User Manuals: Yamaha YZ250 2022 Motocross Motorcycle

User Manuals: Yamaha YZ250 2022 Motocross Motorcycle

Manuals and User Guides for Yamaha YZ250 2022 Motocross Motorcycle. We have 1 Yamaha YZ250 2022 Motocross Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha YZ250 2022 Owner's Service Manual

Yamaha YZ250 2022 Owner's Service Manual (274 pages)

Brand: Yamaha | Category: Motorcycle | Size: 11.13 MB

Table of Contents

Table of Contents

9
- Safety Information
  13
- For Safety, be Sure to Obey the Following
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- Included Parts
  19
- Sidestand
  19
- Nipple Wrench
  19
- Valve Joint
  19
- Set Pin
  19
- Important Information
  20
- Preparation for Removal and Disassembly
  20
- Replacement Parts
  20
- Gaskets, Oil Seals and O-Rings
  20
- Circlips
  21
- Bearings and Oil Seals
  21
- Lock Washers/Plates and Cotter Pins
  21
- Basic Service Information
  22
- Electrical System
  22
- Special Tools
  24
- Fuel Cock
  28
- Rear Brake Pedal
  28
- Front Brake Lever
  28
- Kickstarter Lever
  28
- Shift Pedal
  28
- Engine Stop Switch
  28
- Instrument and Control Functions
  28
- Starter Knob (Choke)
  29
- Starting and Break-In
  30
- Fuel and Engine Mixing Oil
  30
- Starting a Cold Engine
  30
- Starting a Warm Engine
  30
- Break-In Procedures
  30
- Air Filter Maintenance
  32
- Major Maintenance
  32
- Maintenance after Break-In
  32
- Torque-Check Points
  33
- Motorcycle Care and Storage
  35
- Care
  35
- Storage
  36
Specifications

39
- General Specifications
  40
- Engine Specifications
  41
- Chassis Specifications
  46
- Electrical Specifications
  47
- General Tightening Torque Specifications
  48
- Tightening Torques
  48
- Engine Tightening Torques
  49
- Chassis Tightening Torques
  51
- Cable Routing Diagram
  54
Periodic Checks and Adjustments

65
Chassis

93
- General Chassis
  96
- Removing the Number Plate
  96
- Removing the Side Cover
  96
- Front Wheel
  97
- Assembling the Front Wheel
  98
- Checking the Front Wheel
  98
- Disassembling the Front Wheel
  98
- Removing the Front Wheel
  98
- Installing the Front Wheel
  99
- Checking and Replacing the Rear Wheel Sprocket
  102
- Checking the Rear Wheel
  102
- Disassembling the Rear Wheel
  102
- Rear Wheel
  102
- Removing the Rear Wheel
  102
- Assembling the Rear Wheel
  103
- Installing the Rear Wheel
  103
- Front Brake
  105
- Checking the Front Brake Disc
  109
- Introduction
  109
- Replacing the Front Brake Pads
  109
- Assembling the Front Brake Caliper
  111
- Checking the Front Brake Caliper
  111
- Disassembling the Front Brake Caliper
  111
- Removing the Front Brake Caliper
  111
- Installing the Front Brake Caliper
  112
- Assembling the Front Brake Master Cylinder
  113
- Checking the Front Brake Master Cylinder
  113
- Removing the Front Brake Master Cylinder
  113
- Installing the Front Brake Master Cylinder
  114
- Rear Brake
  116
- Checking the Rear Brake Disc
  120
- Introduction
  120
- Replacing the Rear Brake Pads
  120
- Checking the Rear Brake Caliper
  122
- Disassembling the Rear Brake Caliper
  122
- Removing the Rear Brake Caliper
  122
- Assembling the Rear Brake Caliper
  123
- Installing the Rear Brake Caliper
  123
- Assembling the Rear Brake Master Cylinder
  124
- Checking the Rear Brake Master Cylinder
  124
- Removing the Rear Brake Master Cylinder
  124
- Installing the Rear Brake Master Cylinder
  125
- Checking the Handlebar
  128
- Handlebar
  128
- Installing the Handlebar
  128
- Removing the Handlebar
  128
- Disassembling the Front Fork Legs
  135
- Removing the Front Fork Legs
  135
- Checking the Front Fork Legs
  136
- Assembling the Front Fork Legs
  137
- Installing the Front Fork Legs
  143
- Steering Head
  145
- Checking the Steering Head
  146
- Installing the Steering Head
  146
- Removing the Lower Bracket
  146
- Rear Shock Absorber Assembly
  149
- Checking the Connecting Arm and Relay Arm
  151
- Checking the Rear Shock Absorber Assembly
  151
- Disposing of a Rear Shock Absorber
  151
- Handling the Rear Shock Absorber
  151
- Removing the Rear Shock Absorber Assembly
  151
- Installing the Rear Shock Absorber Assembly
  152
- Installing the Relay Arm
  152
- Swingarm
  154
- Checking the Swingarm
  155
- Installing the Swingarm
  155
- Removing the Swingarm
  155
- Chain Drive
  157
- Checking the Drive Chain
  158
- Removing the Drive Chain
  158
- Checking the Drive Sprocket
  159
- Checking the Rear Wheel Sprocket
  159
- Installing the Drive Chain
  159
Engine

161
- Engine Removal
  163
- Installing the Engine
  165
- Removing the Engine
  165
- Cylinder Head, Cylinder and Piston
  166
- Removing the Cylinder Head
  168
- Removing the Piston
  168
- Removing the Push Rod
  168
- Checking the Cylinder and Piston
  169
- Checking the Cylinder Head
  169
- Combination of Piston and Cylinder
  170
- Checking the Piston Pin
  171
- Checking the Piston Ring
  171
- Assembling the Power Valve
  172
- Checking the Power Valve
  172
- Checking the Power Valve Hole on Cylinder
  172
- Checking the Small End Bearing
  172
- Installing the Piston and Cylinder
  174
- Installing the Cylinder Head
  176
- CDI Magneto
  177
- Checking the CDI Magneto
  178
- Checking the Woodruff Key
  178
- Installing the CDI Magneto
  178
- Removing the Rotor
  178
- Kickstarter
  180
- Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
  181
- Checking the Kick Shaft and Ratchet Wheel
  181
- Installing the Kick Shaft Assembly
  181
- Removing the Kick Shaft Assembly
  181
- Removing the Primary Drive Gear
  181
- Installing the Kick Idle Gear
  182
- Installing the Kickstarter Lever
  183
- Installing the Primary Drive Gear
  183
- Ypvs Governor
  184
- Checking the Bearing
  185
- Checking the Governor Groove
  185
- Installing the Governor
  185
- Removing the Governor
  185
- Clutch
  187
- Checking the Clutch Boss
  189
- Checking the Clutch Housing
  189
- Checking the Clutch Plates
  189
- Checking the Clutch Springs
  189
- Checking the Friction Plates
  189
- Removing the Clutch
  189
- Checking the Pressure Plate
  190
- Checking the Primary Drive Gear
  190
- Checking the Primary Driven Gear
  190
- Checking the Push Lever Shaft
  190
- Checking the Push Rods
  190
- Installing the Clutch
  190
- Shift Shaft
  194
- Checking the Shift Shaft
  195
- Checking the Stopper Lever
  195
- Installing the Shift Shaft
  195
- Removing the Segment
  195
- Crankcase
  198
- Assembling the Crankcase
  199
- Checking the Crankcase
  199
- Disassembling the Crankcase
  199
- Crankshaft
  201
- Checking the Crankshaft
  202
- Installing the Crankshaft
  202
- Removing the Crankshaft
  202
- Transmission
  203
- Checking the Shift Drum Assembly
  204
- Checking the Shift Forks
  204
- Checking the Transmission
  204
- Removing the Transmission
  204
- Installing the Transmission
  205
Cooling System

207
- Cooling System Diagrams
  208
- Radiator
  209
- Checking the Radiator
  210
- Installing the Radiator
  210
- Water Pump
  212
- Assembling the Water Pump
  213
- Checking the Water Pump
  213
- Disassembling the Water Pump
  213
Fuel System

215
- Fuel Tank
  216
- Air Filter
  217
- Carburetor
  218
- Checking the Carburetor
  221
- Handling Note
  221
- Checking the Reed Valve
  222
- Installing the Reed Valve
  222
- Assembling the Carburetor
  223
- Installing the Carburetor
  225
- Measuring and Adjusting the Fuel Level
  226
Electrical System

227
- Color Code
  228
- Wiring Diagram
  228
- Ignition System
  229
- Troubleshooting
  229
- Solenoid Valve System
  230
- Troubleshooting
  230
- Throttle Position Sensor System
  231
- Troubleshooting
  231
- Electrical Components
  232
- Checking the Switches
  233
- Checking the Ignition Coil
  235
- Checking the Ignition Spark Gap
  235
- Checking the Spark Plug Cap
  235
- Checking the Pickup Coil
  236
- Checking the Source Coil
  236
- Checking the Solenoid Valve Coil
  237
- Checking the Solenoid Valve Operation
  237
- Changing and Adjusting the Throttle Position Sensor
  238
- Checking the Throttle Position Sensor Coil
  238
- Handling Note
  238
- Checking the Throttle Position Sensor Input Voltage
  240
Troubleshooting

241
- Troubleshooting
  242
- Troubleshooting of Engine
  242
- Troubleshooting of Clutch
  247
- Troubleshooting of Transmission
  248
- Troubleshooting of Cooling System
  249
- Troubleshooting of Brake
  250
- Troubleshooting of Suspension
  250
- Troubleshooting of Steering/Handling
  252
Tuning

255
- Atmospheric Conditions and Carburetor Settings
  256
- Engine
  256
- Test Run
  256
- Adjusting the Power Jet
  257
- Effects of the Setting Parts on the Throttle Valve Opening
  257
- Main Jet Adjustment
  257
- Pilot Air Screw Adjustment
  257
- Jet Needle Adjustment
  258
- Pilot Jet Adjustment
  258
- Jet Needle Groove Position Adjustment
  259
- Relationship with Throttle Opening
  259
- Carburetor Setting Parts
  260
- Road Condition and Examples of Carburetor Setting
  262
- Symptom
  263
- Change of the Heat Range of Spark Plugs
  264
- Chassis
  265
- Drive and Rear Wheel Sprockets Setting Parts
  265
- Selection of the Secondary Reduction Ratio (Sprocket)
  265
- Change in Amount and Characteristics of Fork Oil
  266
- Front Fork Setting
  266
- Setting of Spring after Replacement
  266
- Choosing Set Length
  267
- Front Fork Setting Parts
  267
- Rear Suspension Setting
  267
- Rear Shock Absorber Setting Parts
  268
- Setting of Spring after Replacement
  268
- Suspension Setting (Front Fork)
  270
- Suspension Setting (Rear Shock Absorber)
  271

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