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Yamaha YZ250FR 2003 Service Manual
Factory Service Repair Manual Pdf Download contains all the repair procedures you need.
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 ......................... 1-10
FUEL ....................................................... 1-13
STARTING AND BREAK-IN ................... 1-14
TORQUE-CHECK POINTS ..................... 1-18
CLEANING AND STORAGE ................... 1-19
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................. 2-1
MAINTENANCE SPECIFICATIONS ......... 2-4
GENERAL TORQUE
SPECIFICATIONS ................................... 2-17
DEFINITION OF UNITS ........................... 2-17
CABLE ROUTING DIAGRAM ................. 2-18
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS ................... 3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE ................................ 3-4
ENGINE ..................................................... 3-5
CHASSIS ................................................. 3-24
ELECTRICAL .......................................... 3-45
CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ................................. 4-1
EXHAUST PIPE AND SILENCER ............ 4-3
RADIATOR ................................................ 4-5
CARBURETOR ......................................... 4-8
CAMSHAFTS .......................................... 4-21
CYLINDER HEAD ................................... 4-30
VALVES AND VALVE SPRINGS ........... 4-33
CYLINDER AND PISTON ....................... 4-42
CLUTCH .................................................. 4-49
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER ...... 4-56
BALANCER ............................................. 4-63
OIL PUMP ............................................... 4-66
KICK SHAFT AND SHIFT SHAFT .......... 4-71
CDI MAGNETO ....................................... 4-78
ENGINE REMOVAL ................................ 4-82
CRANKCASE AND CRANKSHAFT ....... 4-87
TRANSMISSION, SHIFT CAM
AND SHIFT FORK .................................. 4-96
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ....... 5-1
FRONT BRAKE AND REAR BRAKE ..... 5-10
FRONT FORK ......................................... 5-26
HANDLEBAR .......................................... 5-39
STEERING .............................................. 5-45
SWINGARM ............................................ 5-50
REAR SHOCK ABSORBER ................... 5-58
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM ........................... 6-1
MAP-CONTROLLED CDI UNIT ................ 6-2
IGNITION SYSTEM ................................... 6-3
THROTTLE POSITION SENSOR
SYSTEM .................................................... 6-7
CHAPTER 7
TUNING
ENGINE ..................................................... 7-1
CHASSIS ................................................. 7-11
General Information
Specifications
Periodic Checks and Adjustments
Engine
Carburetor
Drive Train
Chassis
Electrical
Troubleshooting
Wiring Diagram
File Data
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