Yamaha YZ250 2018 Manuals

Manuals and User Guides for Yamaha YZ250 2018. We have 1 Yamaha YZ250 2018 manual available for free PDF download: Owner's Service Manual

Yamaha YZ250 2018 Owner's Service Manual (252 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10 MB

Important Manual Information
4
Safety Information
5
How to Use this Manual
7
Manual Format
7
Illustrated Symbols
9
Table of Contents
11
General Information
12
Specifications
12
Regular Inspection and Adjustments
12
Engine
13
Chassis
13
Electrical
13
Tuning
14
Consumer Information
17
Vehicle Identification Number
17
Engine Serial Number
17
Included Parts
18
Nipple Wrench
18
Preparation for Removal and Disassembly
19
All Replacement Parts
19
Gaskets, Oil Seals and O-Rings
19
Lock Washers/Plates and Cotter Pins
20
Bearings and Oil Seals
20
Checking of Connection
21
Special Tools
22
Control Functions
25
Rear Brake Pedal
26
Starter Knob (Choke)
26
Starting and Break-In
27
Break-In Procedures
28
Torque-Check Points
29
Maintenance after Break-In
30
Major Maintenance
30
Cleaning and Storage
31
Specifications General Specifications
32
Maintenance Specifications
35
Tightening Torques
41
General Torque Specifications
46
Definition of Units
47
Cable Routing Diagram
48
Maintenance Intervals
59
Pre-Operation Inspection and Maintenance
62
General Inspection and Maintenance
62
Checking the Coolant Level
63
Changing the Coolant
63
Checking the Radiator Cap Opening Pressure
64
Checking the Cooling System
65
Adjusting the Clutch Lever Position
65
Adjusting the Clutch Lever Free Play
65
Adjusting the Throttle Grip Free Play
66
Cleaning the Air Filter Element
67
Checking the Transmission Oil Level
68
Changing the Transmission Oil
69
Adjusting the Engine Idling Speed
70
Checking the Exhaust Pipe
70
Bleeding the Hydraulic Brake System
71
Adjusting the Front Brake
71
Adjusting the Rear Brake
72
Checking the Rear Brake Pad Insulator
75
Checking the Brake Fluid Level
76
Adjusting the Drive Chain Slack
79
Checking the Front Fork
79
Checking the Front Fork Protector Guide
80
Cleaning the Front Fork Oil Seal and Dust Seal
80
Checking the Tire Pressure
84
Checking and Tightening the Spokes
85
Checking the Wheels
85
Checking and Adjusting the Steering Head
85
Checking the Spark Plug
90
Checking the Ignition Timing
90
Seat, Fuel Tank and Side Covers
92
Removing the Side Cover
94
Removing the Number Plate
94
Exhaust Pipe and Silencer
95
Changing the Silencer Fiber
96
Removing the Radiator
97
Checking the Radiator
98
Installing the Radiator
98
Carburetor and Reed Valve
100
Disassembling the Carburetor
101
Handling Note
102
Checking the Carburetor
102
Checking the Jet Needle
103
Checking the Reed Valve
104
Assembling the Carburetor
105
Installing the Carburetor
107
Cylinder Head, Cylinder and Piston
109
Removing the Cylinder Head and Cylinder
109
Checking the Cylinder Head
113
Checking the Cylinder
114
Checking the Piston
115
Checking the Piston Ring
116
Checking the Piston Clearance
116
Removing the Clutch
123
Kick Shaft and Shift Shaft
129
Removing the Primary Drive Gear
129
Installing the Segment
133
Installing the Shift Guide and Shift Lever Assembly
133
Installing the Stopper Lever
133
Installing the Kick Shaft Assembly
134
Installing the Shift Shaft
134
Installing the Kick Idle Gear
135
Installing the Primary Drive Gear
135
Ypvs Governor
137
Checking the Bearing
138
Disassembling the Water Pump
140
Installing the Oil Seal
142
CDI Magneto
144
Removing the Rotor
145
Checking the Woodruff Key
145
Engine Removal
147
Removing the Engine
147
Handling Note
149
Removing the Drive Sprocket
149
Installing the Engine
149
Installing the Brake Pedal
150
Installing the Drive Sprocket
150
Crankcase and Crankshaft
151
Removing the Crankshaft
151
Removing the Segment
153
Disassembling the Crankcase
153
Removing the Crankcase Bearing
153
Checking the Crankcase
154
Checking the Crankshaft
154
Installing the Crankshaft
155
Transmission, Shift Cam and Shift Fork
158
Removing the Transmission
159
Installing the Transmission
160
Front Wheel and Rear Wheel
163
Removing the Front Wheel
163
Removing the Rear Wheel
165
Checking the Brake Disc
167
Installing the Front Wheel
167
Installing the Rear Wheel
168
Front Brake and Rear Brake
171
Installing the Brake Caliper Piston
177
Checking the Brake Hose
177
Installing the Front Brake Caliper
178
Installing the Rear Brake Caliper
178
Installing the Front Brake Master Cylinder
180
Installing the Rear Brake Master Cylinder
181
Removing the Front Fork
185
Installing the Front Fork
196
Removing the Handlebar
198
Checking the Handlebar
200
Installing the Handlebar
201
Checking the Steering Stem
207
Removing the Swingarm
210
Disassembling the Swingarm
211
Installing the Swingarm
214
Removing the Rear Shock Absorber
217
Notes on Disposal (Yamaha Dealers Only)
219
Removing the Bearing
219
Checking the Rear Shock Absorber
220
Installing the Bearing
220
Installing the Rear Shock Absorber
221
Electrical Components and Wiring Diagram
223
Wiring Diagram
224
Color Code
224
Ignition System
225
Inspection Steps
225
Spark Gap Test
226
Checking the Ignition Coil
226
Checking the Spark Plug Cap
227
Checking the Neutral Switch
228
Checking the CDI Unit
228
Solenoid Valve System
229
Throttle Position Sensor System
231
Checking the Throttle Position Sensor Input Voltage
234
Carburetor Setting Parts
239
Selection of the Secondary Reduction Ratio (Sprocket)
243
Drive and Rear Wheel Sprockets Setting Parts
243
Tire Pressure
243
Front Fork Setting
244
Change in Amount and Characteristics of Fork Oil
244
Setting of Spring after Replacement
244
Suspension Setting (Front Fork)
248
Suspension Setting (Rear Shock Absorber)
249

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Yamaha YZ250 2018 Owner's Service Manual (252 pages)

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