Yamaha YZ250M 2021 Manuals

Manuals and User Guides for Yamaha YZ250M 2021. We have 1 Yamaha YZ250M 2021 manual available for free PDF download: Owner's Service Manual

Yamaha YZ250M 2021 Owner's Service Manual (274 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9 MB

Important Manual Information
4
How to Use this Manual
5
General Information
7
Table of Contents
9
Safety Information
11
For Safety, be Sure to Obey the Following
11
Location of Important Labels
14
Description
17
Identification
18
Vehicle Identification Number
18
Engine Serial Number
18
Included Parts
19
SIDESTAND (for YZ250)
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
Lock Washers/Plates and Cotter Pins
21
Bearings and Oil Seals
21
Circlips
21
Basic Service Information
22
Electrical System
22
Special Tools
24
Instrument and Control Functions
28
Engine Stop Switch
28
Shift Pedal
28
Kickstarter Lever
28
Front Brake Lever
28
Rear Brake Pedal
28
FUEL COCK (for YZ250)
28
FUEL COCK (for YZ250X)
29
Starter Knob (Choke)
29
SIDESTAND (for YZ250X)
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
Maintenance after Break-In
32
Major Maintenance
32
Air Filter Maintenance
32
Torque-Check Points
33
Motorcycle Care and Storage
35
Care
35
Storage
36
Specifications
40
General Specifications
40
Engine Specifications
41
Chassis Specifications
44
Electrical Specifications
47
Tightening Torques
48
General Tightening Torque Specifications
48
Engine Tightening Torques
49
Chassis Tightening Torques
51
Cable Routing Diagram
54
Maintenance Intervals
67
Pre-Operation Inspection and Maintenance
70
General Inspection and Maintenance
70
Engine
71
Adjusting the Pilot Air Screw
71
Checking the Engine Idling Speed
71
Checking the Throttle Grip
71
Checking the Spark Plug
72
Checking the Transmission Oil Level
72
Changing the Transmission Oil
73
Adjusting the Clutch Lever Free Play
73
Adjusting the Clutch Lever Position
74
Cleaning the Air Filter Element
74
Checking the Carburetor Joint
75
Checking the Carburetor Hoses
76
Checking the Exhaust System
76
Checking the Coolant Level
77
Checking the Cooling System
77
Changing the Coolant
77
Chassis
79
Adjusting the Front Disc Brake
79
Adjusting the Rear Disc Brake
79
Checking the Brake Fluid Level
80
Checking the Front Brake Pads
80
Checking the Rear Brake Pads
81
Checking the Front Brake Hose
81
Checking the Rear Brake Hose
81
Checking the Brake Operation
81
Bleeding the Hydraulic Brake System
81
Drive Chain Slack
82
Lubricating the Drive Chain
83
Checking and Adjusting the Steering Head
83
Lubricating the Steering Head
84
Checking the Front Fork Legs
84
Adjusting the Front Fork Legs
85
Checking the Rear Shock Absorber Assembly
86
Adjusting the Rear Shock Absorber Assembly
87
Checking the Swingarm Operation
89
Lubricating the Swingarm Pivot
89
Checking the Connecting Arm and Relay Arm
89
Checking the Tires
89
Checking and Tightening the Spokes
89
Checking the Wheels
90
Checking the Wheel Bearings
90
Checking the Chassis Fasteners
90
Checking and Lubricating the Cables
90
Lubricating the Brake Lever
90
Lubricating the Clutch Lever
91
Lubricating the Pedal
91
CHECKING the SIDESTAND (for YZ250X)
91
LUBRICATING the SIDESTAND (for YZ250X)
91
Electrical System
92
Checking the Ignition Timing
92
General Chassis
95
Removing the Number Plate
96
Removing the Side Cover
96
Front Wheel
97
Removing the Front Wheel
98
Disassembling the Front Wheel
98
Checking the Front Wheel
98
Assembling the Front Wheel
99
Installing the Front Wheel
99
Rear Wheel
101
Removing the Rear Wheel
102
Disassembling the Rear Wheel
102
Checking the Rear Wheel
102
Checking and Replacing the Rear Wheel Sprocket
102
Assembling the Rear Wheel
103
Installing the Rear Wheel
103
Front Brake
105
Introduction
109
Checking the Front Brake Disc
109
Replacing the Front Brake Pads
109
Removing the Front Brake Caliper
111
Disassembling the Front Brake Caliper
111
Checking the Front Brake Caliper
111
Assembling the Front Brake Caliper
112
Installing the Front Brake Caliper
112
Removing the Front Brake Master Cylinder
113
Checking the Front Brake Master Cylinder
113
Assembling the Front Brake Master Cylinder
113
Installing the Front Brake Master Cylinder
114
Brake System
115
Rear Brake
116
Introduction
120
Checking the Rear Brake Disc
120
Replacing the Rear Brake Pads
120
Removing the Rear Brake Caliper
122
Disassembling the Rear Brake Caliper
122
Checking the Rear Brake Caliper
122
Assembling the Rear Brake Caliper
122
Installing the Rear Brake Caliper
123
Removing the Rear Brake Master Cylinder
123
Checking the Rear Brake Master Cylinder
124
Assembling the Rear Brake Master Cylinder
124
Installing the Rear Brake Master Cylinder
125
Handlebar
127
Removing the Handlebar
127
Checking the Handlebar
127
Installing the Handlebar
127
Front Fork
132
Removing the Front Fork Legs
134
Disassembling the Front Fork Legs
134
Checking the Front Fork Legs
135
Assembling the Front Fork Legs
136
Installing the Front Fork Legs
142
Steering Head
144
Removing the Lower Bracket
145
Checking the Steering Head
145
Installing the Steering Head
145
Rear Shock Absorber Assembly
148
Handling the Rear Shock Absorber
150
Disposing of a Rear Shock Absorber
150
Removing the Rear Shock Absorber Assembly
150
Checking the Rear Shock Absorber Assembly
150
Checking the Connecting Arm and Relay Arm
150
Installing the Relay Arm
151
Installing the Rear Shock Absorber Assembly
151
Swingarm
153
Removing the Swingarm
154
Checking the Swingarm
154
Installing the Swingarm
154
Chain Drive
156
REMOVING the DRIVE CHAIN (for YZ250)
157
REMOVING the DRIVE CHAIN (for YZ250X)
157
CHECKING the DRIVE CHAIN (for YZ250)
157
CHECKING the DRIVE CHAIN (for YZ250X)
158
Checking the Drive Sprocket
159
Checking the Rear Wheel Sprocket
159
INSTALLING the DRIVE CHAIN (for YZ250)
159
INSTALLING the DRIVE CHAIN (for YZ250X)
160
Engine Removal
165
Removing the Engine
167
Installing the Engine
167
Cylinder Head, Cylinder and Piston
168
Removing the Cylinder Head
170
Removing the Push Rod
170
Removing the Piston
170
Checking the Cylinder Head
171
Checking the Cylinder and Piston
171
Combination of Piston and Cylinder
172
Checking the Piston Ring
173
Checking the Piston Pin
173
Checking the Small End Bearing
174
Checking the Power Valve
174
Checking the Power Valve Hole on Cylinder
174
Assembling the Power Valve
174
Installing the Piston and Cylinder
176
Installing the Cylinder Head
178
CDI Magneto
179
Removing the Rotor
180
Checking the CDI Magneto
180
Checking the Woodruff Key
180
Installing the CDI Magneto
180
Kickstarter
183
Removing the Primary Drive Gear
183
Removing the Kick Shaft Assembly
183
Checking the Kick Shaft and Ratchet Wheel
183
Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
183
Installing the Kick Shaft Assembly
183
Installing the Kick Idle Gear
184
Installing the Primary Drive Gear
185
Installing the Kickstarter Lever
185
Ypvs Governor
186
Removing the Governor
187
Checking the Governor Groove
187
Checking the Bearing
187
Installing the Governor
187
Clutch
191
Removing the Clutch
191
Checking the Friction Plates
191
Checking the Clutch Plates
191
Checking the Clutch Springs
191
Checking the Clutch Housing
191
Checking the Clutch Boss
192
Checking the Pressure Plate
192
Checking the Push Lever Shaft
192
Checking the Push Rods
192
Checking the Primary Drive Gear
192
Checking the Primary Driven Gear
192
Installing the Clutch
192
Shift Shaft
195
Removing the Segment
196
Checking the Shift Shaft
196
Checking the Stopper Lever
196
Installing the Shift Shaft
196
Crankcase
200
Disassembling the Crankcase
200
Checking the Crankcase
200
Assembling the Crankcase
200
Crankshaft
202
Removing the Crankshaft
203
Checking the Crankshaft
203
Installing the Crankshaft
203
Transmission
205
Removing the Transmission
205
Checking the Shift Forks
205
Checking the Shift Drum Assembly
205
Checking the Transmission
205
Installing the Transmission
206
Cooling System
210
Cooling System Diagrams
210
Radiator
212
Checking the Radiator
212
Installing the Radiator
212
Water Pump
214
Disassembling the Water Pump
215
Checking the Water Pump
215
Assembling the Water Pump
215
Fuel Tank
218
Air Filter
219
Carburetor
223
Handling Note
223
Checking the Carburetor
223
Checking the Reed Valve
224
Installing the Reed Valve
224
Assembling the Carburetor
225
Installing the Carburetor
227
Measuring and Adjusting the Fuel Level
228
Wiring Diagram
230
Color Code
230
Ignition System
231
Troubleshooting
231
Solenoid Valve System
232
Troubleshooting
232
Troubleshooting
233
Adjusting the Throttle Po- Sition Sensor
233
Throttle Position Sensor System
233
Electrical Components
234
Checking the Switches
235
Checking the Ignition Spark Gap
237
Checking the Spark Plug Cap
237
Checking the Ignition Coil
237
Checking the Pickup Coil
238
Checking the Source Coil
238
Checking the Solenoid Valve Operation
239
Checking the Solenoid Valve Coil
239
Handling Note
240
Checking the Throttle Position Sensor Coil
240
Changing and Adjusting the Throttle Position Sensor
240
Idling Speed
241
Checking the Throttle Position Sensor Input Voltage
242
Troubleshooting
244
General Information
244
Engine
258
Carburetor Setting
258
Atmospheric Conditions and Carburetor Settings
258
Test Run
258
Effects of the Setting Parts on the Throttle Valve Opening
259
Main Jet Adjustment
259
Adjusting the Power Jet
259
Pilot Air Screw Adjustment
259
Pilot Jet Adjustment
260
Jet Needle Adjustment
260
Jet Needle Groove Position Adjustment
261
Relationship with Throttle Opening
261
Carburetor Setting Parts
262
Road Condition and Examples of Carburetor Setting
263
Examples of Carburetor Setting Depending on Symptom
263
Change of the Heat Range of Spark Plugs
265
Chassis
266
Selection of the Secondary Reduction Ratio (Sprocket)
266
Drive and Rear Wheel Sprockets Setting Parts
266
Tire Pressure
266
Front Fork Setting
267
Change in Amount and Characteristics of Fork Oil
267
Setting of Spring after Replacement
267
Front Fork Setting Parts
268
Rear Suspension Setting
268
Choosing Set Length
268
Setting of Spring after Replacement
269
Rear Shock Absorber Setting Parts
269
Suspension Setting (Front Fork)
271
Suspension Setting (Rear Shock Absorber)
272

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

Yamaha YZ250M 2021 Manuals

Yamaha YZ250M 2021 Owner's Service Manual (274 pages)

Table of Contents

Related Products

Yamaha Categories