YZ250FR ASSEMBLY MANUAL LIT-11666-16-39 5UL-28107-10
EAA00002 FOREWORD This Assembly Manual contains the information required for the correct reassembly of this Yamaha machine prior to delivery to the customer. Since some external parts of the machine have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled machine should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer.
(1) (2) (3) (4) (5) (6) (7) (8) EAA00008 SYMBOLS USED IN ASSEMBLY MANUAL In order to simplify descriptions in this assembly manuals, the following symbols are used: (1) Coat with lithium-soap-based-grease. (2) Tighten to 10 Nm. (10 Nm = 1.0mdkg = 7.2 ftdlb) (3) Towards the front of the machine. (4) Clearance required. (5) Install so that the arrow mark faces upward. (6) Apply a motor oil. (7) Made of rubber or plastics. (8) A: Ref No. (indicating the order of operations.
EAA00040 PREPARATION To assemble the machine correctly, supplies (e.g. oils, greases, and shop rags) and sufficient working space are required. Workshop The workshop where the machine is assembled, should be clean, specious, and have a level floor. Self-protection Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves and shoes.
EAA00060 UNPACKING 1. Remove the frame cover (1). NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the carton boxes (2), front tire (3). 3. Remove the packing frame bolt (4), and handlebar holder bolts (5). 4. Remove the packing frames (in order of sideways (6), upward (7), and front/back (8)). NOTE: Hold the frame while removing the frame bolts. 5. Remove the bolts (9). (front axle fixed plate (10)).
EAA00070 PARTS LOCATION 1. Front wheel 2. Front fender 3. Carton Box 1 4.
Packing frame 1. Front wheel 2. Front fender EAA00080 Carton Box 1 3. Handlebar 4. Side stand 5. Plastic bag 6. Handlebar upper holder 7. Flange bolt [d=8, l=35 (1.38)] 8. Master cylinder bracket 9. Flange bolt [d=6 (0.24), l=22 (0.87)] 10.Engine stop button holder (Upper and lower) 11.Panhead screw with spring washer [d=3 (0.12), l=14 (0.55)] 12.Collar Carton Box 2 13.Number plate 14.Owner’s service manual 15.Plastic bag 16.Hose cover 17.Fuel tank breather hose 18.Spark plug wrench 19.Nipple wrench 20.
EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.
EAA00200 1. HANDLEBAR A: Clean the right handlebar end. Apply light coat grease. B: Before inserting the handlebar into the throttle grip, make sure the collar is installed. D: First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side to specification. Bolt: 28 Nm (2.8 mdkg, 20 ftdlb) NOTE: The upper handlebar holder should be installed with the punched mark (a) forward.
EAA00030 4. FRONT BRAKE HOSE HOLDER A: Remove the front fork cover bolts to slide the front fork cover upwards. B: NOTE: D Align the top (d) of the brake hose neck with the brake hose holder bottom (c). D Pass the brake hose in front of the axle boss (a), then fit it into the brake hose groove (b). D Make sure that brake hose does not contact the front axle nut. C: Tighten the brake hose holder bolts to specification. Bolt: 10 Nm (1.0 mdkg, 7.
EAA00109 6. FRONT FENDER A: Install the collars. B: Tighten the bolts to specification. Bolt: 7 Nm (0.7 mdkg, 5.1 ftdlb) CAUTION: Be careful not to scratch the front fender with the front fork outer tubes. 1 Front fender Hexagon bolt with plain 2 washer 3 Collar 1 S 4 V d=6 (0.24), l=20 (0.78) 4 V d=6 (0.24) W Proper cable routing is essential to assure safe motorcycle operation. Refer to "CABLE ROUTING". EAA00033 7. FRONT BRAKE MASTER CYLINDER A: Lubricate the pivoting part of the brake lever.
EAA00198 9. HOT STARTER (CHOKE) CABLE A: Install the boot to the hot starter (choke) lever. B: Lubricate the pivoting part of the hot starter (choke) lever. Recommended lubricants: Yamaha cable lube or motor oil 1 Hot starter (choke) lever 2 Boot 1 1 C: Insert the cable end into the lever hole, then squeeze the lever. While pulling the outer cable in the direction opposite to the lever, release the lever quickly. * * EAA00207 10.
EAA01070 12. NUMBER PLATE A: Tighten the bolt to specification. Bolt: 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Number plate 2 Flange bolt 1 1 C V d=6 (0.24), l=14 (0.55) EAA00071 13. FUEL TANK BREATHER HOSE A: Connect one end of the breather hose to the fuel tank filler cap, and insert the other end into the hole of the number plate. NOTE: Refer to "CABLE ROUTING". 1 Fuel tank breather hose 1 V CAUTION: Install the hose joint with its arrow mark facing the TANK side.
EAA00900 CABLE ROUTING CAUTION: Proper cable and lead routing are essential to insure safe machine operation. (C)Pass the clutch cable throught the cable guides. (D)Pass the clutch cable in front of the radiator mounting boss. (E)Fit the brake hose into the guides on the protector.
(1) Hot starter (choke) cable (2) Throttle cable (return) (3) Throttle cable (pull) (4) Cable guide (5) Ignition coil (A)Pass the hot starter (choke) cable and throttle cables through the cable guides. (B)Pass the hot starter (choke) cable and throttle cables between the radiator and frame, then under the radiator mounting boss. (C)Pass the throttle cables on the outside of the ignition coil.
(1) Throttle Cable (2) Fuel tank breather hose (3) Clamp (4) Clutch cable (5) Hot starter (choke) cable (6) “ENGINE STOP” button lead (7) Brake hose (8) Hose guide (A)Fasten the “ENGINE STOP” button lead to the handlebar with the plastic band. (B)Pass the brake hose in front of the number plate. (C)Pass the hot starter (choke) cable and throttle cables through the cable guide.
EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown.
EAA01005 3. Tighten the drain screw securely. A. DRAINING THE FUEL 1. Put a rag under the carburetor drain hose so fuel does not contact the crankcase. 2. Loosen the drain screw (1) and drain the standing fuel. W FUEL IS HIGHLY FLAMMABLE: D Always turn off the engine when draining fuel. D Take care not to spill any fuel on the engine or exhaust pipe(s)/muffler(s) when draining fuel. D Never drain fuel while smoking or in the vicinity of an open flame. EAA01009 B. MEASURING THE TIRE PRESSURE 1.
EAA01022 D. ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting throttle cable free play, the engine idling speed should be adjusted. 1. Measure: Dthrottle cable free play (a) Out of specification>Adjust. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: Dthrottle grip free play a. Slide back the rubber cover. EAA01024 E. ADJUSTING THE FRONT BRAKE 1.
2. Bleed: Dhydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the brake master cylinder reservoir diaphragm. c. Connect a clear plastic hose (1) tightly to the bleed screw (2). (A) Front brake (B) Rear brake d. Place the other end of the hose into a container. e. Slowly squeeze the brake lever several times and release it. f. Fully squeeze the brake lever and do not release it. g. Loosen the bleed screw.
2. Adjust: Dbrake pedal position a. Loosen the locknut (1). b. Turn the adjusting nut (2) in direction (a) or (b) until the specified brake pedal position is obtained. Direction (a) Brake pedal is raised. Direction (b) Brake pedal is lowered. W D Adjust the pedal position between the highest position (A) and the lowest position (B) as shown. (In this adjustment, the bolt (3) end (c) should protrude out of the 2 mm (0.08 in) (d) away from the brake pedal (5)).
EAA01020 J. ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 4. Adjust: Dengine idling speed a. Turn the throttle stop screw (1) in direction (a) or (b) until the specified engine idling speed is obtained. Direction (a) Engine idling speed is increased. Direction (b) Engine idling speed is decreased. 1.
EAA01059 M. ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked above the drive chain guide bolt. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the machine on a level surface. 4. Loosen: Dwheel axle nut (1) 5. Adjust: Ddrive chain slack a. Loosen both locknuts (3). b.
Rebound damping NOTE: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark (c) on the adjuster with the punch mark (d) on the bracket.) CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Drebound damping a. Turn the adjusting screw (3) in direction (a) or (b). Direction (a) Rebound damping is increased (suspension is harder). Direction (b) Rebound damping is decreased (suspension is softer).
Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Remove: Drubber cap 2. Adjust: Dcompression damping a. Turn the adjusting screw (2) in direction (a) or (b). Direction (a) Compression damping is increased (suspension is harder). Direction (b) Compression damping is decreased (suspension is softer). Adjusting positions Standard: 12 clicks out* Minimum: 0 clicks out* Maximum: 20 clicks out* *: from the fully turned-in position 3.
EAA10000 APPENDICES SERVICE DATA Engine idling speed: Spark plug: Type /Manufacturer Gap Fuel: Recommended fuel Fuel tank capacity Valve clearance (cold): IN EX Tire air pressure: (measured on cold tires) 1,900~2,100r/min CR8E/NGK (resistance type) 0.7~0.8 mm (0.028~0.031 in) Premium unleaded gasoline only with a research octane number of 95 or higher. 7.0L (1.54 lmp gal, 1.85 US gal) 0.10~0.15 mm (0.0039~0.0059 in) 0.17~0.22 mm (0.0067~0.0087 in) Front 100 kPa (1.0kgf/cm2, 15 psi) Rear100 kPa (1.
EAA10300 TIGHTENING TORQUE Tightening torque Item Thread size Engine: Engine oil drain bolt (oil filter) Spark plug Chassis: Handle crown and outer tube Under bracket and outer tube Handle crown and steering shaft Handlebar holder (upper) Steering ring nut Front fork and cap bolt Front fork and base valve Cap bolt and damper rod (front fork) Bleed screw (front fork) and cap bolt Front fork and cover Front fork and brake hose holder Front fork and hose cover Front fork and hose cover Throttle cable cap Cl
Tightening torque Item Thread size Rear wheel axle and nut Driven sprocket and wheel hub Nipple (spoke) Disc cover and rear brake caliper Protector and rear brake caliper Chain puller adjust bolt and locknut Engine mounting: Engine bracket and frame Engine and engine bracket (front) Engine and engine bracket (upper) Engine and frame (lower) Engine guard (lower) CDI unit bracket mounting Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shock absorber and
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