Yamaha Yz250Fr 2003 Service Manual (MT037320)

Yamaha Yz250Fr 2003 Service Manual (MT037320)

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  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