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2018
OWNER'S SERVICE MANUAL
YZ250
YZ250X
Read this manual carefully before operating this vehicle.
YZ250J2
YZ250XJ
LIT-11626-31-12
1SS-28199-16

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Summarization of Contents

General Information
Location of Important Labels
Details the placement and meaning of crucial safety and information labels on the vehicle.
Description
Identifies key components and controls of the motorcycle through diagrams and labels.
Consumer Information
Explains the importance of vehicle and engine serial numbers for identification and security purposes.
Included Parts
Lists and illustrates special tools and parts included with the motorcycle for specific functions.
Important Information
Provides essential preparation and general notes for disassembly, assembly, and parts replacement.
Checking of Connection
Outlines procedures for inspecting and cleaning electrical connectors to ensure proper function.
Special Tools
Details specific Yamaha tools required for maintenance and assembly, with part numbers and uses.
Control Functions
Explains the operation and location of essential controls like the engine stop switch and throttle grip.
Starting and Break-in
Covers fuel requirements, starting procedures, and break-in guidelines for optimal engine performance.
Torque-Check Points
Lists critical fasteners and their specified torque values for safety and reliability checks.
Maintenance After Break-in
Details major maintenance tasks for the engine and chassis after the initial break-in period.
Cleaning and Storage
Provides instructions for cleaning the motorcycle and preparing it for long-term storage.
Specifications
General Specifications
Presents detailed specifications for the motorcycle's model, dimensions, weight, and engine.
Maintenance Specifications Engine
Lists standard and limit values for engine components like cylinders, pistons, and crankshafts.
Tightening Torques
Provides comprehensive torque specifications for engine, chassis, and electrical components.
Cable Routing Diagram
Illustrates the correct routing paths for various cables and hoses on the motorcycle frame.
Regular Inspection and Adjustments
Maintenance Intervals
Outlines a schedule for regular inspections and maintenance based on time or usage intervals.
Pre-Operation Inspection and Maintenance
Details essential checks and maintenance steps to perform before operating the vehicle.
Engine
Covers procedures for checking and changing engine coolant, including radiator and cap checks.
Chassis
Provides instructions for bleeding hydraulic brake systems and adjusting brake lever positions.
Electrical
Details inspection procedures for spark plugs, ignition timing, and related electrical components.
Engine
Seat, Fuel Tank and Side Covers
Explains the removal and installation procedures for the seat, fuel tank, and side covers.
Exhaust Pipe and Silencer
Details the removal and installation of the exhaust pipe and silencer, including fiber replacement.
Radiator
Covers the removal, installation, and checking procedures for the motorcycle's radiator system.
Carburetor and Reed Valve
Explains the removal, disassembly, inspection, and assembly of the carburetor and reed valve.
Cylinder Head, Cylinder and Piston
Details the removal, inspection, and installation of the cylinder head, cylinder, and piston components.
Clutch
Provides procedures for removing, inspecting, and installing the clutch assembly, plates, and springs.
Kick Shaft and Shift Shaft
Covers the removal, inspection, and installation of the kick shaft, shift shaft, and related gears.
YPVS Governor
Explains the removal, inspection, and installation of the YPVS governor assembly.
Water Pump
Details the disassembly, inspection, and installation of the water pump and its components.
CDI Magneto
Covers the removal, inspection, and installation of the CDI magneto, rotor, and stator.
Engine Removal
Provides step-by-step instructions for safely removing and installing the entire engine assembly.
Crankcase and Crankshaft
Details the disassembly, inspection, and installation of the crankcase and crankshaft assembly.
Transmission, Shift Cam and Shift Fork
Explains the removal, inspection, and installation of the transmission, shift cam, and shift forks.
Chassis
Front Wheel and Rear Wheel
Covers the removal, inspection, and installation procedures for both front and rear wheels.
Front Brake and Rear Brake
Details the removal, disassembly, and installation of front and rear brake systems, including calipers and master cylinders.
Front Fork
Provides comprehensive steps for removing, disassembling, checking, and assembling the front fork.
Handlebar
Explains the removal, disassembly, and installation of the handlebar, throttle, and control components.
Steering
Covers the removal, inspection, and installation of the steering stem, bearings, and related components.
Swingarm
Details the removal, disassembly, inspection, and installation of the swingarm and its associated bearings.
Rear Shock Absorber
Provides instructions for removing, inspecting, and installing the rear shock absorber and its spring.
Electrical
Electrical Components and Wiring Diagram
Illustrates electrical components and provides wiring diagrams for system troubleshooting.
Ignition System
Details inspection steps for the ignition system, including spark plugs and ignition coils.
Solenoid Valve System
Outlines inspection steps for the solenoid valve operation and coil resistance.
Throttle Position Sensor System
Covers inspection and adjustment procedures for the throttle position sensor system.
Tuning
Engine
Covers carburetor settings, atmospheric conditions, and test run procedures for engine tuning.
Chassis
Details suspension settings for front fork and rear shock absorber based on riding conditions.

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