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YZ250FXR 2024
Owner's service manual
Yamaha YZ250FXR 2024 Owner's Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Information
Fcc Caution
Important Manual Information
How to Use this Manual
General Information
Table of Contents
Safety Information
For Safety, be Sure to Obey the Following
About the Battery
Lithium-Ion Battery
Lithium-Ion Battery Degradation
Location of Important Labels
Description
Engine Serial Number
Vehicle Identification Number
Identification
Included Parts
Nipple Wrench
Handlebar Protector
Fuel Hose Joint Cover
Power Tuner
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Circlips
Bearings and Oil Seals
Lock Washers/Plates and Cotter Pins
Basic Service Information
Electrical System
Special Tools
Instrument and Control Functions
Warning Lights
Engine Stop Switch
Start Switch
Mode Switch
Starter Knob
Rear Brake Pedal
Sidestand
Front Brake Lever
Shift Pedal
Fuel Tank Cap
Starting and Break-In
Fuel
Starting a Cold Engine
Starting a Warm Engine
Break-In Procedures
Engine Starting Precaution
Air Filter Maintenance
Maintenance after Break-In
Major Maintenance
Torque-Check Points
Motorcycle Care and Storage
Care
Storage
Specifications
General Specifications
Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
General Tightening Torque Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Cable Routing Diagram
Periodic Checks and Adjustments
Maintenance Intervals
General Inspection and Maintenance
Pre-Operation Inspection and Maintenance
Adjusting the Valve Clearance
Engine
Valve Clearance Shim Chart
Checking the Engine Idling Speed
Checking the Throttle Grip
Checking the Spark Plug
Changing the Engine Oil
Checking the Engine Oil Level
Adjusting the Clutch Lever Free Play
Adjusting the Clutch Lever Position
Cleaning the Air Filter Element
Checking the Fuel Line
Checking the Throttle Body Joint
Checking the Cylinder Head Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Changing the Coolant
Checking the Cooling System
Adjusting the Front Disc Brake
Adjusting the Rear Disc Brake
Chassis
Checking the Brake Fluid Level
Checking the Front Brake Hose
Checking the Front Brake Pads
Checking the Rear Brake Hose
Checking the Rear Brake Pads
Bleeding the Hydraulic Brake System
Checking the Brake Operation
Drive Chain Slack
Checking and Adjusting the Steering Head
Lubricating the Drive Chain
Checking the Front Fork Legs
Lubricating the Steering Head
Adjusting the Front Fork Legs
Adjusting the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Checking the Swingarm Operation
Lubricating the Swingarm Pivot
Checking and Tightening the Spokes
Checking the Tires
Checking the Wheel Bearings
Checking the Wheels
Checking and Lubricating the Cables
Checking the Chassis Fasteners
Checking the Sidestand
Lubricating the Brake Lever
Lubricating the Clutch Lever
Lubricating the Pedal
Lubricating the Sidestand
Checking and Charging the Battery
Checking the Fuses
Electrical System
Chassis
General Chassis
Removing the Number Plate
Removing the Seat
Installing the Air Scoop
Installing the Side Cover
Removing the Side Cover
Front Wheel
Assembling the Front Wheel
Checking the Front Wheel
Disassembling the Front Wheel
Removing the Front Wheel
Installing the Front Wheel
Rear Wheel
Checking and Replacing the Rear Wheel Sprocket
Checking the Rear Wheel
Disassembling the Rear Wheel
Removing the Rear Wheel
Assembling the Rear Wheel
Installing the Rear Wheel
Front Brake
Checking the Front Brake Disc
Introduction
Replacing the Front Brake Pads
Assembling the Front Brake Caliper
Checking the Front Brake Caliper
Disassembling the Front Brake Caliper
Removing the Front Brake Caliper
Installing the Front Brake Caliper
Assembling the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Removing the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Brake System
Rear Brake
Checking the Rear Brake Disc
Introduction
Replacing the Rear Brake Pads
Checking the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Removing the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Assembling the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Removing the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Handlebar
Checking the Handlebar
Installing the Handlebar
Removing the Handlebar
Front Fork
Disassembling the Front Fork Legs
Removing the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Checking the Steering Head
Installing the Steering Head
Removing the Lower Bracket
Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Disposing of a Rear Shock Absorber
Handling the Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Installing the Connecting Arm
Installing the Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm
Checking the Swingarm
Installing the Swingarm
Removing the Swingarm
Chain Drive
Checking the Drive Chain
Removing the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Sprocket
Installing the Drive Chain
Engine
Engine Oil Lubrication Chart
Lubrication System Chart and Diagrams
Lubrication Diagrams
Engine Removal
Installing the Engine
Removing the Engine
Installing the Exhaust Pipe and Muffler
Camshaft
Removing the Camshaft
Checking the Camshaft
Checking the Decompression System
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Tensioners
Installing the Camshafts
Cylinder Head
Checking the Cylinder Head
Checking the Timing Chain Guide (Intake Side)
Installing the Cylinder Head
Removing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Lifters
Installing the Valves
Cylinder and Piston
Checking the Cylinder and Piston
Removing the Piston
Checking the Piston Pin
Checking the Piston Rings
Installing the Piston and Cylinder
Generator
Checking the Generator
Checking the Woodruff Key
Installing the Generator
Removing the Generator
Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Removing the Starter Clutch
Electric Starter
Assembling the Starter Motor
Checking the Starter Motor
Clutch
Checking the Clutch Housing
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Friction Plates
Removing the Clutch
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Primary Drive Gear
Checking the Primary Driven Gear
Checking the Push Lever Shaft
Checking the Push Rods
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Removing the Segment
Oil Pump
Removing the Balancer
Assembling the Oil Pump
Checking the Oil Pump
Installing the Oil Pump
Crankcase
Checking the Crankcase
Checking the Timing Chain Guide (Exhaust Side)
Disassembling the Crankcase
Assembling the Crankcase
Crankshaft and Balancer Shaft
Checking the Crankshaft
Removing the Crankshaft
Installing the Crankshaft
Transmission
Checking the Shift Drum Assembly
Checking the Shift Forks
Removing the Transmission
Checking the Transmission
Installing the Transmission
Cooling System
Cooling System
Cooling System Diagrams
Radiator
Checking the Radiator
Installing the Radiator
Water Pump
Assembling the Water Pump
Checking the Water Pump
Disassembling the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Removing the Fuel Pump
Removing the Fuel Tank
Installing the Fuel Pump
Installing the Fuel Tank
Throttle Body
Checking the Fuel Pressure
Checking the Injector
Checking the Throttle Body
Adjusting the Throttle Position Sensor
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Engine Specifications
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2024
OWNER'S SERVICE MANUAL
YZ250FX
Read this manual carefully before operating this vehicle.
YZ250FXR
LIT-11626-37-35
BAJ-2819U-14
Table of
Contents
Previous
Page
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Page
1
2
3
4
5
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Chapters
General Information
11
Specifications
45
Periodic Checks and Adjustments
75
Chassis
113
Engine
187
Cooling System
265
Fuel System
275
Electrical System
285
Troubleshooting
347
Tuning
363
Table of Contents
Troubleshooting
TROUBLESHOOTING
290
TROUBLESHOOTING
294
TROUBLESHOOTING
298
TROUBLESHOOTING
302
TROUBLESHOOTING METHOD
307
TROUBLESHOOTING DETAILS (FAULT CODE)
310
TROUBLESHOOTING
332
GENERAL INFORMATION
348
TROUBLESHOOTING OF CLUTCH
351
TROUBLESHOOTING OF TRANSMISSION
353
TROUBLESHOOTING OF COOLING SYSTEM
354
TROUBLESHOOTING OF BRAKE
355
TROUBLESHOOTING OF STEERING/HANDLING
357
TROUBLESHOOTING OF CHARGING SYSTEM
358
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Summarization of Contents
General Information
Safety Information
Critical safety guidelines for operating and maintaining the vehicle.
Description
Overview of vehicle components and controls with visual identification.
Instrument and Control Functions
Explanation of dashboard indicators, switches, and levers for vehicle operation.
Starting and Break-in
Procedures for starting the engine and initial break-in period for new vehicles.
Motorcycle Care and Storage
Guidelines for cleaning, maintenance, and proper storage of the motorcycle.
Specifications
General Specifications
Key physical dimensions and weight of the vehicle.
Engine Specifications
Detailed technical data for the engine, including bore, stroke, and fluid capacities.
Chassis Specifications
Technical data for the frame, wheels, brakes, and suspension systems.
Tightening Torques
Specified torque values for various fasteners crucial for assembly and maintenance.
Cable Routing Diagram
Visual guide illustrating the correct routing of electrical wires and cables on the frame.
Periodic Checks and Adjustments
Servicing Parts
List of essential parts for regular maintenance and replacement.
Maintenance Intervals
Recommended schedule for checks and replacements based on usage or time.
Pre-operation Inspection and Maintenance
Essential checks to perform before operating the vehicle for safety and performance.
Engine
Adjusting the Valve Clearance
Step-by-step guide for checking and adjusting valve clearances for optimal engine performance.
Checking the Engine Idling Speed
Procedure to measure and adjust the engine's idling speed for smooth operation.
Checking the Spark Plug
Instructions for removing, checking, cleaning, and installing the spark plug.
Changing the Engine Oil
Procedure for draining and refilling the engine oil to maintain lubrication.
Cleaning the Air Filter Element
Instructions for cleaning and oiling the air filter for proper engine air intake.
Checking the Coolant Level
Procedure to verify the coolant level in the radiator for proper engine cooling.
Changing the Coolant
Steps for draining, flushing, and refilling the engine's cooling system.
Chassis
Front Wheel
Procedures for removing, disassembling, checking, and assembling the front wheel.
Rear Wheel
Procedures for removing, checking, and assembling the rear wheel and sprocket.
Front Brake
Detailed instructions for checking, replacing pads, and servicing the front brake system.
Rear Brake
Detailed instructions for checking, replacing pads, and servicing the rear brake system.
Steering Head
Procedures for removing, checking, and adjusting the steering head assembly for smooth operation.
Front Fork
Steps for removing, disassembling, checking, and assembling the front fork legs.
Rear Shock Absorber Assembly
Procedures for removing, disassembling, and checking the rear shock absorber assembly.
Swingarm
Steps for removing, checking, and installing the swingarm and its related components.
Chain Drive
Instructions for removing, checking, cleaning, lubricating, and installing the drive chain and sprockets.
Cooling System
Cooling System Diagrams
Schematic representation of the vehicle's cooling system components and their connections.
Radiator
Procedures for removing, checking, and installing the radiator and its associated hoses.
Water Pump
Steps for removing, disassembling, checking, and assembling the water pump.
Fuel System
Fuel Tank
Procedures for removing and installing the fuel tank and related components.
Throttle Body
Steps for removing, checking, and adjusting the throttle body and its sensors.
Electrical System
Ignition System
Information on the ignition system circuit diagram and troubleshooting common issues.
Electric Starting System
Details on the electric starting system circuit diagram and troubleshooting no-crank conditions.
Charging System
Explanation of the charging system circuit diagram and troubleshooting battery charging issues.
Signaling System
Information on the signaling system circuit diagram and troubleshooting non-functional indicator lights.
Fuel Injection System
Circuit diagram, ECU self-diagnostic function, and troubleshooting for the fuel injection system.
Electrical Components
Procedures for checking various electrical components like switches, fuses, battery, and sensors.
Troubleshooting
General Information
General guidance and tips for effective troubleshooting of vehicle issues.
Troubleshooting of Engine (fault code not detected)
Common engine symptoms, causes, and actions when no fault code is detected.
Troubleshooting of Clutch
Diagnosis and solutions for clutch-related problems like slippage and noise.
Troubleshooting of Transmission
Troubleshooting steps for transmission shifting issues and noise problems.
Troubleshooting of Cooling System
Diagnosis and solutions for engine overheating and water pump noise issues.
Troubleshooting of Brake
Troubleshooting steps for poor disc brake performance and related issues.
Troubleshooting of Suspension
Diagnosis and solutions for front and rear suspension stiffness or softness.
Troubleshooting of Steering/Handling
Troubleshooting for handlebar wobble, heavy steering, and wheel vibration.
Troubleshooting of Charging System
Steps to diagnose and resolve issues where the battery is not charging.
Troubleshooting of Signaling System
Troubleshooting steps for non-functional indicator lights or fuel level warnings.
Tuning
Chassis Tuning
General chassis tuning considerations, including sprockets and tire pressure.
Front Fork Setting
Guidance on adjusting front fork settings for air spring, spring preload, and damping.
Rear Shock Absorber Setting Parts
Information on selecting and setting rear shock absorber springs based on rider preference.
Suspension Setting (Front Fork)
Specific adjustments for front fork stiffness, oil amount, and damping based on riding conditions.
Suspension Setting (Rear Shock Absorber)
Adjustments for rear suspension stiffness, rebound, compression, and spring preload.
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