Yamaha YZ250XP 2023 Manuals

Manuals and User Guides for Yamaha YZ250XP 2023. We have 1 Yamaha YZ250XP 2023 manual available for free PDF download: Owner's Service Manual

Yamaha YZ250XP 2023 Owner's Service Manual (276 pages)

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

Important Manual Information
4
How to Use this Manual
6
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
Nipple Wrench
19
Valve Joint
19
SET PIN (Tool for YPVS)
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
28
Starter Knob (Choke)
29
Sidestand
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
39
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
Periodic Checks and Adjustments
65
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
71
Checking the Transmission Oil Level
72
Changing the Transmission Oil
72
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
75
Checking the Exhaust System
75
Checking the Coolant Level
76
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
80
Checking the Front Brake Hose
80
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
86
Checking the Swingarm Operation
88
Lubricating the Swingarm Pivot
88
Checking the Connecting Arm and Relay Arm
88
Checking the Tires
89
Checking and Tightening the Spokes
89
Checking the Wheels
89
Checking the Wheel Bearings
89
Electrical System
91
Checking the Ignition Timing
91
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
98
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
111
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
123
Installing the Rear Brake Caliper
123
Removing the Rear Brake Master Cylinder
124
Checking the Rear Brake Master Cylinder
124
Assembling the Rear Brake Master Cylinder
124
Installing the Rear Brake Master Cylinder
125
Handlebar
128
Removing the Handlebar
128
Checking the Handlebar
128
Installing the Handlebar
128
Front Fork
133
Removing the Front Fork Legs
135
Disassembling 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
146
Removing the Lower Bracket
147
Checking the Steering Head
147
Installing the Steering Head
147
Rear Shock Absorber Assembly
150
Handling the Rear Shock Absorber
152
Disposing of a Rear Shock Absorber
152
Removing the Rear Shock Absorber Assembly
152
Checking the Rear Shock Absorber Assembly
152
Checking the Connecting Arm and Relay Arm
152
Installing the Relay Arm
153
Installing the Connecting Arm
153
Installing the Rear Shock Absorber Assembly
153
Swingarm
156
Removing the Swingarm
157
Checking the Swingarm
157
Installing the Swingarm
157
Chain Drive
159
Removing the Drive Chain
160
Checking the Drive Chain
160
Checking the Drive Sprocket
161
Checking the Rear Wheel Sprocket
161
Installing the Drive Chain
161
Engine
163
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
182
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
189
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
196
Removing the Segment
197
Checking the Shift Shaft
197
Checking the Stopper Lever
197
Installing the Shift Shaft
197
Crankcase
200
Disassembling the Crankcase
201
Checking the Crankcase
201
Assembling the Crankcase
201
Crankshaft
203
Removing the Crankshaft
204
Checking the Crankshaft
204
Installing the Crankshaft
204
Transmission
205
Removing the Transmission
206
Checking the Shift Forks
206
Checking the Shift Drum Assembly
206
Checking the Transmission
206
Installing the Transmission
207
Cooling System
209
Cooling System Diagrams
210
Radiator
211
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 System
217
Fuel Tank
218
Air Filter
219
Carburetor
220
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
Electrical System
229
Wiring Diagram
230
Color Code
230
Ignition System
231
Troubleshooting
231
Solenoid Valve System
232
Troubleshooting
232
Throttle Position Sensor System
233
Troubleshooting
233
Adjusting the Throttle Po- Sition Sensor
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
243
Troubleshooting
244
General Information
244
Troubleshooting of Engine
244
Troubleshooting of Clutch
249
Troubleshooting of Transmission
250
Troubleshooting of Cooling System
251
Troubleshooting of Brake
252
Troubleshooting of Suspension
252
Troubleshooting of Steering/Handling
254
Tuning
257
Engine
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
264
Symptom
265
Change of the Heat Range of Spark Plugs
266
Chassis
267
Selection of the Secondary Reduction Ratio (Sprocket)
267
Drive and Rear Wheel Sprockets Setting Parts
267
Tire Pressure
267
Front Fork Setting
268
Change in Amount and Characteristics of Fork Oil
268
Setting of Spring after Replacement
268
Front Fork Setting Parts
269
Rear Suspension Setting
269
Choosing Set Length
269
Setting of Spring after Replacement
270
Rear Shock Absorber Setting Parts
270
Suspension Setting (Front Fork)
272
Suspension Setting (Rear Shock Absorber)
273

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Yamaha YZ250XP 2023 Owner's Service Manual (276 pages)

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