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YAMAHA YZ250(N)/LC Owner's Service Manual

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Table of Contents
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER-UND
WARTUNGS-HANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ250 ( N ) /LC
5MW-28199-30

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Table of Contents

   Summary of Contents for YAMAHA YZ250(N)/LC

  • Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER-UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 ( N ) /LC 5MW-28199-30...
  • Page 2 EC010010 YZ250(N)/LC OWNER’S SERVICE MANUAL ©2000 by Yamaha Motor Co., Ltd. 1st Edition, July 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
  • Page 3 FAHRER-UND MANUALE DI SERVIZIO DEL DU PROPRIETAIRE WARTUNGSHANDBUCH PROPRIETARIO ©2000 Yamaha Motor Co.,Ltd. ©2000 der Yamaha Motor Co., Ltd. ©2000 by Yamaha Motor Co., Ltd. 1ère Edition, Juillet 2000 1. Ausgabe, Juli 2000 1a Edizione, Luglio 2000 Tous droits réservés.
  • Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 5 Wir möchten Ihnen zum Kauf einer Complimenti per avere acquistato una Yamaha séries YZ. Ce modèle est Yamaha YZ Serie, herzlich gratulie- Yamaha serie YZ. Questo modello è il l’aboutissement de la vaste expérience ren. Dieses Modell entspricht fort- culmine della vasta esperienza della...
  • Page 6: Important Notice

    EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.
  • Page 7: Wichtige Hinweise

    IC040001 NOTICE IMPORTANTE WICHTIGE HINWEISE NOTA IMPORTANTE CETTE MACHINE EST STRICTE- DIESE MASCHINE IST NUR FÜR QUESTO VEICOLO È PROGETTA- MENT DESTINEE A LA COMPETI- RENNEN AUF GESCHLOSSENEN TO PER ESSERE USATO RIGORO- TION, UNIQUEMENT SUR CIRCUIT KURSEN KONSTRUIERT. ES VER- SAMENTE IN GARA, SOLTANTO FERME.
  • Page 8 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refuel- ing. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-...
  • Page 9 5. L’ESSENCE EST HAUTE- 5. LA BENZINA È ALTAMEN- 5. BENZIN IST BRENNBAR. MENT INFLAMMABLE. TE INFIAMMABILE. Immer den Motor abstellen, Toujours arrêter le moteur en Spegnere sempre il motore bevor aufgetankt wird. Dar- faisant le plein. Faire attention durante il rifornimento di car- auf achten, daß...
  • Page 10 Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha deal- EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel...
  • Page 11 SECONDO LA F.I.M.: Maschine auftauchen sollten, wen- Poids des machines sans carbu- Pesi dei veicoli senza carburante den Sie sich bitte an Ihren Yamaha rant I pesi minimi per i veicoli per moto- Fachhändler. Les poids minimum admis pour les cross sono: GEWICHT DER F.I.M.
  • Page 12: Description

    EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT IN FORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
  • Page 13: Chapitre

    IC080000 COMMENT VERWENDUNG COME USARE IL DIESER ANLEITUNG UTILISER CE PRESENTE MANUEL MANUALE IC081000 WICHTIGE INFORMATION INFORMATIONS INFORMAZIONI PARTICULIEREMENT PARTICOLARMENTE Sicherheitssymbol bedeutet IMPORTANTES IMPORTANTI „AUFPASSEN“! VORSICHT GEBOTEN Le symbole d’alerte de sécurité signifie Il Simbolo di Allerta in materia di Sicu- IHRER EIGENEN SICHERHEIT.
  • Page 14 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains com- prehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9Bearings...
  • Page 15 IC083000 FORMAT DU MANUEL FORMAT DER ANLEITUNG FORMATO DEL Allen dieser Anleitung enthaltenen Dans ce manuel, toutes les procédures MANUALE sont décrites pas à pas. Les informa- Vorgänge sind sequentiell in der Tutte le procedure contenute nel pre- tions ont été condensées pour fournir au durchzuführenden Reihenfolge aufge- sente manuale sono organizzate in for- mécanicien un guide pratique et facile à...
  • Page 16 EC085002 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text.
  • Page 17 IC085002 SYMBOLES GRAPHIQUES ABGEBILDETEN SYMBOLE SIMBOLI ILLUSTRATI (Voir l’illustration) (Siehe Abbildung) (Fare riferimento all’illustra- Les symboles graphiques 1 à 7 ser- Die abgebildeten Symbole 1 bis 7 zione) vent à repérer les différents chapitres et sind zur einfachen Auffindung der Sei- I simboli illustrati da 1 a 7 sono pro- à...
  • Page 18 EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
  • Page 19 INDEX INDEX IC090010 INDICE ANALITICO ALLGEMEIN RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI INFO TECHINSCHE CARACTERISTIQUES SPECIFICHE DATEN SPEC REGELMÄSSIGE VERIFICATION ET ISPEZIONE E PRÜFUNG REGLAGES REGOLAZIONI INSP COURANTS REGOLARI EINSTELLUNGEN MOTOR MOTEUR MOTORE FAHRGESTELL PARTIE CYCLE TELAIO CHAS ELEKTRISCHE PARTIE PARTE ELETTRICA EINRICHTUNGEN ELECTRIQUE ELEC...
  • Page 20: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ..........1-1 MACHINE IDENTIFICATION ......1-2 IMPORTANT INFORMATION .....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS........1-7 CONTROL FUNCTIONS......1-9 FUEL AND ENGINE MIXING OIL.....1-12 STARTING AND BREAK-IN .....1-13 TORQUE-CHECK POINTS .......1-16 CLEANING AND STORAGE ....1-17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....2-1 MAINTENANCE SPECIFICATIONS ...2-3...
  • Page 21: Table Of Contents

    IC0A0000 TABLES DES INHALTSVERZEICHNIS INDICE MATIERES CAPITOLO 1 CHAPITRE 1 KAPITEL 1 INFORMAZIONI RENSEIGNEMENTS ALLGEMEIN GENERALI GENERAUX ANGABEN DESCRIPTION ...........1-1 BESCHREIBUNG ........1-1 DESCRIZIONE ...........1-1 IDENTIFICATION DE LA MACHINE ...1-2 MASCHINEN-IDENTIFIKATION....1-2 IDENTIFICAZIONE DEL VEICOLO ..1-2 INFORMATIONS IMPORTANTES ..1-3 WICHTIGE INFORMATIONEN ....1-3 INFORMAZIONI IMPORTANTI.....1-3 VERIFICATION DES CONNEXIONS ..1-6 ANSCHLÜSSE PRÜFEN ......1-6...
  • Page 22: Table Of Contents

    CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .............4-1 EXHAUST PIPE AND SILENCER ....4-3 RADIATOR ..........4-4 CARBURETOR AND REED VALVE ...4-7 CYLINDER HEAD , CYLINDER AND PISTON .............4-17 CLUTCH AND PRIMARY DRIVEN GEAR ............4-32 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR......4-39 YPVS GOVERNOR ........4-48 WATER PUMP ..........4-50...
  • Page 23: Table Of Contents

    CHAPITRE 4 KAPITEL 4 CAPITOLO 4 MOTEUR MOTOR MOTORE SELLE, RESERVOIR A ESSENCE SITZ, KRAFTSTOFFTANK UND SELLA, SERBATOIO DEL ET COUVERCLES LATERAUX....4-1 SEITENDECKEL.........4-1 CARBURANTE E COPERTURE LATERALI ..........4-1 AUSPUFFROHR UND TUYAU D’ECHAPPEMENT ET SILENCIEUX ..........4-3 SCHALLDÄMPFER ........4-3 TUBO DI SCARICO E SILENZIATORE.........4-3 RADIATEUR ..........4-4 KÜHLER............4-4...
  • Page 24 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........6-1 IGNITION SYSTEM........6-2 SOLENOID VALVE SYSTEM......6-6 TPS (THROTTLE POSITION SENSOR) SYSTEM............6-8 CHAPTER 7 TUNING ENGINE............7-1 CHASSIS...........7-13...
  • Page 25: Table Of Contents

    CHAPITRE 6 KAPITEL 6 CAPITOLO 6 PARTIE ELEKTRISCHE PARTE ELETTRICA ELECTRIQUE EINRICHTUNGEN COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE UND COMPONENTI ELETTRICI E SCHEMA ET SCHEMA DE CABLAGE ....6-1 SCHALTPLAN ..........6-1 ELETTRICO ..........6-1 SYSTEME D’ALLUMAGE .......6-2 ZÜNDANLAGE ...........6-2 SISTEMA DI ACCENSIONE ....6-2 SYSTEME D’ELECTROVANNE .....6-6 MAGNETVENTILSYSTEM ......6-6 SISTEMA ELETTROVALVOLA .....6-6 SYSTEME TPS (CAPTEUR DE...
  • Page 26: Engine

    DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 NOTE: DESCRIPTION 9The machine you have purchased may differ 1 Clutch lever 2 “ENGINE STOP” button slightly from those shown in the following. 3 Front brake lever 9Designs and specifications are subject to 4 Throttle grip change without notice.
  • Page 27: Informazioni Generali

    DESCRIPTION BESCHREIBUNG DESCRIZIONE INFO IC100000 RENSEIGNEMENTS ALLGEMEIN INFORMAZIONI GENERAUX ANGABEN GENERALI IC110000 DESCRIPTION BESCHREIBUNG DESCRIZIONE 1 Levier d’embrayage 1 Kupplungshebel 1 Leva di comando della frizione 2 Bouton de coupe-circuit de sécurité 2 Motorstoppknopf „ENGINE STOP“ 2 Pulsante “ARRESTO MOTORE” 3 Handbremshebel “ENGINE STOP”...
  • Page 28: Machine Identification

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
  • Page 29: Identificazione Del Veicolo, Identification De La Machine

    Seriennummer ange- cessionario Yamaha per un’identi- Yamaha qui pourra identifier clai- geben werden, damit Ihr Yamaha ficazione certa del modello posse- rement le modèle correspondant à Fachhändler das Modell richtig duto.
  • Page 30: Important Information, Covers

    IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DIS ASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts as follows. 9Silencer end 9Air filter intake slit 9Water pump housing hole at the bottom...
  • Page 31: Informations Importantes

    INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC130000 INFORMATIONS WICHTIGE INFORMAZIONI IMPORTANTES INFORMATIONEN IMPORTANTI IC131010 PREPARATION POUR LA DEPO- VORBEREITUNG FÜR DEN PREPARAZIONE PER LA RIMO- SE ET DEMONTAGE AUSBAU UND DER DEMONTAGE ZIONE E LO SMONTAGGIO 1. Eliminer soigneusement crasse, 1.
  • Page 32 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended Yamaha assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
  • Page 33 Yamaha per tutti i ricambi. Bauteile zu verwenden. Für Ein- les remplacements. Utiliser les Usare olio e/o grasso raccomandati bau und Einstellungen nur das huiles/graisses recommandées par dalla Yamaha per il montaggio e la Yamaha empfohlene Öl Yamaha lors des remontages et regolazione.
  • Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.
  • Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC136000 CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO 1. Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Si dovrebbero ispezionare attenta- doivent être soigneusement véri- dereinbau gründlich prüfen. Die mente tutti gli anelli elastici di fiés.
  • Page 36: Checking Of Connection

    CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 9Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
  • Page 37: Controllo Dei Collegamenti, Verification Des Connexions

    VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO IC1C0001 VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI Bei Flecken, Rost, Feuchtigkeit u.ä. CONNEXIONS COLLEGAMENTI auf einem Steckverbinder: Traitement des taches, de la rouille, de Come trattare macchie, ruggine, umi- 1. Lösen: l’humidité, etc.
  • Page 38: Special Tools

    SPECIAL TOOLS INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed.
  • Page 39 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the igni- tion system components. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
  • Page 40: Outils Speciaux

    OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de pièce des outils spéciaux diffèrent selon les pays.
  • Page 41 Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé pour monter les bagues d’étanchéité de fourche. YU-3112-C, 90890-03112 Testeur de poche Yamaha YU-3112-C 90890-03112 Utiliser cet outil pour examiner la résistance de bobine, la tension de sortie et l’intensité. YU-8036-B...