and Shift Shaft
  113
- Kick Shaft and Shift Shaft
  113
- Removing the Kick Shaft Assembly
  115
- Removing the Shift Guide and Shift Lever Assembly
  115
- Removing the Segment
  115
- Installing the Segment
  115
- Kick Shaft and Shift Shaft
  115
- Installing the Kick Shaft Assembly
  116
- Installing the Shift Shaft
  116
- Installing the Shift Guide and Shift Lever Assembly
  116
- Installing the Kick Idle Gear
  117
- Removing the CDI Magneto
  118
- Removing the Rotor
  119
- Checking the CDI Magneto
  119
- Checking the Woodruff Key
  119
- Installing the CDI Magneto
  119
- Engine Removal
  120
- Removing the Engine
  120
- Removing the Drive Sprocket
  122
- Installing the Engine
  122
- Installing the Brake Pedal
  122
- Installing the Neutral Switch
  123
- Removing the Crankshaft
  124
- Crankcase and Crankshaft
  124
- Removing the Crankcase Bearing
  126
- Checking the Crankshaft
  127
- Checking the Timing Chain and Timing Chain Guide
  127
- Disassembling the Crankcase
  127
- Checking the Crankcase
  127
- Checking the Oil Strainer
  128
- Checking the Oil Delivery Pipe 2
  128
- Installing the Crankcase Bearing
  128
- Installing the Crankshaft
  128
- Removing the Transmission, Shift Cam and Shift Fork
  130
- Removing the Transmission
  131
- Checking the Gears
  131
- Checking the Bearing
  131
- Installing the Transmission
  131
- Removing the Front Wheel
  133
- Front Wheel and Rear Wheel
  133
- Removing the Rear Wheel
  134
- Installing the Front Wheel
  135
- Front Wheel and Rear Wheel
  135
- Checking the Brake Disc
  135
- Checking the Wheel
  135
- Removing the Wheel Bearing
  135
- Installing the Rear Wheel
  136
- Removing the Front Brake
  138
- Front Brake and Rear Brake
  138
- Removing the Rear Brake
  139
- Disassembling the Brake Caliper
  140
- Disassembling the Brake Master Cylinder
  141
- Checking the Brake Master Cylinder
  142
- Removing the Brake Caliper Piston
  142
- Removing the Brake Caliper Piston Seal Kit
  142
- Draining the Brake Fluid
  142
- Checking the Brake Caliper
  143
- Checking the Brake Hose
  143
- Installing the Brake Caliper Piston
  143
- Installing the Front Brake Caliper
  143
- Installing the Rear Brake Caliper
  144
- Installing the Brake Master Cylinder Kit
  144
- Installing the Front Brake Master Cylinder
  144
- Installing the Rear Brake Master Cylinder
  145
- Installing the Front Brake Hose
  145
- Installing the Rear Brake Hose
  146
- Filling the Brake Fluid
  146
- Removing the Front Fork
  148
- Disassembling the Front Fork
  149
- Removing the Damper Assembly
  150
- Removing the Adjuster
  150
- Removing the Inner Tube
  150
- Removing the Base Valve
  150
- Checking the Base Valve
  151
- Checking the Collar
  151
- Checking the Fork Spring
  151
- Checking the Inner Tube
  151
- Installing the Front Fork
  154
- Removing the Handlebar
  156
- Installing the Handlebar
  157
- Checking the Handlebar
  157
- Removing the Grip
  157
- Removing the Brake Master Cylinder
  157
- Removing the Steering
  160
- Removing the Steering Ring Nut
  162
- Removing the Lower Bearing
  162
- Removing the Bearing Race
  162
- Installing the Lower Bracket
  162
- Removing the Swingarm
  164
- Disassembling the Swingarm
  165
- Checking the Relay Arm
  166
- Removing the Cap
  166
- Checking the Swingarm
  166
- Removing the Bearing
  166
- Installing the Swingarm
  167
- Removing the Rear Shock Absorber
  169
- Notes on Disposal
  171
- Checking the Rear Shock Absorber
  171
- Installing the Bearing
  171
- Installing the Rear Shock Absorber
  172
- Installing the Spring (Rear Shock Absorber)
  172
- Electrical Components and Wiring Diagram
  174
- Ignition System Inspection Steps
  175
- Spark Gap Test
  176
- Checking the Couplers, Leads and Ignition Coil Connection
  176
- Checking the Ignition Coil
  176
- Checking the Engine Stop Switch
  176
- Checking the Neutral Switch
  177
- Checking the CDI Unit
  177
- Throttle Position Sensor System
  178
- Checking the Throttle Position Sensor Coil
  179
- Changing and Adjusting the Throttle Position Sensor
  179
- Checking the Couplers and Leads Connection
  179
- Checking the Throttle Position Sensor Input Voltage
  180
- Tuning Engine
  181
- Carburetor Setting
  181
- Atmospheric Conditions and Carburetor Settings
  181
- Adjusting the Main Jet
  181
- Relationship with Throttle Opening
  182
- Adjusting the Pilot Jet
  182
- Adjusting the Jet Needle
  182
- Adjusting the Jet Needle Groove Position
  182
- Carburetor Setting Parts
  183
- Specifications of Jet Needle
  184
- Examples of Carburetor Setting Depending on Symptom
  184
- Selection of the Secondary Reduction Ratio (Sprocket)
  186
- Drive and Rear Wheel Sprockets Setting Parts
  186
- Tire Pressure
  186
- Front Fork Setting
  186
- Setting of Spring after Replacement
  187
- Front Fork Setting Parts
  187
- Rear Suspension Setting
  187
- Choosing Set Length
  187
- Rear Shock Absorber Setting Parts
  188
- Suspension Setting (Front Fork)
  189
- Suspension Setting (Rear Shock Absorber)
  190

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