Table of Contents
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Table of Contents
Related Manuals for Yamaha 2002 YZ250FR
Summary of Contents for Yamaha 2002 YZ250FR
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Page 3: Assembly Manual
YZ250FR ASSEMBLY MANUAL LIT-11666-16-39 5UL-28107-10... -
Page 4: Yz250Fr Assembly Manual
Since some external parts of the machine have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled machine should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer. -
Page 5: Symbols Used In Assembly Manual
EAA00008 SYMBOLS USED IN ASSEMBLY MANUAL In order to simplify descriptions in this assembly manuals, the following symbols are used: (1) Coat with lithium-soap-based-grease. (2) Tighten to 10 Nm. (10 Nm = 1.0mdkg = 7.2 ftdlb) (3) Towards the front of the machine. (4) Clearance required. - Page 6 EAA00040 PREPARATION To assemble the machine correctly, sup- plies (e.g. oils, greases, and shop rags) and sufficient working space are required. Workshop The workshop where the machine is assem- bled, should be clean, specious, and have a level floor. Self-protection Protect your eyes with suitable safety glass- es or goggles when using compressed air, when grinding or when doing any operation...
- Page 7 EAA00060 UNPACKING 1. Remove the frame cover (1). NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the carton boxes (2), front tire (3). 3. Remove the packing frame bolt (4), and handlebar holder bolts (5).
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Page 8: Parts Location
EAA00070 PARTS LOCATION 1. Front wheel 2. Front fender 3. Carton Box 1 4. Carton Box 2 - 2 -... - Page 9 Packing frame 1. Front wheel 2. Front fender EAA00080 Carton Box 1 3. Handlebar 4. Side stand 5. Plastic bag 6. Handlebar upper holder 7. Flange bolt [d=8, l=35 (1.38)] 8. Master cylinder bracket 9. Flange bolt [d=6 (0.24), l=22 (0.87)] 10.Engine stop button holder (Upper and lower) 11.Panhead screw with spring washer...
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Page 10: Setup Procedures
EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown. - 4 -... -
Page 11: Throttle Grip
EAA00200 D: First tighten the bolts on the 1. HANDLEBAR front side of the handlebar holder, and then tighten the A: Clean the right handlebar bolts on the rear side to spec- end. Apply light coat grease. ification. B: Before inserting the handle- bar into the throttle grip, make Bolt: sure the collar is installed. - Page 12 EAA00030 4. FRONT BRAKE HOSE HOLDER A: Remove the front fork cover bolts to slide the front fork cover upwards. NOTE: D Align the top (d) of the brake hose neck with the brake hose holder bottom (c). D Pass the brake hose in front of the axle boss (a), then fit it into the brake hose groove (b).
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Page 13: Front Fender
B: Lubricate the pivoting part of socket. the clutch lever. NOTE: Recommended lubricants: Check clutch lever Yamaha cable lube smooth action. Refer or motor oil "ADJUSTMENTS AND PREDE- C: To install the clutch cable, be LIVERY SERVICE". sure to proceed as follows: a. -
Page 14: Engine Stop Switch
B: Lubricate the pivoting part of "ADJUSTMENTS AND PREDE- the hot starter (choke) lever. LIVERY SERVICE". Recommended lubricants: Yamaha cable lube or motor oil Proper cable routing is essen- C: Insert the cable end into the tial to assure safe machine lever hole, then squeeze the operation. -
Page 15: Number Plate
EAA01070 12. NUMBER PLATE A: Tighten the bolt to specifica- tion. Bolt: 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Number plate 2 Flange bolt d=6 (0.24), l=14 (0.55) EAA00071 13. FUEL TANK BREATHER HOSE A: Connect one end of the breather hose to the fuel tank filler cap, and insert the other end into the hole of the num-... -
Page 16: Cable Routing
EAA00900 CABLE ROUTING (C)Pass the clutch cable throught the cable guides. CAUTION: (D)Pass the clutch cable in front of the radiator mounting boss. Proper cable and lead routing are essential to insure safe (E)Fit the brake hose into the guides on the protector. machine operation. - Page 17 (1) Hot starter (choke) cable (2) Throttle cable (return) (3) Throttle cable (pull) (4) Cable guide (5) Ignition coil (A)Pass the hot starter (choke) cable and throttle cables through the cable guides. (B)Pass the hot starter (choke) cable and throttle cables between the radiator and frame, then under the radiator mounting boss.
- Page 18 (1) Throttle Cable (2) Fuel tank breather hose (3) Clamp (4) Clutch cable (5) Hot starter (choke) cable (6) “ENGINE STOP” button lead (7) Brake hose (8) Hose guide (A)Fasten the “ENGINE STOP” button lead to the handlebar with the plastic band. (B)Pass the brake hose in front of the number plate.
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Page 19: Adjustments And Predelivery Service
EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown. - 13 -... -
Page 20: Draining The Fuel
EAA01005 3. Tighten the drain screw securely. A. DRAINING THE FUEL 1. Put a rag under the carburetor drain hose so fuel does not contact the crankcase. 2. Loosen the drain screw (1) and drain the standing fuel. FUEL IS HIGHLY FLAMMABLE: D Always turn off the engine when draining fuel. -
Page 21: Adjusting The Throttle Cable Free Play
EAA01022 b. Loosen the locknut (1). D. ADJUSTING THE THROTTLE c. Turn the adjusting nut (2) in direction (a) or (b) until the specified throttle cable CABLE FREE PLAY free play is obtained. NOTE: Direction (a) Prior to adjusting throttle cable free play, the Throttle cable free play is increased. -
Page 22: Checking The Brake Fluid Level
2. Bleed: i. Repeat steps (e) to (h) until all of the air Dhydraulic brake system bubbles have disappeared from the a. Add the recommended brake fluid to the brake fluid in the plastic hose. proper level. j. Tighten the bleed screw to specification. b. -
Page 23: Checking The Engine Oil Level
2. Adjust: c. Tighten the locknut (1). Dbrake pedal position a. Loosen the locknut (1). A soft or spongy feeling in the brake b. Turn the adjusting nut (2) in direction (a) pedal can indicate the presence of air in or (b) until the specified brake pedal the brake system. -
Page 24: Adjusting The Engine Idling Speed
EAA01020 4. Adjust: J. ADJUSTING THE ENGINE IDLING Dengine idling speed SPEED a. Turn the throttle stop screw (1) in direc- tion (a) or (b) until the specified engine NOTE: idling speed is obtained. Prior to adjusting the engine idling speed, Direction (a) the carburetor synchronization should be Engine idling speed is increased. -
Page 25: Adjusting The Drive Chain Slack
EAA01059 4. Loosen: M. ADJUSTING THE DRIVE CHAIN Dwheel axle nut (1) 5. Adjust: SLACK Ddrive chain slack a. Loosen both locknuts (3). NOTE: The drive chain slack must be checked b. Turn both adjusting bolts (2) in direction above the drive chain guide bolt. (a) or (b) until the specified drive chain slack is obtained. -
Page 26: Adjusting The Front Fork Legs
Rebound damping a. Turn the adjusting screw (4) in direction (a) or (b). NOTE: This is the position which is back by the Direction (a) specific number of clicks from the fully Low compression damping is turned-in position. (Which align the punch increased (suspension is harder). - Page 27 Compression damping CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Remove: Drubber cap 2. Adjust: Dcompression damping a. Turn the adjusting screw (2) in direction (a) or (b). Direction (a) Compression damping is increased (suspension is harder). Direction (b) Compression damping is decreased (suspension is softer).
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Page 28: Service Data
EAA10000 APPENDICES SERVICE DATA Engine idling speed: 1,900~2,100r/min Spark plug: Type /Manufacturer CR8E/NGK (resistance type) 0.7~0.8 mm (0.028~0.031 in) Fuel: Recommended fuel Premium unleaded gasoline only with a research octane number of 95 or higher. Fuel tank capacity 7.0L (1.54 lmp gal, 1.85 US gal) Valve clearance (cold): 0.10~0.15 mm (0.0039~0.0059 in) 0.17~0.22 mm (0.0067~0.0087 in) -
Page 29: Tightening Torque
EAA10300 TIGHTENING TORQUE Tightening torque Item Thread size mdkg ftdlb Engine: Engine oil drain bolt (oil filter) M 6 x1.0 Spark plug M10Sx1.0 Chassis: Handle crown and outer tube M 8 x1.25 Under bracket and outer tube M 8 x1.25 Handle crown and steering shaft M24x1.0 14.5... - Page 30 Tightening torque Item Thread size mdkg ftdlb Rear wheel axle and nut M20x1.5 12.5 Driven sprocket and wheel hub M 8 x1.25 Nipple (spoke) Disc cover and rear brake caliper M 6 x1.0 Protector and rear brake caliper M 6 x1.0 Chain puller adjust bolt and locknut M 8 x1.25 Engine mounting:...
- Page 31 PRINTED IN U.S.A.