Yz250 - 2021 Workshop Manual

2021
OWNER’S MANUAL
YZ250
YZ250X
Read this manual carefully before operating this vehicle.
YZ250M2
PRINTED IN JAPAN
YZ250XM
2020.04-0.9×1 ! LIT-11626-34-11 BF1-28199-10
(E)
BF1-28199-10_cover.indd 1-3 2020/03/10 13:38:50

For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts text
EAM20160
Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones
originally equipped on your vehicle, providing you with the performance and durability you have come
to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction?
Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for
quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right
and perform right – right out of the box.
Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
They’re formulated and approved by the toughest judges we know: the Yamaha engineering teams that
know your Yamaha from the inside out.
Genuine Yamaha Service Manuals – Get the same factory manual for your vehicle that the techni-
cians at your authorized Yamaha dealer use. Service manuals are available through your Yamaha
dealer or you can order them directly through yamahapubs.com.
Genuine Yamaha products are available only from your Yamaha dealer.
Operating, servicing and Find out more at yamaha-motor.com

maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more
information go to
www.P65Warnings.ca.gov/passenger-vehicle
Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle
if it is sold.
BF1-28199-10_cover.indd 4-6 2020/03/10 13:38:50

EAM20080
YZ250M2
YZ250XM
OWNER’S MANUAL
©2021 by Yamaha Motor Corporation, U.S.A.
First edition, April 2020
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
P/N. LIT-11626-34-11
Printed in Japan.
EAM20180
IMPORTANT
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have
any questions about this manual or your machine, please contact your Yamaha dealer.
TIP
• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor dis-
crepancies between your machine and this manual. If you have any questions concerning this man-
ual, please consult your Yamaha dealer.
• This manual is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disassem-
bly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical
damage.
EWA20270
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAM30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EAM20162
YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED

WARRANTY
TABLE OF CONTENTS
EAM10003
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
ELECTRICAL SYSTEM 6
TROUBLESHOOTING 7
TUNING 8
GENERAL INFORMATION
SAFETY INFORMATION ..................................................................................1-1

FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:...........................1-1
LOCATION OF IMPORTANT LABELS.............................................................1-4 1

DESCRIPTION..................................................................................................1-5
IDENTIFICATION ..............................................................................................1-6
2
VEHICLE IDENTIFICATION NUMBER ......................................................1-6
ENGINE SERIAL NUMBER........................................................................1-6
INCLUDED PARTS ...........................................................................................1-7

SIDESTAND (for YZ250) ............................................................................1-7
3
NIPPLE WRENCH ......................................................................................1-7
4
VALVE JOINT .............................................................................................1-7
SET PIN......................................................................................................1-7
IMPORTANT INFORMATION ...........................................................................1-8

PREPARATION FOR REMOVAL AND DISASSEMBLY ............................1-8
REPLACEMENT PARTS ............................................................................1-8
5
INSTRUMENT AND CONTROL FUNCTIONS .................................................1-9
ENGINE STOP SWITCH ............................................................................1-9
SHIFT PEDAL.............................................................................................1-9
KICKSTARTER LEVER ..............................................................................1-9
FRONT BRAKE LEVER .............................................................................1-9
6
REAR BRAKE PEDAL................................................................................1-9
FUEL COCK (for YZ250) ............................................................................1-9
FUEL COCK (for YZ250X)........................................................................1-10
STARTER KNOB (CHOKE)......................................................................1-10
SIDESTAND (for YZ250X)........................................................................1-10
7
STARTING AND BREAK-IN ...........................................................................1-11
FUEL AND ENGINE MIXING OIL.............................................................1-11
STARTING A COLD ENGINE ..................................................................1-11
8
STARTING A WARM ENGINE .................................................................1-11
BREAK-IN PROCEDURES ......................................................................1-11
MAINTENANCE AFTER BREAK-IN ..............................................................1-13

9
MAJOR MAINTENANCE ..........................................................................1-13
AIR FILTER MAINTENANCE ...................................................................1-13
TORQUE-CHECK POINTS.............................................................................1-14 10
MOTORCYCLE CARE AND STORAGE.........................................................1-16
CARE ........................................................................................................1-16
STORAGE ................................................................................................1-17
SAFETY INFORMATION
EAM20168
ator only. No passengers.
SAFETY INFORMATION 3. The failure of motorists to detect and recog-
Be sure to read this manual carefully and com- nize motorcycles in traffic is the predominat-
pletely in order to operate the machine safely ing cause of automobile/motorcycle
and correctly prior to riding the Yamaha ma- accidents. Many accidents have been
chine, and take care to maintain it properly and caused by an automobile driver who did not
operate it safely. see the motorcycle. Making yourself conspic-
EAM30401
uous appears to be very effective in reducing
FOR SAFETY, BE SURE TO OBEY THE the chance of this type of accident.
FOLLOWING: Therefore:
Be a Responsible Owner • Wear a brightly colored jacket.
As the vehicle’s owner, you are responsible for • Use extra caution when you are approaching
the safe and proper operation of your motorcy- and passing through intersections, since in-
cle. tersections are the most likely places for mo-
Motorcycles are single-track vehicles. torcycle accidents to occur.
Their safe use and operation are dependent • Ride where other motorists can see you.
upon the use of proper riding techniques as well Avoid riding in another motorist’s blind spot.
as the expertise of the operator. Every operator • Never maintain a motorcycle without proper
should know the following requirements before knowledge. Contact an authorized motorcy-
riding this motorcycle. cle dealer to inform you on basic motorcycle
He or she should: maintenance. Certain maintenance can only
1. Obtain thorough instructions from a compe- be carried out by certified staff.
tent source on all aspects of motorcycle oper- 4. Many accidents involve inexperienced opera-
ation. tors.
2. Observe the warnings and maintenance re- • Make sure that you are qualified and that you
quirements in this manual. only lend your motorcycle to other qualified
3. Obtain qualified training in safe and proper operators.
riding techniques. • Know your skills and limits. Staying within
4. Obtain professional technical service as indi- your limits may help you to avoid an accident.
cated in this manual and/or when made nec- • We recommend that you practice riding your
essary by mechanical conditions. motorcycle until you have become thoroughly
5. Never operate a motorcycle without proper familiar with the motorcycle and all of its con-
training or instruction. Take a training course. trols.
Beginners should receive training from a cer- 5. Many accidents have been caused by error of
tified instructor. Contact an authorized motor- the motorcycle operator. A typical error made
cycle dealer to find out about the training by the operator is veering wide on a turn due
courses nearest you. to excessive speed or under cornering (insuf-
Safe Riding ficient lean angle for the speed). Never travel
Perform the pre-operation checks each time you faster than warranted by conditions.
use the vehicle to make sure it is in safe operat- 6. Ride cautiously in unfamiliar areas. You may
ing condition. Failure to inspect or maintain the encounter hidden obstacles that could cause
vehicle properly increases the possibility of an an accident.
accident or equipment damage. Refer to “PRE- 7. The posture of the operator is important for
OPERATION INSPECTION AND MAINTE- proper control. The operator should keep
NANCE” on page 3-4 for a list of pre-operation both hands on the handlebar and both feet on
checks. the operator footrests during operation to
1. This motorcycle is designed for off-road use maintain control of the motorcycle.
only, therefore, it is illegal to operate it on 8. Never ride under the influence of alcohol or
public streets, roads, or highways, even a dirt other drugs.
or gravel one. Off-road use on public lands 9. Be sure the transmission is in neutral before
may be illegal. Please check local regulations starting the engine.
before riding. Protective Apparel
2. This motorcycle is designed to carry the oper- The majority of fatalities from motorcycle acci-
1-1
SAFETY INFORMATION
dents are the result of head injuries. The use of er modifications for Yamaha vehicles. Yamaha
a safety helmet is the single most critical factor is not in a position to test the products that these
in the prevention or reduction of head injuries. aftermarket companies produce. Therefore,
1. Always wear an approved helmet. Yamaha can neither endorse nor recommend
2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or
unprotected eyes could contribute to an im- modifications not specifically recommended by
pairment of vision that could delay seeing a Yamaha, even if sold and installed by a Yamaha
hazard. dealer.
3. The use of a jacket, heavy boots, trousers, Aftermarket Parts, Accessories, and Modifi-
gloves, etc., is effective in preventing or re- cations
ducing abrasions or lacerations. While you may find aftermarket products similar
4. Never wear loose-fitting clothes, otherwise in design and quality to genuine Yamaha acces-
they could catch on the control levers, foot- sories, recognize that some aftermarket acces-
rests, or wheels and cause injury or an acci- sories or modifications are not suitable because
dent. of potential safety hazards to you or others. In-
5. Always wear protective clothing that covers stalling aftermarket products or having other
your legs, ankles, and feet. The engine or ex- modifications performed to your vehicle that
haust system become very hot during or after change any of the vehicle’s design or operation
operation and can cause burns. characteristics can put you and others at greater
Avoid Carbon Monoxide Poisoning risk of serious injury or death. You are responsi-
All engine exhaust contains carbon monoxide, a ble for injuries related to changes in the vehicle.
deadly gas. Breathing carbon monoxide can Keep the following guidelines in mind, as well as
cause headaches, dizziness, drowsiness, nau- those provided under “Loading” when mounting
sea, confusion, and eventually death. accessories.
Carbon Monoxide is a colorless, odorless, taste- 1. Never install accessories that would impair
less gas which may be present even if you do the performance of your motorcycle. Careful-
not see or smell any engine exhaust. Deadly lev- ly inspect the accessory before using it to
els of carbon monoxide can collect rapidly and make sure that it does not in any way reduce
you can quickly be overcome and unable to save ground clearance or cornering clearance, lim-
yourself. Also, deadly levels of carbon monoxide it suspension travel, steering travel or control
can linger for hours or days in enclosed or poorly operation.
ventilated areas. If you experience any symp- • Accessories fitted to the handlebar or the
toms of carbon monoxide poisoning, leave the front fork area can create instability due to im-
area immediately, get fresh air, and SEEK MED- proper weight distribution. If accessories are
ICAL TREATMENT. added to the handlebar or front fork area,
1. Do not run engine indoors. Even if you try to they must be as lightweight as possible and
ventilate engine exhaust with fans or open should be kept to a minimum.
windows and doors, carbon monoxide can • Bulky or large accessories may seriously af-
rapidly reach dangerous levels. fect the stability of the motorcycle. Wind may
2. Do not run engine in poorly ventilated or par- attempt to lift the motorcycle, or the motorcy-
tially enclosed areas such as barns, garages, cle may become unstable in cross winds.
or carports. • Certain accessories can displace the opera-
3. Do not run engine outdoors where engine ex- tor from his or her normal riding position. This
haust can be drawn into a building through improper position limits the freedom of move-
openings such as windows and doors. ment of the operator and may limit control
Genuine Yamaha Accessories ability, therefore, such accessories are not
Choosing accessories for your vehicle is an im- recommended.
portant decision. Genuine Yamaha accessories, 2. Use caution when adding electrical accesso-
which are available only from a Yamaha dealer, ries. If electrical accessories exceed the ca-
have been designed, tested, and approved by pacity of the motorcycle’s electrical system,
Yamaha for use on your vehicle. an electric failure could result, which could
Many companies with no connection to Yamaha cause a dangerous loss of lights or engine
manufacture parts and accessories or offer oth- power.
1-2
SAFETY INFORMATION
Aftermarket Tires and Rims

The tires and rims that came with your motorcy-
cle were designed to match the performance ca-
pabilities and to provide the best combination of
handling, braking, and comfort. Other tires, rims,
sizes, and combinations may not be appropriate.
Refer to “CHECKING THE TIRES” on page 3-23
for tire specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instructions before
transporting the motorcycle in another vehicle.
1. Remove all loose items from the motorcycle.
2. Check that the fuel cock (if equipped) is in the
“OFF” position and that there are no fuel
leaks.
3. Point the front wheel straight ahead on the
trailer or in the truck bed, and choke it in a rail
to prevent movement.
4. Shift the transmission in gear (for models with
a manual transmission).
5. Secure the motorcycle with tie-downs or suit-
able straps that are attached to solid parts of
the motorcycle, such as the frame or upper
front fork triple clamp (and not, for example,
to rubber-mounted handlebars or turn sig-
nals, or parts that could break). Choose the
location for the straps carefully so the straps
will not rub against painted surfaces during
transport.
6. The suspension should be compressed
somewhat by the tie-downs, if possible, so
that the motorcycle will not bounce exces-
sively during transport.
1-3
LOCATION OF IMPORTANT LABELS
EAM20085
LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.
1-4
DESCRIPTION
EAM20086
DESCRIPTION
1. Clutch lever 11.Check bolt (Transmission oil level)

2. Engine stop switch 12.Rear brake pedal
3. Front brake lever 13.Valve joint
4. Throttle grip 14.Fuel cock
5. Radiator cap 15.Starter knob
6. Fuel tank cap 16.Drive chain
7. Kickstarter lever 17.Air filter
8. Fuel tank 18.Shift pedal
9. Radiator 19.Front fork
10.Coolant drain bolt
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please note
that the descriptions in this manual may be different from those for the vehicle you have purchased.
1-5
IDENTIFICATION
EAM20087
IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive identi-
fication of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
EAM30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the frame.
EAM30003
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
elevated part of the right-side of the engine.
1-6
INCLUDED PARTS
EAM20088
INCLUDED PARTS
EAM30372
SIDESTAND (for YZ250)

This sidestand “1” is used to support only the
machine when standing or transporting it.
EWA20260
WARNING
• Never apply additional force to the sides-
tand.
• Remove this sidestand before starting out. EAM30535
SET PIN
This set pin “1” is used to remove and install the
push rod of the engine.
ECA27140
NOTICE
Be sure to use the set pin. If the set pin is not
used, the power valve constituent parts will
result in damage.
EAM30005
NIPPLE WRENCH
The nipple wrench “1” is used to tighten the
spoke.
EAM30534
VALVE JOINT
This valve joint “1” prevents fuel from flowing out
and is installed to the fuel tank breather hose.
ECA27110
NOTICE
In this installation, make sure the arrow fac-
es the fuel tank and also downward.
1-7
IMPORTANT INFORMATION
EAM20089
soapy water.
IMPORTANT INFORMATION • If it is swallowed, immediately induce vom-
EAM30009
iting and get medical attention.
PREPARATION FOR REMOVAL AND
DISASSEMBLY EAM30010
REPLACEMENT PARTS
1. Before the jobs, completely remove mud,
Make sure that the parts and grease or oil to be
dust, and the like in order to prevent the entry
used for repair of the vehicle, including periodic
of them into the inside during the jobs.
replacement parts, are new YAMAHA genuine
Refer to “CARE” on page 1-16.
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar appear-
ances or because the quality may be changed
by aging.
2. During disassembly, check and measure the

required parts, and make a record of them so
that you may refer to the record when install-
ing them. Moreover, arrange gears, cylin-
ders, pistons, and other parts for each section
so as not to confuse or lose them.
3. During disassembly, clean each of the parts,

and store them in trays for each section.
4. Flammable. Keep servicing areas away from
any source of fire.
5. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
6. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore, rinse
it out with water in good time.
EWA18970
WARNING
Coolant is potentially harmful and should be
handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes, quick-
ly wash it away with water and then with
1-8
INSTRUMENT AND CONTROL FUNCTIONS
EAM20181
INSTRUMENT AND CONTROL

FUNCTIONS
EAM30182
ENGINE STOP SWITCH

The engine stop switch “1” is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
EAM30188
FRONT BRAKE LEVER

The front brake lever “1” is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
1
EAM30185
SHIFT PEDAL
The shift pedal “1” has adopted a method of 1
down & 4 ups (press-down & kick-ups).
Press it down for N (neutral) to 1st, and kick it up
for 2nd to 5th.
EAM30189
REAR BRAKE PEDAL

The rear brake pedal “1” is in the right of the
chassis. Press down on the brake pedal to acti-
vate the rear brake.
EAM30186
KICKSTARTER LEVER
Rotate the kickstarter lever “1” away from the en-
gine. Push the starter down lightly with your foot
until the gears engage, then kick smoothly and
forcefully to start the engine. This model has a
primary kickstarter lever so the engine can be EAM30536
started in any gear if the clutch is disengaged. In FUEL COCK (for YZ250)
normal practices, however, shift to neutral be- The fuel cock supplies fuel from the tank to car-
fore starting. buretor and also filters the fuel. The fuel cock
has the two positions:
OFF:
With the lever in this position, fuel will not flow.
Always return the lever to this position when the
engine is not running.
ON:
With the lever in this position, fuel flows to the
carburetor. Normal riding is done with the lever
1-9
INSTRUMENT AND CONTROL FUNCTIONS
in this position.
EAM30190
EAM30537 SIDESTAND (for YZ250X)

FUEL COCK (for YZ250X) This sidestand “1” is used to support only the
The fuel cock supplies fuel from the tank to car- machine when standing or transporting it.
buretor and also filters the fuel. The fuel cock EWA18980
has the three positions: WARNING

OFF: • Never apply additional force to the sides-
With the lever in this position, fuel will not flow. tand.
Always return the lever to this position when the • Hold up the sidestand before starting out.
engine is not running.
ON:
With the lever in this position, fuel flows to the
carburetor. Normal riding is done with the lever
in this position.
RES:
With the lever in this position fuel flows to the
carburetor from the reserve section of the fuel
tank after the main supply of the fuel has been
depleted. Normal riding is possible with the lever
is in this position, but it is recommended to add
fuel as soon as possible.
EAM30444
STARTER KNOB (CHOKE)

When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the starter knob “1”, sup-
plies this mixture. Pull the starter knob out to
open the circuit for starting. When the engine
has warmed up, push it in to close the circuit.
1-10
STARTING AND BREAK-IN
EAM20123
engine by kicking the kickstarter forcefully
STARTING AND BREAK-IN with firm stroke.
EAM30538
4. Run the engine at idle or slightly higher until it
FUEL AND ENGINE MIXING OIL warms up: this usually takes about one or two
Mix oil with the gas at the ratio specified below. minutes.
Always use fresh, name-brand gasoline, and 5. The engine is warmed up when it responds
mix the oil and gas the day of the race. Do not normally to the throttle with the starter knob
use premix that is more than a few hours old. (CHOKE) turned off.
EWA19030
Recommended fuel WARNING

Premium unleaded gasoline Since exhaust gas contains harmful ingredi-
(E10 acceptable) ents, do not start or warm it up at an illventi-
lated place or a closed narrow place.
TIP
If knocking or pinging occurs, use a different 6. To stop the engine, push the engine stop
brand of gasoline or higher octane grade. switch.
TIP
ECA22260
Continue pushing the engine stop switch till the
NOTICE
engine comes to a full stop.
Never mix two types of oil in the same batch;
clotting of the oil could result. If you wish to EAM30197
change oil types, be sure to drain the fuel STARTING A WARM ENGINE
tank and the carburetor float bowl of old pre- Do not operate the starter knob (CHOKE). Open
mix prior to filling with the new type. the throttle slightly and start the engine by kick-
ing the kickstarter forcefully with firm stroke.
Fuel tank capacity EAM30198
8.0 L (2.1 US gal, 1.8 Imp.gal) BREAK-IN PROCEDURES
Fuel reserve amount
A break-in is important so that rotating portion,
2.0 L (0.53 US gal, 0.44 Imp.gal)
(YZ250X) sliding surfaces, and mounted areas may fit one
another, and that the rider may become accus-
tomed to the machine.
Engine oil ECA25811
Lubrication system NOTICE

Premix lubrication Before running, do maintenance on the air
Engine oil filter element.
YAMALUBE 2R
Premix ratio 1. Before starting the engine, fill the fuel tank
30 with a break-in oil-fuel mixture as follows.
Engine oil
YAMALUBE 2R
Premix ratio
15
2. Start and warm up the engine.

3. After warming up the engine, drive it for about
20 minutes at a throttle opening of 1/2 or less.
4. Make a pit stop, and check mounted areas for
looseness, oil leaks, or other problems.
5. Then, drive it for about 40 minutes at a throt-
EAM30196
tle opening of 3/4 or less.
STARTING A COLD ENGINE 6. Make a pit stop again, and thoroughly check
1. Shift the transmission into neutral. mounted areas for looseness, oil leaks, or
2. Turn the fuel cock to “ON” and full open the other problems. Thorough checks and ad-
starter knob (CHOKE). justments are required in particular for stretch
3. With the throttle completely closed start the
1-11
STARTING AND BREAK-IN
of cables, free play of the brake, stretch of the

drive chain, looseness of the spoke, and so
on.
ECA25821
NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them.
Also when the following parts are replaced, a
break-in is required.
• Cylinder and Crankshaft: A break-in is re-
quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine carefully
during a break-in.
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN”. If any prob-
lem is found, immediately stop the engine
and make a checkup.
1-12
MAINTENANCE AFTER BREAK-IN
EAM20124
• Cable
MAINTENANCE AFTER BREAK-IN Grease and adjust cables.
After a break-in, perform careful maintenance to • Drive chain
get ready for the next practice or race. Lubricate the drive chain and adjust its ten-
Refer to “PRE-OPERATION INSPECTION AND sion.
MAINTENANCE” on page 3-4. • Fuel tank
EAM30199
Clean the inside of the fuel tank and the fuel
MAJOR MAINTENANCE cock. Check for leaks.
1. For the engine • Suspension
• Leaks around the engine Check for oil leaks in the front fork or the rear
Check for pressure leaks from the cylinder shock absorber. Check that the mounted
head or the cylinder, oil leaks from the crank- conditions are good.
case or the case cover, leaks from the cool- • Sprocket
ant system, and other leaks. Check for looseness in the sprocket mounted
• Check that the cylinder, the piston, and the on the rear wheel.
piston ring fit one another, and that contact • Mounting bolts and nuts
between the cylinder and the piston are cor- Check mounted areas for looseness.
ECA25831
rect.
NOTICE
• Transmission oil change
Drain the oil, and check for dirt and foreign After a break-in or before each race, always
materials such as metal chips. (If any foreign check the points shown in “TORQUE-
material is mixed, disassemble and check the CHECK POINTS” for tightening torques and
transmission.) retighten them.
Pour the specified amount of the recom- • Greasing and oiling
mended oil. Always grease or oil the specified points.
• Carburetor
EAM30195
Disassemble the carburetor and clean the AIR FILTER MAINTENANCE
small holes, blowing them with compressed Apply the Yamaha foam air filter oil or other qual-
air. ity foam air filter oil to the element. (Excess oil in
• CDI magneto the element may adversely affect engine start-
Check for looseness in mounted areas of the ing.)
rotor and the stator. Refer to “CLEANING THE AIR FILTER ELE-
Check that the connector is not being discon- MENT” on page 3-8.
nected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel(s)
Check the wheel for runout. Check the spoke
for looseness.
• Brake(s)
Check the brake disc mounting bolt for loose-
ness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
1-13
TORQUE-CHECK POINTS
EAM20125
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel(s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank
Shift pedal Shift pedal to shift shaft
1-14
TORQUE-CHECK POINTS
Plastic cover Tightening of front fender

Tightening of fork leg protector
Tightening of air scoop
Left cover to rear frame
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake disc cover
Tightening of rear brake caliper
cover
TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-7.
1-15
MOTORCYCLE CARE AND STORAGE
EAM20126
ucts are used on hard-to-remove dirt, do
MOTORCYCLE CARE AND STOR- not leave the cleaner on the affected area
AGE any longer than instructed. Also, thorough-
ly rinse the area off with water, immediately
EAM30200
dry it, and then apply a corrosion protec-
CARE
tion spray.
While the open design of a motorcycle reveals
• Improper cleaning can damage plastic
the attractiveness of the technology, it also
parts (such as cowlings, panels, wind-
makes it more vulnerable. Rust and corrosion
shields, headlight lenses, meter lenses,
can develop even if high-quality components are
etc.) and the mufflers. Use only a soft, clean
used. A rusty exhaust pipe may go unnoticed on
cloth or sponge with water to clean plastic.
a car, however, it detracts from the overall ap-
However, if the plastic parts cannot be thor-
pearance of a motorcycle. Frequent and proper
oughly cleaned with water, diluted mild de-
care does not only comply with the terms of the
tergent with water may be used. Be sure to
warranty, but it will also keep your motorcycle
rinse off any detergent residue using plenty
looking good, extend its life and optimize its per-
of water, as it is harmful to plastic parts.
formance.
• Do not use any harsh chemical products on
Before cleaning
plastic parts. Be sure to avoid using cloths
TIP or sponges which have been in contact
Be sure to confirm that the vehicle is completely
with strong or abrasive cleaning products,
cooled.
solvent or thinner, fuel (gasoline), rust re-
1. Block or cover the following parts with suit- movers or inhibitors, brake fluid, antifreeze
able measures. or electrolyte.
• Side cover air intake port “1” • For motorcycles equipped with a wind-
• Water pump housing hole at the bottom “2” shield: Do not use strong cleaners or hard
• Crankcase cover hole at the bottom (left side) sponges as they will cause dulling or
“3” scratching. Some cleaning compounds for
• Silencer exhaust port “4” plastic may leave scratches on the wind-
• End of each hose shield. Test the product on a small hidden
part of the windshield to make sure that it
1 does not leave any marks. If the windshield
is scratched, use a quality plastic polishing
compound after washing.
4 • When cleaning using either a high-pres-
sure cleaning machine or a water hose, do
not direct the water jet toward the following
areas:(Otherwise, it could cause either
damage due to the water pressure or mal-
3 2
function due to water entry.)
Wheels or swing arm bearings
2. Make sure that all caps and covers as well as
Fork seals or brake seals
all electrical couplers and connectors, includ-
Electrical parts, such as couplers, switch-
ing the spark plug cap, are tightly installed.
es, battery, etc.
3. Remove extremely stubborn dirt, like oil burnt
Muffler or hoses
onto the crankcase, with a degreasing agent
Air cleaner intake port
and a brush, but never apply such products
• Do not clean using a water jet with the seat
onto seals, gaskets, sprockets, the drive
or cover removed.
chain and wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA26730
NOTICE
• Avoid using strong acidic wheel cleaners,
especially on spoked wheels. If such prod-
1-16
6. Touch up minor paint damage caused by

stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before
storing or covering it.
EWA19050
WARNING
Contaminants on the brakes or tires can
cause loss of control.
• Make sure that there is no oil or wax on the
brakes or tires.
After normal use • If necessary, clean the brake discs and
Remove dirt with warm water, a mild detergent, brake linings with a regular brake disc
and a soft, clean sponge, and then rinse thor- cleaner or acetone, and wash the tires with
oughly with clean water. Use a toothbrush or warm water and a mild detergent. Before
bottlebrush for hard-to-reach areas. Stubborn riding at higher speeds, test the motorcy-
dirt and insects will come off more easily if the cle’s braking performance and cornering
area is covered with a wet cloth for a few min- behavior.
utes before cleaning.
ECA24240
After riding in the rain, near the sea or on salt-
NOTICE
sprayed roads
Since sea salt or salt sprayed on roads during • Apply spray oil and wax sparingly and
winter are extremely corrosive in combination make sure to wipe off any excess.
with water, carry out the following steps after • Never apply oil or wax to any rubber and
each ride in the rain, near the sea or on salt- plastic parts, but treat them with a suitable
sprayed roads. care product.
• Avoid using abrasive polishing com-
TIP
Salt sprayed on roads in the winter may remain pounds as they will wear away the paint.
well into spring. TIP
• Consult a Yamaha dealer for advice on what
1. Clean the motorcycle with cold water and a
products to use.
mild detergent, after the engine has cooled
• Washing, rainy weather or humid climates can
down.
cause the headlight lens to fog. Turning the
NOTICE: Do not use warm water since it
headlight on for a short period of time will help
increases the corrosive action of the salt.
remove the moisture from the lens.
2. Apply a corrosion protection spray on all met-
al, including chrome- and nickel-plated, sur-
EAM30201
faces to prevent corrosion. STORAGE
After cleaning Short-term
1. Dry the motorcycle with a chamois or an ab- Always store your motorcycle in a cool, dry place
sorbing cloth. and, if necessary, protect it against dust with a
2. Immediately dry the drive chain and lubricate porous cover. Be sure the engine and the ex-
it to prevent it from rusting. haust system are cool before covering the mo-
3. Use a chrome polish to shine chrome, alumi- torcycle.
num and stainless- steel parts, including the ECA24250
exhaust system. (Even the thermally induced NOTICE

discoloring of stainless- steel exhaust sys- • Storing the motorcycle in a poorly ventilat-
tems can be removed through polishing.) ed room or covering it with a tarp, while it is
4. To prevent corrosion, it is recommended to still wet, will allow water and humidity to
apply a corrosion protection spray on all met- seep in and cause rust.
al, including chrome- and nickel-plated, sur- • To prevent corrosion, avoid damp cellars,
faces. stables (because of the presence of ammo-
5. Use spray oil as a universal cleaner to re- nia) and areas where strong chemicals are
move any remaining dirt.
1-17
stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in “CARE” on page
1-16.
2. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug, pour a tablespoon
of motor oil in the spark plug hole, and re-
install the plug. With the engine stop
switch pushed in, kick the engine over
several times to coat the cylinder walls
with oil.
4. Lubricate all control cables and the pivoting
points of all levers and pedals as well as of
the sidestand.
5. Check and, if necessary, correct the tire air
pressure, and then lift the motorcycle so that
both of its wheels are off the ground. Alterna-
tively, turn the wheels a little every month in
order to prevent the tires from becoming de-
graded in one spot.
6. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
TIP
Make any necessary repairs before storing the
motorcycle.
1-18
SPECIFICATIONS
GENERAL SPECIFICATIONS ..........................................................................2-1
ENGINE SPECIFICATIONS..............................................................................2-2
1
CHASSIS SPECIFICATIONS............................................................................2-4
TIGHTENING TORQUES..................................................................................2-7
GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................2-7
2
ENGINE TIGHTENING TORQUES ............................................................2-8
CHASSIS TIGHTENING TORQUES ........................................................2-10
3
4
5
6
7
8
9
10
GENERAL SPECIFICATIONS
EAM20127
GENERAL SPECIFICATIONS
Model
Model B9U9 (YZ250)
BF1M (YZ250X)
Dimensions
Overall length 2185 mm (86.0 in)
Overall width 825 mm (32.5 in)
Overall height 1290 mm (50.8 in)
Seat height 970 mm (38.2 in)
Wheelbase 1485 mm (58.5 in)
Ground clearance 360 mm (14.17 in)
Weight
Curb weight 103 kg (227 lb) (YZ250)
104 kg (229 lb) (YZ250X)
2-1
ENGINE SPECIFICATIONS
EAM20128
Engine
Combustion cycle 2-stroke
Cooling system Liquid cooled
Induction system Reed valve
Displacement 250 cm³
Number of cylinders Single cylinder
Bore  stroke 66.4  72.0 mm (2.61  2.83 in)
Compression ratio 7.9–9.4 : 1 (YZ250X)
8.9–10.6 : 1 (YZ250)
Starting system Kickstarter
Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
Fuel tank capacity 8.0 L (2.1 US gal, 1.8 Imp.gal)
Fuel reserve amount 2.0 L (0.53 US gal, 0.44 Imp.gal) (YZ250X)
Engine oil
Recommended brand YAMALUBE
Lubrication system Premix lubrication
Engine oil YAMALUBE 2R
Premix ratio 30
Transmission oil
Type Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled) 0.80 L (0.85 US qt, 0.70 Imp.qt)
Quantity 0.75 L (0.79 US qt, 0.66 Imp.qt)
Cooling system
Coolant quantity
Radiator (including all routes) 1.20 L (1.27 US qt, 1.06 Imp.qt)
Spark plug(s)
Manufacturer/model NGK/BR8EG
Spark plug gap 0.5–0.6 mm (0.020–0.024 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 8 pcs
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Plate quantity 7 pcs
Warpage limit 0.20 mm (0.008 in)
Clutch spring free length 44.00 mm (1.73 in) (YZ250X)
50.00 mm (1.97 in) (YZ250)
Clutch spring free length limit 41.80 mm (1.65 in) (YZ250X)
48.00 mm (1.89 in) (YZ250)
Push rod bending limit 0.30 mm (0.012 in)
Drivetrain
Primary reduction ratio 3.000 (63/21)
Transmission type Constant mesh 5-speed
2-2
Gear ratio
1st 1.929 (27/14)
2nd 1.533 (23/15)
3rd 1.278 (23/18) (YZ250)
1.313 (21/16) (YZ250X)
4th 1.050 (21/20) (YZ250X)
1.091 (24/22) (YZ250)
5th 0.840 (21/25) (YZ250X)
0.952 (20/21) (YZ250)
Secondary reduction ratio 3.571 (50/14)
Final drive Chain
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Carburetor
Type  quantity PWK38  1
ID mark 1P87 50
Main jet #178
Main air jet #200
Jet needle N3-EW-2
Needle jet ø2.9(#6)
Cutaway #7
Pilot outlet 0.8
Pilot jet #50
Bypass 1 1.5
Air screw turns out 1-1/4
Valve seat size 3.8
Starter jet 1 #85
Power Jet #50
Float height 6.5 mm (0.26 in)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-3
CHASSIS SPECIFICATIONS
EAM20129
Chassis
Frame type Semi double cradle
Caster angle 27.7 
Trail 122 mm (4.8 in)
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.60
Rear wheel
Wheel type Spoke wheel
Rim size 18 x 2.15 (YZ250X)
19 x 2.15 (YZ250)
Front tire
Type With tube
Size 80/100-21 51M (YZ250)
90/90-21 54M (YZ250X)
Manufacturer/model DUNLOP/AT81F (YZ250X)
DUNLOP/MX52F (YZ250)
Rear tire
Type With tube
Size 110/100-18 64M (YZ250X)
110/90-19 62M (YZ250)
Manufacturer/model DUNLOP/AT81 (YZ250X)
DUNLOP/MX52 (YZ250)
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm², 15 psi)
Rear 100 kPa (1.00 kgf/cm², 15 psi)
Front brake
Type Hydraulic single disc brake
Brake pad lining thickness limit 1.0 mm (0.04 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Brake pedal position 0.0 mm (0.00 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 300 mm (11.8 in)
Fork spring free length limit 449.0 mm (17.68 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil S1
Quantity (left) 515.0 cm³ (17.41 US oz, 18.16 Imp.oz)
Quantity (right) 515.0 cm³ (17.41 US oz, 18.16 Imp.oz)
2-4
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position 20
(Soft)
Adjustment value from the start position 10 (YZ250X)
(STD) 12 (YZ250)
(Hard)
Compression damping
Unit for compression damping adjustment Click
(Soft)
Adjustment value from the start position 12 (YZ250)
(STD) 13 (YZ250X)
(Hard)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 315 mm (12.4 in)
Spring preload
Adjustment value (Soft) 1.5 mm (0.06 in)
Adjustment value (STD) 12.0 mm (0.47 in)
Adjustment value (Hard) 18.0 mm (0.71 in)
Rebound damping
(Soft)
Adjustment value from the start position 10 (YZ250)
(STD) 11 (YZ250X)
(Hard)
Compression damping
Fast compression damping
Unit for adjustment Turn
(Soft)
Adjustment value from the start position 1-3/8 (YZ250)
(STD) 1-5/8 (YZ250X)
(Hard)
Slow compression damping
(Soft)
2-5

(STD)
(Hard)
Drive chain
Size 520
Chain type Non-sealed type (YZ250)
Sealed type (YZ250X)
Number of links 114
Drive chain slack (Maintenance stand) 48.0–58.0 mm (1.89–2.28 in)
15-link length limit 239.3 mm (9.42 in) (YZ250X)
242.9 mm (9.56 in) (YZ250)
2-6
TIGHTENING TORQUES
EAM20131
TIGHTENING TORQUES
EAM30205
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96
2-7
TIGHTENING TORQUES
EAM30203
ENGINE TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
Thread
Item Q’ty Tightening torques Remarks
size
Spark plug M14S 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Cylinder head nut M8 6 25 N·m (2.5 kgf·m, 18 lb·ft)
Cylinder head stud bolt M8 6 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder nut M10 4 42 N·m (4.2 kgf·m, 31 lb·ft)
Cylinder stud bolt M10 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Power valve holder 2 M5 2 6 N·m (0.6 kgf·m, 4.4 lb·ft) LT
Link rod screw M5 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)

Push rod bolt M5 1 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Thrust plate screw M5 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Side holder screw M5 4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Power valve link lever bolt M4 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Pulley bolt M4 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Power valve cover screw M5 4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Governor fork screw M4 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Power valve housing bolt M5 4 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Impeller M8 1 14 N·m (1.4 kgf·m, 10 lb·ft)
Water pump housing cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator guard bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator hose clamp M6 8 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Air filter element M6 1 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
Carburetor joint bolt M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Air filter case bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) 
Air filter guide clamp M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Reed valve screw M3 4 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
Locknut (throttle cable handlebar
M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
side)
Locknut (throttle cable carburetor
M6 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
side)
Exhaust pipe bolt (front) M6 1 14 N·m (1.4 kgf·m, 10 lb·ft) 
Exhaust pipe bolt (rear) M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) 
Exhaust pipe stay bolt (front) M8 1 25 N·m (2.5 kgf·m, 18 lb·ft) 
Exhaust pipe stay bolt (rear) M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) 
2-8
TIGHTENING TORQUES
Thread
size
Silencer bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT
Fiber bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Crankcase bolt M6 11 14 N·m (1.4 kgf·m, 10 lb·ft)

Crankcase cover screw (left) M6 5 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Drive sprocket cover screw M6 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Crankcase cover screw (right) M6 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Bearing plate cover screw (drive axle
M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
left) LT
Bearing plate cover bolt (main axle

M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
right) LT
Holder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Oil drain bolt M12 1 23 N·m (2.3 kgf·m, 17 lb·ft)

Oil check bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Neutral switch lead holder bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Kickstarter lever M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Ratchet wheel stopper bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Clutch cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Primary drive gear bolt M10 1 55 N·m (5.5 kgf·m, 41 lb·ft)
Use a
Clutch boss nut M20 1 75 N·m (7.5 kgf·m, 55 lb·ft) Lock
washer.
Clutch spring bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Locknut (clutch cable side) M6 1 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
Push lever shaft bolt M5 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Use a
Drive sprocket nut M20 1 75 N·m (7.5 kgf·m, 55 lb·ft) Lock
washer.
Shift guide bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Tension spring (shift shaft) stopper

M8 1 22 N·m (2.2 kgf·m, 16 lb·ft)
bolt
Segment M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Bearing plate cover screw (shift cam
right) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft)

Stator coil screw M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
CDI magneto rotor nut M12 1 56 N·m (5.6 kgf·m, 41 lb·ft)
Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Neutral switch screw M5 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LT
2-9
TIGHTENING TORQUES
EAM30204
CHASSIS TIGHTENING TORQUES

TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
Thread
size
Upper bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

Lower bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 
Steering stem nut M24 1 145 N·m (14.5 kgf·m, 107 lb·ft) 
Upper handlebar holder bolt M8 4 28 N·m (2.8 kgf·m, 21 lb·ft) 
Lower handlebar holder nut M12 2 40 N·m (4.0 kgf·m, 30 lb·ft) 
Steering ring nut M28 1 Refer to TIP. 
Damper assembly (front fork) M51 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Inner tube and adjuster M22 2 55 N·m (5.5 kgf·m, 41 lb·ft) LT
Base valve (front fork) M42 2 29 N·m (2.9 kgf·m, 21 lb·ft)

Adjuster (damper assembly) M12 2 29 N·m (2.9 kgf·m, 21 lb·ft)
Bleed screw (front fork) M5 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Front fork protector bolt M6 6 5 N·m (0.5 kgf·m, 3.7 lb·ft) 
Front brake hose holder bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
Throttle cable cap screw M4 2 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Grip cap bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Clutch lever nut M6 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Clutch lever holder bolt M6 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Locknut (clutch lever position) M5 1 4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
Engine stop switch screw M3 1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
Front brake master cylinder holder
M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft) 
bolt
Front brake master cylinder reservoir
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap screw
Front brake lever pivot bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake lever pivot nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Locknut (front brake lever position) M6 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Cable guide screw M6 1 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 
Front brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Front brake caliper bolt M8 2 28 N·m (2.8 kgf·m, 21 lb·ft) 
Brake pad pin plug M10 2 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Brake pad pin M10 2 17 N·m (1.7 kgf·m, 13 lb·ft) 
Brake caliper bleed screw M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft) 
Front wheel axle nut M16 1 105 N·m (10.5 kgf·m, 77 lb·ft) 
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 
2-10
TIGHTENING TORQUES
Thread
size
Front brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT
Rear brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT
Footrest bracket bolt M10 4 55 N·m (5.5 kgf·m, 41 lb·ft) LT
Rear brake pedal bolt M8 1 26 N·m (2.6 kgf·m, 19 lb·ft) 

Rear brake pedal adjusting locknut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Rear brake master cylinder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake master cylinder reservoir
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap bolt
Rear brake hose union bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft) 
Rear wheel axle nut M20 1 125 N·m (12.5 kgf·m, 92 lb·ft) 
Rear wheel sprocket nut M8 6 42 N·m (4.2 kgf·m, 31 lb·ft) 
Nipple (spoke) — 72 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 
Rear brake disc cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear brake caliper protector bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Drive chain puller locknut M8 2 19 N·m (1.9 kgf·m, 14 lb·ft)
Engine bracket nut (upper side) M8 2 34 N·m (3.4 kgf·m, 25 lb·ft) 
Engine bracket nut (lower side) M10 1 64 N·m (6.4 kgf·m, 47 lb·ft) 
Engine mounting nut (front side) M10 1 64 N·m (6.4 kgf·m, 47 lb·ft) 
Engine mounting nut (lower side) M10 1 64 N·m (6.4 kgf·m, 47 lb·ft) 
Pivot shaft nut M16 1 85 N·m (8.5 kgf·m, 63 lb·ft) 
Relay arm nut (swingarm side) M14 1 70 N·m (7.0 kgf·m, 52 lb·ft) 
Connecting arm nut (relay arm side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Connecting arm nut (frame side) M14 1 80 N·m (8.0 kgf·m, 59 lb·ft) 
Rear shock absorber assembly
M10 1 56 N·m (5.6 kgf·m, 41 lb·ft) 
upper nut
Rear shock absorber assembly M10 1 53 N·m (5.3 kgf·m, 39 lb·ft) 
lower nut
Rear frame bolt (upper) M8 1 32 N·m (3.2 kgf·m, 24 lb·ft) 
Rear frame bolt (lower) M8 2 29 N·m (2.9 kgf·m, 21 lb·ft) 
Brake hose holder screw M5 4 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 
Swingarm and patch screw M4 4 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) LT
Drive chain tensioner bolt M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)

Drive chain tensioner nut M8 1 16 N·m (1.6 kgf·m, 12 lb·ft)
Drive chain support bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Drive chain support nut M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Drive chain guide bolt M5 4 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Fuel tank bolt (boss) M10 2 20 N·m (2.0 kgf·m, 15 lb·ft) / LT
2-11
TIGHTENING TORQUES
Thread
size
Fuel tank bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) 

Fuel cock screw M6 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 
Fuel tank screw (seat set side) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank screw (fitting band side) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank bracket bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat bolt M8 2 19 N·m (1.9 kgf·m, 14 lb·ft) 
Side cover bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (fuel tank) M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Air scoop bolt (radiator guard) M6 2 6 N·m (0.6 kgf·m, 4.4 lb·ft) 
Front fender bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) 
Rear fender bolt (front side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Rear fender bolt (rear side) M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT
Screw (mud flap) — 2 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 

Number plate bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) 
Sidestand bolt (YZ250X) M10 1 25 N·m (2.5 kgf·m, 18 lb·ft)
TIP
Steering ring nut
1. First, tighten the steering ring nut approximately 38 N·m (3.8 kgf·m, 28 lb·ft) by using the steering nut
wrench, then loosen the steering ring nut one turn.
2. Retighten the steering ring nut 7 N·m (0.7 kgf·m, 5.2 lb·ft).
2-12
TIGHTENING TORQUES
2-13
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS ...........................................................................3-1

MAINTENANCE INTERVALS.....................................................................3-1
PRE-OPERATION INSPECTION AND MAINTENANCE .................................3-4

GENERAL INSPECTION AND MAINTENANCE ........................................3-4
1
ENGINE.............................................................................................................3-5
ADJUSTING THE PILOT AIR SCREW ......................................................3-5
CHECKING THE ENGINE IDLING SPEED................................................3-5
2
CHECKING THE THROTTLE GRIP ...........................................................3-5
CHECKING THE SPARK PLUG.................................................................3-5
CHECKING THE TRANSMISSION OIL LEVEL .........................................3-6
CHANGING THE TRANSMISSION OIL .....................................................3-6
ADJUSTING THE CLUTCH LEVER FREE PLAY ......................................3-7
3
ADJUSTING THE CLUTCH LEVER POSITION.........................................3-8
4
CLEANING THE AIR FILTER ELEMENT ...................................................3-8
CHECKING THE CARBURETOR JOINT ...................................................3-9
CHECKING THE CARBURETOR HOSES .................................................3-9
CHECKING THE EXHAUST SYSTEM .......................................................3-9
CHECKING THE COOLANT LEVEL ........................................................3-10
5
CHECKING THE COOLING SYSTEM .....................................................3-11
CHANGING THE COOLANT ....................................................................3-11
CHASSIS ........................................................................................................3-13
6
ADJUSTING THE FRONT DISC BRAKE .................................................3-13
ADJUSTING THE REAR DISC BRAKE ...................................................3-13
CHECKING THE BRAKE FLUID LEVEL ..................................................3-14
CHECKING THE FRONT BRAKE PADS .................................................3-14
CHECKING THE REAR BRAKE PADS....................................................3-15
7
CHECKING THE FRONT BRAKE HOSE .................................................3-15
CHECKING THE REAR BRAKE HOSE ...................................................3-15
CHECKING THE BRAKE OPERATION ...................................................3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM.....................................3-15
DRIVE CHAIN SLACK ..............................................................................3-16
LUBRICATING THE DRIVE CHAIN .........................................................3-17
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-17
LUBRICATING THE STEERING HEAD ...................................................3-18
8
CHECKING THE FRONT FORK LEGS....................................................3-18
ADJUSTING THE FRONT FORK LEGS ..................................................3-19
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................3-20
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ...................3-21
CHECKING THE SWINGARM OPERATION ...........................................3-23
9
LUBRICATING THE SWINGARM PIVOT ................................................3-23
CHECKING THE TIRES ...........................................................................3-23
CHECKING AND TIGHTENING THE SPOKES .......................................3-23
CHECKING THE WHEELS ......................................................................3-24
CHECKING THE CHASSIS FASTENERS ...............................................3-24
10
CHECKING AND LUBRICATING THE CABLES......................................3-24
LUBRICATING THE BRAKE LEVER .......................................................3-24
LUBRICATING THE CLUTCH LEVER .....................................................3-24
LUBRICATING THE PEDAL.....................................................................3-24
CHECKING THE SIDESTAND (for YZ250X) ...........................................3-24
LUBRICATING THE SIDESTAND (for YZ250X) ......................................3-25
MAINTENANCE INTERVALS
EAM20157
EAM30369
ECA25871
NOTICE
• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them.
• Periodic inspection is essential in making full use of the machine performance. The life of
parts varies significantly according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
Every Every Every

After race third race fifth race As
No. Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required
hours) hours) hours)
• Check piston for carbon deposits

and cracks or damage.  
1 * Piston • Clean.
• Replace.  
• Check piston ring end gap and  

rings for damage.
2 * Piston rings
• Replace.  
• Check piston pin and small end

3 * Piston pin and small bearing for damage.
end bearing
• Replace. 
• Check cylinder head for carbon

deposits.  
• Clean.
• Check cylinder head gasket for
4 * Cylinder head
damage.  
• Tighten cylinder head nuts if nec-
essary.
• Replace cylinder head gasket. 
• Check cylinder for score marks or

wear.  
5 * Cylinder • Clean.
• Replace. 
• Check YPVS for carbon deposits

and cracks or damage.  
6 * YPVS
• Clean.  
• Check clutch housing, friction

plates, clutch plates and clutch
springs for wear or damage.  
7 * Clutch
• Adjust.
• Replace. 
• Change the transmission oil.  
8 * Transmission • Check transmission for damage. 
• Replace bearings. 
• Check all parts for wear and dam-

9 * Shift forks, guide age. 
bars, shift cam
• Replace if necessary.
3-1
Every Every Every

10 * Rotor nut (flywheel • Tighten.  

magneto)
• Check idle gear for damage.

11 * Kickstarter system • Replace if necessary. 
• Check exhaust pipe and muffler

for carbon deposits.  
12 * Exhaust system
• Clean. 
• Check crankshaft for carbon  

deposits and damage.
13 * Crankshaft
• Clean.  
• Check carburetor settings and for

 
14 * Carburetor obstructions.
• Adjust and clean.  
• Check condition.
• Clean and regap.  
15 Spark plug
• Replace. 
• Check chain slack, alignment and

condition.
• Adjust and thoroughly lubricate  
16 * Drive chain chain with Yamaha chain and
cable lube or equivalent.
• Replace. 
• Check coolant level and for leak-
 
age.
• Check hoses for cracks or dam-

17 * Cooling system age.
• Check radiator cap spring opera-

tion.
• Change coolant. Every 2 years 
• Check all chassis fitting and fas-

18 * Chassis fasteners teners.  
• Correct or tighten if necessary.
• Clean.  
19 Air filter element
• Replace. 
20 * Frame • Clean and check for damage.  
21 * Fuel line • Clean and check for leakage.  
• Adjust lever position and pedal

position.
• Lubricate pivot points.
• Check brake disk surface.
• Check fluid level and for leakage.  
22 * Brakes • Tighten brake disk bolts, caliper
bolts, master cylinder bolts and
union bolts.
• Replace brake pads. 
• Replace brake fluid. Every year 
3-2
Every Every Every

• Check operation and for oil leak-

age.
• Adjust if necessary.  
• Clean dust seal and lubricate with
lithium-soap-based grease.
23 * Front fork
• Replace fork oil.  
• Replace oil seals. 
• Replace protector seal. 
• Check operation and adjust.

• Tighten if necessary.  
• Lubricate with lithium-soap-based 

Shock absorber grease. (After
24 *
assembly washing
 the motor-
cycle or
riding in
the rain)
25 * Drive chain roller and • Check for wear or damage. 

support guide • Replace if necessary.
• Check operation and tighten if  

necessary.
26 * Rear suspension
• Lubricate with molybdenum disul-  
fide grease.
• Check bearing assemblies for

Swingarm pivot bear- looseness.
27 * ings • Lubricate with molybdenum disul-  
fide grease.
• Lubricate with lithium-soap-based

28 Sidestand (YZ250X) 
grease.
• Check operation, free play, and
 
tighten if necessary.
29 * Steering head • Clean and lubricate with lithium-

soap-based grease.
• Replace bearings. 
• Check tire air pressure, wheel

runout, spokes for looseness, and  
tires for wear.
• Tighten sprocket bolts if neces-
 
sary.
30 * Tires and wheels • Check wheel bearings for loose-

ness.
• Lubricate wheel bearings with lith-

ium-soap-based grease.
• Replace wheel bearings. 
Moving parts and • Lubricate.

31 * cables  
• Check operation.
• Check throttle grip free play, and
32 * Throttle grip  
adjust if necessary.
• Lubricate cable and grip housing.
3-3
PRE-OPERATION INSPECTION AND MAINTENANCE
EAM20134
PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating con-
dition.
Before using this machine, check the following points.
EAM30209
GENERAL INSPECTION AND MAINTENANCE

Item Inspect Page
Coolant Check that coolant is filled up to the radiator cap. 3-10, 3-11, 3-11
Check the cooling system for leakage.
Check that a fresh gasoline is filled in the fuel tank.
Fuel 1-11
Check the fuel line for leakage.
Check that the oil level is correct. Check the crankcase for
Transmission oil 3-6, 3-6
leakage.
Check that gears can be shifted correctly in order and that
Gear shifter and clutch 3-7, 3-8
the clutch operates smoothly.
Check that the throttle grip operation and free play are cor-
Throttle grip/Housing rectly adjusted. Lubricate the throttle grip and housing, if 3-5, 3-24
necessary.
3-13, 3-13, 3-14,
Check the play of front brake and effect of front and rear
Brakes 3-14, 3-15, 3-15,
brake.
3-15, 3-15
Check drive chain slack and alignment. Check that the 3-16, 4-29, 4-29,
Drive chain
drive chain is lubricated properly. 4-31, 4-31, 4-31
Check for excessive wear and tire pressure. Check for
Wheels 3-23, 3-23, 3-24
loose spokes and have no excessive play.
Check that the handlebar can be turned smoothly and have
Steering 3-17
no excessive play.
Front forks and rear Check that they operate smoothly and there is no oil leak- 3-18, 3-19, 3-20,
shock absorber age. 3-21, 3-23
Check that the clutch and throttle cables move smoothly.
Cables (wires) Check that they are not caught when the handlebars are —
turned or when the front forks travel up and down.
Check that the exhaust pipe is tightly mounted and has no
Exhaust pipe 3-9
cracks.
Check that the rear wheel sprocket tightening bolt is not
Rear wheel sprocket 4-3, 4-3, 4-3
loose.
3-24, 3-24, 3-24,
Lubrication Check for smooth operation. Lubricate if necessary. 3-24
Bolts and nuts Check the chassis and engine for loose bolts and nuts. 1-14
Check that the stator coil assembly, ECU and ignition coil
Lead connectors are connected tightly. —
Is the machine set suitably for the condition of the racing 8-9, 8-9, 8-9, 8-10,
course and weather or by taking into account the results of 8-10, 8-11, 8-11,
Settings
test runs before racing? Are inspection and maintenance 8-12, 8-12, 8-14,
completely done? 8-15
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple setting
adjustments may only be left, in order to get enough time to use effectively.
3-4
ENGINE
EAM20135
gine idling speed should be adjusted.
ENGINE
1. Check:
EAM30607 • Throttle grip free play “a”
ADJUSTING THE PILOT AIR SCREW Out of specification  Regulate.
1. Adjust:
• Pilot air screw “1” Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
TIP G088895
To optimize the fuel flow at a smaller throttle
2. Adjust:
opening, each vehicle’s pilot air screw has been
• Throttle grip free play
individually set at the factory. Before adjusting
a. Slide the adjuster cover.
the pilot air screw, turn it in fully and count the
b. Loosen the locknut “1”.
number of turns. Record this number as the fac-
c. Turn the adjuster “2” until the specified
tory-set number of turns out.
free play is obtained.
a. Turn in the pilot air screw until it is lightly d. Tighten the locknut.
seated. EWA18470
WARNING
b. Turn out the pilot air screw to the factory-
set number of turns. After adjusting the throttle grip free play,
start the engine and turn the handlebar to the
Air screw turns out right and to the left to ensure that this does
1-1/4 not cause the engine idling speed to change.
EAM30412
CHECKING THE ENGINE IDLING SPEED

1. Start the engine and thoroughly warm it up.
2. Adjust:
• Engine idling speed
a. Turn the throttle stop screw “1” until the
engine runs at the lowest possible speed.
EAM30254
CHECKING THE SPARK PLUG

1. Disconnect:
• Spark plug cap
2. Remove:
• Spark plug
ECA13330
NOTICE
EAM30475
CHECKING THE THROTTLE GRIP Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
TIP
with compressed air to prevent it from falling
Prior to adjusting throttle grip free play, the en-
3-5
ENGINE
into the cylinder. 3. Check:

3. Check: • Transmission oil level
• Spark plug type a. Remove the oil check bolt “1”.
Incorrect  Change. b. Inspect the oil level.
TIP
Manufacturer/model Be sure the machine is positioned straight up
NGK/BR8EG when inspecting the oil level.
EWA21090
4. Check: WARNING
• Electrode “1”
Never attempt to remove the oil check bolt
Damage/wear  Replace the spark plug.
just after high speed operation. The heated
• Insulator “2”
Abnormal color  Replace the spark plug. oil could spout out, causing danger. Wait un-
til the oil cools down.
Normal color is medium-to-light tan.
5. Clean: Oil flows out  Oil level is correct.
• Spark plug Oil does not flow out  Oil level is low.
(with a spark plug cleaner or wire brush) Add transmission oil until oil flows out.
6. Measure:
• Spark plug gap “a” Type
Motor oil SAE 10W-40 type SG or
(with a wire thickness gauge)
higher
Out of specification  Regap. Quantity (disassembled)
Spark plug gap 0.80 L (0.85 US qt, 0.70 Imp.qt)
0.5–0.6 mm (0.020–0.024 in) Quantity
0.75 L (0.79 US qt, 0.66 Imp.qt)
c. Inspect the gasket (oil check bolt), replace

if damaged.
d. Tighten the oil check bolt.
Oil check bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
G088879
7. Install:
• Spark plug
Spark plug
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
TIP
Before installing the spark plug, clean the spark
plug and gasket surface. EAM30540
CHANGING THE TRANSMISSION OIL

8. Connect:
1. Start the engine and warm it up for several
• Spark plug cap
minutes and wait for five minute.
EAM30539 2. Place the machine on a level place and hold
CHECKING THE TRANSMISSION OIL LEVEL it on upright position by placing the mainte-
1. Start the engine, warm it up for several min- nance stand under the engine.
utes and wait for five minutes. 3. Place a suitable container under the engine.
2. Place the machine on a level place and hold 4. Remove:
it up on upright position by placing the main- • Oil drain bolt “1”
tenance stand under the engine. • Oil filler cap “2”
3-6
ENGINE
G088887
2. Adjust:
• Clutch lever free play
Handlebar side
a. Turn the adjuster “1” until the specified
clutch lever free play is obtained.
5. Drain:
• Transmission oil
6. Install:
• Aluminum washer New
• Oil drain bolt
Oil drain bolt TIP
23 N·m (2.3 kgf·m, 17 lb·ft) If the clutch lever free play cannot be obtained
T.
R.
on the handlebar side, use the adjuster on the

7. Fill: clutch cable side.
• Transmission oil
Type Clutch cable side
Motor oil SAE 10W-40 type SG or a. Slide the clutch cable cover.
higher b. Loosen the locknut “1”.
Quantity (disassembled)
c. Turn the adjuster “2” until the specified
0.80 L (0.85 US qt, 0.70 Imp.qt)
Quantity clutch lever free play is obtained.
0.75 L (0.79 US qt, 0.66 Imp.qt) d. Tighten the locknut “1”.
Locknut (clutch cable side)
8. Check: 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
• Oil leakage
T.
R.
9. Check: e. Return the clutch cable cover to its original

• Transmission oil level position.
10.Install:
• Oil filler cap
EAM30216
ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play “a”
Out of specification  Regulate.
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
3-7
ENGINE
EAM30370
a. After washing the element with air filter
ADJUSTING THE CLUTCH LEVER POSITION cleaner or kerosene, squeeze and dry it
1. Adjust: completely.
• Clutch lever position “a” EWA19110
Loosen the locknut “1” and use the adjuster WARNING

“2” to adjust the clutch lever position “a” as Do not use gasoline or organic (acid/alka-
desired. line) volatile oil for washing.
ECA24280
NOTICE
Do not twist the element when squeezing the
element.
4. Check:
• Air filter element
Damage  Replace.
5. Apply:
Yamaha foam air filter oil or other quality
foam air filter oil.
2. Tighten:
a. Put the air filter element into a plastic bag
• Locknut
and drip the filter oil into the bag.
Locknut (clutch lever position) b. With the element inside the bag, rub it
4.8 N·m (0.48 kgf·m, 3.5 lb·ft) thoroughly so that the element is evenly
T.
permeated with the oil.

R.
EAM30219 c. Wrap the element in a clean cloth, rub the

CLEANING THE AIR FILTER ELEMENT element gently, and wipe off any excess
1. Remove: oil.
• Seat TIP
2. Remove: • The element should be permeated with oil so
• Fitting bolt “1” that it is wet but not dripping.
• Washer “2” • When replacing the element, permeate the el-
• Air filter element “3” ement in oil by using the same procedure as
• Air filter guide “4” when cleaning.
ECA14401
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect carburetor
synchronization, leading to poor engine per-
formance and possible overheating.
6. Install:
• Air filter guide “1”
TIP
Align the projection “a” on filter guide with the
hole “b” in air filter element.
3. Wash:
• Air filter element
3-8
ENGINE
worn.
EAM30541
CHECKING THE CARBURETOR JOINT

1. Check:
• Carburetor joint “1”
Cracks/damage  Replace.
7. Apply:
• Lithium soap base grease
(on the matching surface “a” on air filter ele-
ment)
a
EAM30542
CHECKING THE CARBURETOR HOSES

The following procedure applies to all of the fuel
and vacuum hoses.
1. Check:
• Fuel hose
• Carburetor breather hose “1”
• Overflow hose “2”
8. Install: Cracks/damage  Replace.
• Air filter element “1” Loose connection  Connect properly.
• Washer
• Fitting bolt
1 1
Fitting bolt
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
TIP
Align the projection “a” on filter guide with the
hole “b” in air filter case.
2
EAM30221
CHECKING THE EXHAUST SYSTEM

1. Remove:
• Exhaust pipe
• Silencer
2. Check:
• Exhaust pipe
• Silencer
Crack/damage  Replace.
ECA26420 3. Check:
NOTICE • Silencer fiber
Make sure that the air filter element is prop- Damage  Replace.
erly seated in the air filter case. The engine 4. Replace:
should never be operated without the air fil- • Silencer fiber
ter element installed, otherwise the piston(s) a. Remove the silencer bolts “1”, silencer “2”
and/or cylinder(s) may become excessively and fiber bolts “3”.
3-9
ENGINE
TIP
Remove the inner pipe while holding the silencer Fiber bolt “1”
10 N·m (1.0 kgf·m, 7.4 lb·ft)
in place with a vise etc.
T.
LOCTITE®
R.
Silencer bolt “2”
12 N·m (1.2 kgf·m, 8.9 lb·ft)
LOCTITE®
Side cover bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
LT 2
2
b. Remove the inner pipe “1”.

c. Replace the fiber “2”. 1
1 1
d. Install the inner pipe.
TIP LT
Apply heat-resistant sealant to the areas shown,
making sure that there are no gaps in the beads EAM30210
of sealant. CHECKING THE COOLANT LEVEL
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
5. Check: sidual pressure to escape. When the hissing
• Gasket “1” New sound has stopped, press down on the radi-
Damage  Replace. ator cap and turn it counterclockwise to re-
TIP move.
Install the gaskets with their depressed “a” fac-
ing outward. 1. Stand the vehicle upright on a level surface.
2. Remove:
• Radiator cap “1”
6. Check:
• Tightening torques 3. Check:
• Coolant level
Maximum level “a” or below  Add coolant
3-10
ENGINE
up to the maximum level. radiator cap as follows:

Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
1. Place a container under the engine.
2. Remove:
• Coolant drain bolt “1”
1. Radiator
ECA24260
NOTICE
• Adding water instead of coolant lowers the
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentration.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Start the engine, warm this up for several 3. Remove:
minutes, and then stop it. • Radiator cap
5. Check: Slowly loosen the radiator cap to drain cool-
• Coolant level ant.
TIP TIP
Before checking the coolant level, wait a few When the radiator cap is loosened, coolant will
minutes until the coolant has settled. gush out transversely; therefore, bring the con-
tainer near to the outlet.
EAM30211
4. Thoroughly flush the cooling system with
CHECKING THE COOLING SYSTEM clean tap water.
1. Remove: 5. Install:
• Seat • Copper washer New
• Side cover (left/right) • Coolant drain bolt
• Air scoop (left/right)
2. Check: Coolant drain bolt
• Radiator 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Radiator hoses
Crack/damage  Replace. 6. Pour coolant.
3. Install: Recommended coolant
• Air scoop (left/right) High quality ethylene glycol
• Seat anti-freeze containing anti-cor-
• Side cover (left/right) rosion for aluminum engine
EAM30212
Radiator (including all routes)
CHANGING THE COOLANT 1.20 L (1.27 US qt, 1.06 Imp.qt)
EWA13030 Coolant mixing ratio
WARNING 1:1 (Coolant:Water)
A hot radiator is under pressure. Therefore, EWA13040
do not remove the radiator cap when the en- WARNING

gine is hot. Scalding hot fluid and steam may • If coolant splashes in your eyes, thorough-
be blown out, which could cause serious in- ly wash them with water and consult a doc-
jury. When the engine has cooled, open the
3-11
ENGINE
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:
• Radiator cap
8. Start the engine, warm this up for several
minutes, stop it, and then wait for it to cool
down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-10.
3-12
CHASSIS
EAM20136
air must be removed by bleeding the brake
CHASSIS system. Air in the brake system will consid-
EAM30479
erably reduce braking performance.
ADJUSTING THE FRONT DISC BRAKE ECA13490
TIP NOTICE
There should be no free play at the brake lever After adjusting the brake lever position,
end. make sure there is no brake drag.
1. Check: 4. Install:
• Brake lever position “a” • Brake lever cover
Brake lever position EAM30480
100 mm (3.94 in) ADJUSTING THE REAR DISC BRAKE

Extent of adjustment 1. Check:
86–105 mm (3.39–4.13 in) • Brake pedal position “a”
Out of specification  Adjust.
G088889
2. Remove:
• Brake lever cover Brake pedal position (above the
3. Adjust: top of the footrest)
• Brake lever position 0.0 mm (0.00 in)
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci- 2. Adjust:
fied brake lever position is obtained. • Brake pedal position
b. Turn the adjusting nut “2” until the speci-
2
fied brake pedal position is obtained.
EWA20710
WARNING
1
Adjust the pedal height between the maxi-
mum “A” and the minimum “B” as shown. (In
this adjustment, the bolt “3” end “a” should
protrude out of the lower adjusting nut “4”
but not be less than 2.0 mm (0.08 in) “b”
away from the brake pedal “5”).
c. Tighten the locknut.
Locknut (front brake lever posi-
tion)
T.
5 N·m (0.5 kgf·m, 3.7 lb·ft)

R.
EWA13050 2
WARNING
A soft or spongy feeling in the brake lever
1
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
3-13
CHASSIS
A B
3 3
4
a b
c. Tighten the locknut to specification. A. Front brake

Rear brake pedal adjusting lock- B. Rear brake
nut EWA13090
T.
6 N·m (0.6 kgf·m, 4.4 lb·ft)

R.
WARNING
• Use only the designated brake fluid. Other
EWA19150
brake fluids may cause the rubber seals to
WARNING
deteriorate, causing leakage and poor
A soft or spongy feeling in the brake pedal brake performance.
can indicate the presence of air in the brake • Refill with the same type of brake fluid that
system. Before running, bleed the brake sys- is already in the system. Mixing brake fluids
tem. Air in the brake system will cause brak- may result in a harmful chemical reaction,
ing performance to be reduced. leading to poor brake performance.
ECA13510
• When refilling, be careful that water does
NOTICE not enter the brake fluid reservoir. Water
After adjusting the brake pedal position, will significantly lower the boiling point of
make sure there is no brake drag. the brake fluid and could cause vapor lock.
ECA13540
EAM30234
NOTICE
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle upright on a level surface. Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
TIP
In order to ensure a correct reading of the brake any spilt brake fluid immediately.
fluid level, make sure that the top of the brake EAM30231
fluid reservoir is horizontal. CHECKING THE FRONT BRAKE PADS
2. Check: The following procedure applies to all of the
• Brake fluid level brake pads.
The minimum level mark “a” or below  Add. 1. Operate the brake.
2. Check:
Specified brake fluid • Front brake pad
DOT 4 Wear indicator grooves “1” almost touch the
brake disc  Replace the brake pads as a
set.
Refer to “FRONT BRAKE” on page 4-5.
3-14
CHASSIS
3. Hold the vehicle upright and apply the rear

brake several times.
1 4. Check:
• Brake hose
Brake fluid leakage  Replace the damaged
hose.
EAM30499
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
EAM30232 Brake not working properly  Check the
CHECKING THE REAR BRAKE PADS brake system.
The following procedure applies to all of the TIP
brake pads. Drive on the dry road, operate the front and rear
1. Operate the brake. brakes separately and check to see if the brakes
2. Check: are operating properly.
• Rear brake pad
Wear indicator grooves “1” almost disap- EAM30477
peared  Replace the brake pads as a set. BLEEDING THE HYDRAULIC BRAKE
Refer to “REAR BRAKE” on page 4-7. SYSTEM
EWA19140
WARNING
Bleed the brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected, or
replaced.
• The brake fluid level is very low.
1 • Brake operation is faulty.
1. Remove:
• Brake master cylinder cap
EAM30478
• Reservoir diaphragm
CHECKING THE FRONT BRAKE HOSE • Reservoir float (front brake)
1. Check: • Protector (rear brake)
• Brake hose TIP
Cracks/damage/wear  Replace. • Be careful not to spill any brake fluid or allow
2. Check: the reservoir to overflow.
• Brake hose clamp • Make sure that there is enough brake fluid be-
Loose connection  Tighten the clamp bolt. fore applying the brake. Ignoring this precau-
3. Stand the vehicle upright and apply the front tion could allow air to enter the brake system,
brake several times. considerably lengthening the bleeding proce-
4. Check: dure.
• Brake hose • If bleeding is difficult, it may be necessary to let
Brake fluid leaks  Replace the damaged the brake fluid settle for a few hours. Repeat
brake hose. the bleeding procedure when the tiny bubbles
in the hose have disappeared.
EAM30498
CHECKING THE REAR BRAKE HOSE 2. Bleed the brake system.

1. Check: a. Fill the reservoir to the proper level with
• Brake hose the recommended brake fluid.
Cracks/damage/wear  Replace. b. Install the reservoir diaphragm.
2. Check: c. Connect the plastic hose “1” to the bleed
• Brake hose holder screw “2” securely, and place a container
Loose connection  Tighten the holder bolt. under the end of the plastic hose.
3-15
CHASSIS
Brake caliper bleed screw

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2 1
j. Pour brake fluid to the reservoir up to the
specified level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAM30481
DRIVE CHAIN SLACK

1 2 ECA13550
NOTICE
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 swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
A. Front its.
B. Rear Checking the drive chain slack
d. Slowly apply the brake several times. 1. Use a maintenance stand to raise the rear
e. Fully pull the brake lever or fully press wheel off the ground.
EWA13120
down the brake pedal and hold it in posi- WARNING
tion.
Securely support the vehicle so that there is
f. Loosen the bleed screw.
no danger of it falling over.
TIP
Loosening the bleed screw will release the pres- 2. Shift the transmission into the neutral posi-
sure in the brake caliper and cause the brake le- tion.
ver to contact the throttle grip or the brake pedal 3. Pull the drive chain up above the drive chain
to fully extend. guide installation bolt with a force of about 50
N (5.0 kgf, 37 lbf).
g. Tighten the bleed screw and then release 4. Check:
the brake lever or brake pedal. • Drive chain slack “a”
h. Repeat steps (d) to (g) until all of the air Out of specification  Regulate.
bubbles have disappeared from the brake
TIP
fluid in the plastic hose.
Measure drive chain slack between the drive
TIP chain guide and the bottom of the chain as
During the procedure, keep adding brake fluid to shown.
the reservoir.
ECA24320
NOTICE
• Wipe off any brake fluid on the brake discs,
tires, wheels, etc.
• Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
i. Tighten the bleed screw.
3-16
CHASSIS
clean the drive chain. Wipe the drive chain dry

Drive chain slack (Maintenance and thoroughly lubricate it with engine oil or
stand)
chain lubricant that is suitable for O-ring chains.
48.0–58.0 mm (1.89–2.28 in)
Do not use any other lubricants on the drive
Adjusting the drive chain slack chain since they may contain solvents that could
EWA13120 damage the O-rings.
WARNING
Recommended lubricant
Securely support the vehicle so that there is Chain lubricant suitable for O-
no danger of it falling over. ring chains
1. Adjust:
• Drive chain slack EAM30247
a. Loosen the wheel axle nut “1”. CHECKING AND ADJUSTING THE
b. Loosen both locknuts “2”. STEERING HEAD
c. Turn the adjusting bolt “3” until the speci- 1. Use a maintenance stand to raise the front
fied drive chain slack is obtained. wheel off the ground.
EWA13120
WARNING
2 no danger of it falling over.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
3 gently rock the front fork.
1 Blinding/looseness  Adjust the steering
head.
3. Remove:
TIP • Handlebar
• To maintain the proper wheel alignment, adjust • Upper bracket
both sides evenly. 4. Adjust:
• Push the rear wheel forward to make sure that • Steering head
there is no clearance between the swingarm a. Remove the washer “1”.
end plates and the ends of the swingarm.
d. Tighten the wheel axle nut.
1
Rear wheel axle nut
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.
e. Tighten the drive chain puller locknut.

Drive chain puller locknut
19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
EAM30251
LUBRICATING THE DRIVE CHAIN b. After loosening the ring nut “2” with a
The drive chain consists of many interacting steering nut wrench “3”, tighten it to the
parts. If the drive chain is not maintained proper- specified torque.
ly, it will wear out quickly. Therefore, the drive TIP
chain should be serviced, especially when the • Set the torque wrench at a right angle to the
vehicle is used in dusty areas. steering nut wrench.
This vehicle has a drive chain with small rubber • Move the steering to the left and right a couple
O-rings between each side plate. Steam clean- of times to check that it moves smoothly.
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosene to
3-17
CHASSIS
1
3
5. Install:
Steering nut wrench • Upper bracket
90890-01403
• Handlebar
Exhaust flange nut wrench
YU-A9472 Refer to “HANDLEBAR” on page 4-9.
EAM30502
LUBRICATING THE STEERING HEAD

Steering ring nut (initial tighten-
1. Lubricate:
ing torque)
• Upper bearing
T.
38 N·m (3.8 kgf·m, 28 lb·ft)

R.
• Lower bearing
c. Turn the front fork to the right and left a few • Bearing race
times, and make sure that the steering ro- Recommended lubricant
tates smoothly. If it does not turn smooth- Lithium-soap-based grease
ly, remove the lower bracket and check
the upper and lower bearings. EAM30338
Refer to “STEERING HEAD” on page CHECKING THE FRONT FORK LEGS

4-24. 1. Stand the vehicle upright on a level surface.
EWA13120
d. Loosen the ring nut fully turn and then
WARNING
tighten it to specification with a steering
nut wrench. Securely support the vehicle so that there is
EWA21110 no danger of it falling over.
WARNING
2. Check:
Do not overtighten the steering ring nut. • Inner tube
Damage/scratches  Replace.
Steering ring nut (final tightening • Front fork leg
torque) Oil leaks between inner tube and outer tube
T.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

R.
 Replace the oil seal.

3. Hold the vehicle upright and apply the front
e. Check the steering head for looseness or brake.
binding by turning the front fork all the way 4. Check:
in both directions. If any binding is felt, re- • Front fork operation
move the lower bracket and check the up- Push down hard on the handlebar several
per and lower bearings. times and check if the front fork rebounds
Refer to “STEERING HEAD” on page smoothly.
4-24. Unsmooth operation  Correct or replace.
f. Install the washer “1”. Refer to “FRONT FORK” on page 4-14.
TIP
If any damage is found or the front fork does not
operate smoothly, have a Yamaha dealer check
or repair it.
5. Check:
• Protector guide “1”
3-18
CHASSIS
Out of specification  Replace. EAM30239
ADJUSTING THE FRONT FORK LEGS

TIP EWA19180
The protector guide reaches the limit of its use WARNING
when it is worn down to the same height “a” as
• Always adjust the left and right front forks
of the outer tube circumference.
evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
1 Rebound damping
ECA24340
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
a
1. Adjust:
• Rebound damping
6. Remove: a. Turn the adjuster “1” in the direction of “a”
• Protector or “b” to make an adjustment.
• Dust seal “1”
ECA24330
Direction “a”
NOTICE Rebound damping is increased (sus-
Be careful not to damage the dust seal and pension is harder).
the inner tube by a driver. Direction “b”
Rebound damping is decreased (sus-
pension is softer).
Rebound damping
Minimum (soft)
20 click(s) in direction “b”*
Standard
1 (YZ250)
(YZ250X)
7. Clean: Maximum (hard)
• Dust seal “a” 0 click(s) in direction “b”*
* With the adjusting screw fully turned in di-
• Oil seal “b”
rection “a”
TIP
• Clean the dust seal and oil seal after every run. TIP
• Apply lithium-soap-based grease on the inner Although the total number of clicks of a damping
tube. force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
a be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.
b
LS
3-19
CHASSIS
Compression damping Air bleeding from front fork

ECA24350
TIP
NOTICE If the front fork initial movement feels stiff during
Do not turn the adjuster forcibly beyond its a run, relieve the front fork internal pressure.
adjusting range.
1. Use a maintenance stand to raise the front
1. Adjust: wheel off the ground.
• Compression damping EWA13120
a. Turn the adjuster “1” in the direction of “a” WARNING

or “b” to make an adjustment. Securely support the vehicle so that there is
Direction “a”
Compression damping is increased 2. Remove the bleed screw “1” and release the
(suspension is harder). internal pressure from the front fork.
Direction “b” 3. Tighten:
Compression damping is decreased • Bleed screw
(suspension is softer).
Bleed screw (front fork)
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
Compression damping
R.
Minimum (soft)
Standard
(YZ250)
13 click(s) in direction“b”*
(YZ250X)
Maximum (hard)
* With the adjusting screw fully turned in di-
rection “a”
EAM30482
TIP
Although the total number of clicks of a damping CHECKING THE REAR SHOCK ABSORBER
force adjusting mechanism may not exactly ASSEMBLY
match the above specifications due to small dif- 1. Stand the vehicle upright on a level surface.
EWA13120
ferences in production, the actual number of WARNING
be advisable to check the number of clicks of
each damping force adjusting mechanism and 2. Check:
to modify the specifications as necessary. • Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear shock
absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-27.
3-20
CHASSIS
3. Check:
• Rear shock absorber assembly smooth ac- Spring preload adjusting positions
Minimum
tion
Position in which the spring is
• Rear suspension link smooth action turned in 1.5 mm (0.06 in) from
Sit astride the seat and shake your body up its free length.
and down several times to check whether the Standard
rear shock absorber assembly operates Position in which the spring is
smoothly. turned in 12.0 mm (0.47 in) from
Unsmooth operation  Correct or replace. its free length.
Maximum
EAM30242
ADJUSTING THE REAR SHOCK ABSORBER
turned in 18.0 mm (0.71 in) from
ASSEMBLY its free length.
Use a maintenance stand to raise the rear wheel
off the ground. TIP
EWA13120
WARNING
• Be sure to remove all dirt and mud from around
the locknut and adjusting ring before adjust-
Securely support the vehicle so that there is ment.
no danger of it falling over. • The length of the spring (installed) changes 1.5
Spring preload mm (0.06 in) per turn of the adjusting ring.
ECA24360
NOTICE
adjusting range. b c
1. Remove:
• Rear frame
2. Adjust:
• Spring preload
b. Loosen the adjuster “2” until there is some
clearance between the spring and the ad-
juster. e. Tighten the locknut.
c. Measure the spring free length “a”. 3. Install:
• Rear frame
Rebound damping
ECA24370
NOTICE
adjusting range.
1. Adjust:
• Rebound damping
a. Turn the adjuster “1” in the direction of “a”
or “b” to make an adjustment.
d. Turn the adjuster in the direction of “b” or
Direction “a”
“c” to make an adjustment. Rebound damping is increased (sus-
pension is harder).
Direction “b”
Direction “b”
Spring preload is increased (suspen-
Rebound damping is decreased (sus-
sion is harder).
pension is softer).
Direction “c”
Spring preload is decreased (suspen-
sion is softer).
3-21
CHASSIS
Rebound damping Fast compression damping

Minimum (soft) Minimum (soft)
20 click(s) in direction “b”* 2 turn(s) in direction “b”*
Standard Standard
10 click(s) in direction “b”* 1-3/8 turn(s) in direction “b”*
(YZ250) (YZ250)
11 click(s) in direction “b”* 1-5/8 turn(s) in direction “b”*
(YZ250X) (YZ250X)
Maximum (hard) Maximum (hard)
0 click(s) in direction “a” 0 turn(s) in direction “b”*
* With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-
rection “a” rection “a”
TIP TIP
Although the total number of clicks of a damping To obtain a precise adjustment, it is advisable to
force adjusting mechanism may not exactly check the actual total number of turns of the
match the above specifications due to small dif- damping force adjusting mechanism. This ad-
ferences in production, the actual number of justment range may not exactly match the spec-
clicks always represents the entire adjusting ifications listed due to small differences in
range. To obtain a precise adjustment, it would production.
Compression damping (for slow compres-

sion damping)
ECA24390
Compression damping (for fast compres- NOTICE

sion damping) Do not turn the adjuster forcibly beyond its
ECA24370 adjusting range.
NOTICE
1. Adjust:
Do not turn the adjuster forcibly beyond its • Compression damping (for slow compression
adjusting range. damping)
1. Adjust: a. Turn the adjuster “1” in the direction of “a”
• Compression damping (for fast compression or “b” to make an adjustment.
damping)
a. Turn the adjuster “1” in the direction of “a” Direction “a”
or “b” to make an adjustment. Compression damping is increased
(suspension is harder).
Direction “a” Direction “b”
Compression damping is increased Compression damping is decreased
(suspension is harder). (suspension is softer).
Direction “b”
Compression damping is decreased
(suspension is softer).
3-22
CHASSIS
Slow compression damping Tire air pressure (measured on

Minimum (soft) cold tires)
20 click(s) in direction “b”* Front
Standard 100 kPa (1.00 kgf/cm², 15 psi)
12 click(s) in direction “b”* Rear
Maximum (hard) 100 kPa (1.00 kgf/cm², 15 psi)
* With the adjusting screw fully turned in di- TIP
rection “a” • Check the tire while it is cold.
• Because if the bead stopper tightening nut is
TIP
loose when the tire pressure is low, the tire
Although the total number of clicks of a damping
could slip off the rim, thus be sure to check and
force adjusting mechanism may not exactly
tighten the bead stopper tightening nut “a”.
match the above specifications due to small dif-
• If the tire valve stem “b” is found tilted, the tire
ferences in production, the actual number of
is considered to be slipping off its position. Cor-
rect the tire position.
a
b
a. Bead stopper tightening nut

b. Tire valve stem
EAM30244
EAM30240 CHECKING AND TIGHTENING THE SPOKES

CHECKING THE SWINGARM OPERATION 1. Check:
1. Check: • Spoke
• Swingarm smooth action Bend/damage  Replace.
• Swingarm free play Loose  Tighten.
Refer to “SWINGARM” on page 4-28.
EAM30500
LUBRICATING THE SWINGARM PIVOT

1. Lubricate:
• Oil seal
• Collar
Lithium-soap-based grease
G089059
EAM30243
CHECKING THE TIRES TIP

1. Measure: A tight spoke will emit a clear, ringing tone; a
• Tire pressure loose spoke will sound flat.
Out of specification  Regulate. 2. Tighten:
• Spoke
(with a spoke nipple wrench “1”)
3-23
CHASSIS
EWA13270
WARNING
1 Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
G089060
Damage  Replace.
2. Check:
Spoke nipple wrench (6–7) • Cable operation
90890-01521 Rough movement  Lubricate.
Spoke nipple wrench (6–7) Recommended lubricant
YM-01521 Engine oil or a suitable cable lu-
bricant
Nipple (spoke)
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) TIP
T.
Hold the cable end upright and pour a few drops

R.
TIP of lubricant into the cable sheath or use a suit-

• Do not give a half turn (180) or more for one able lubricating device.
tightening.
• Make sure that tightening after a break-in is EAM30483
done until the initial looseness in nipples disap- LUBRICATING THE BRAKE LEVER
pears. 1. Lubricate the pivoting points and metal-to-
• Make sure that tightening is done in stages, not metal moving parts of the following parts.
at a time. • Brake lever
EAM30245
CHECKING THE WHEELS Silicone grease

1. Check: EAM30503
• Wheel LUBRICATING THE CLUTCH LEVER
Damage/out-of-round  Replace. 1. Lubricate the pivoting points and metal-to-
EWA13260
WARNING
metal moving parts of the following parts.
• Clutch lever
Never attempt to make any repairs to the
wheel. Recommended lubricant
TIP
After replacing a tire or a wheel, always balance EAM30250
the wheel. LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-met-
EAM30253
al moving parts of the pedal.
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are Recommended lubricant
properly tightened. Lithium-soap-based grease
Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-10. EAM30504
CHECKING THE SIDESTAND (for YZ250X)

EAM30248
1. Check:
CHECKING AND LUBRICATING THE • Sidestand operation
CABLES Check that the sidestand moves smoothly.
The following procedure applies to all of the in- Rough movement  Repair or replace.
ner and outer cables.
3-24
CHASSIS
EAM30252
LUBRICATING THE SIDESTAND (for

YZ250X)
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
3-25
CHASSIS
3-26
CHASSIS
GENERAL CHASSIS........................................................................................4-1
REMOVING THE NUMBER PLATE ...........................................................4-1
REMOVING THE SIDE COVER .................................................................4-1
FRONT WHEEL ................................................................................................4-2

1
REMOVING THE FRONT WHEEL .............................................................4-2
2
INSTALLING THE FRONT WHEEL ...........................................................4-2
REAR WHEEL ..................................................................................................4-3

REMOVING THE REAR WHEEL ...............................................................4-3
CHECKING AND REPLACING THE REAR WHEEL SPROCKET.............4-3
INSTALLING THE REAR WHEEL ..............................................................4-3
3
FRONT BRAKE ................................................................................................4-5
REPLACING THE FRONT BRAKE PADS .................................................4-5
REAR BRAKE ..................................................................................................4-7

4
REPLACING THE REAR BRAKE PADS ....................................................4-7
HANDLEBAR....................................................................................................4-9
REMOVING THE HANDLEBAR .................................................................4-9
CHECKING THE HANDLEBAR..................................................................4-9
5
INSTALLING THE HANDLEBAR................................................................4-9
FRONT FORK.................................................................................................4-14
REMOVING THE FRONT FORK LEGS ...................................................4-14
6
DISASSEMBLING THE FRONT FORK LEGS .........................................4-14
CHECKING THE FRONT FORK LEGS....................................................4-15
ASSEMBLING THE FRONT FORK LEGS ...............................................4-16
INSTALLING THE FRONT FORK LEGS..................................................4-22 7
STEERING HEAD...........................................................................................4-24
REMOVING THE LOWER BRACKET ......................................................4-24
CHECKING THE STEERING HEAD ........................................................4-24
INSTALLING THE STEERING HEAD ......................................................4-24
8
9
REAR SHOCK ABSORBER ASSEMBLY ......................................................4-27
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....................4-27
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................4-27
10
SWINGARM ....................................................................................................4-28
REMOVING THE SWINGARM .................................................................4-28
CHAIN DRIVE .................................................................................................4-29
REMOVING THE DRIVE CHAIN (for YZ250)...........................................4-29
REMOVING THE DRIVE CHAIN (for YZ250X) ........................................4-29
CHECKING THE DRIVE CHAIN (for YZ250) ...........................................4-29
CHECKING THE DRIVE CHAIN (for YZ250X) .........................................4-30
CHECKING THE DRIVE SPROCKET ......................................................4-31
CHECKING THE REAR WHEEL SPROCKET .........................................4-31
INSTALLING THE DRIVE CHAIN (for YZ250) .........................................4-31
INSTALLING THE DRIVE CHAIN (for YZ250X) .......................................4-32
GENERAL CHASSIS
EAM20094
GENERAL CHASSIS
EAM30371
REMOVING THE NUMBER PLATE

1. Remove:
• Number plate bolt
• Number plate “1”
TIP
• The projection “a” is inserted into the band of
the number plate. Pull the band off the projec-
tion before removal.
• Remove the clutch cable “2” from the cable
guide “b” on the number plate.
• The projection “c” on the lower bracket is in-
serted into the number plate. Remove the
number plate by pulling it off the projection.
• When installing the number plate, insert the
projection on the number plate into the hole in
the upper side of the band.
EAM30459
REMOVING THE SIDE COVER

1. Remove:
• Side cover bolt
• Side cover (left and right) “1”
TIP
Draw the side cover backward to remove it be-
cause its claws “a” are inserted in the air filter
case.
4-1
FRONT WHEEL
EAM20095 ECA24430
FRONT WHEEL NOTICE

EAM30017
Before tightening the front wheel axle nut,
REMOVING THE FRONT WHEEL push down hard on the handlebar(s) several
1. Use a maintenance stand to raise the front times and check if the front fork rebounds
wheel off the ground. smoothly.
EWA13120
WARNING
2. Remove:
• Front wheel
EAM30617
INSTALLING THE FRONT WHEEL

1. Install:
• Front wheel
TIP 4. Tighten:
Install the brake disc “1” between the brake pads • Front wheel axle pinch bolt “1”
“2” correctly.
Front wheel axle pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the front
wheel axle.
3. Tighten:
• Front wheel axle nut “1”
Front wheel axle nut
105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
4-2
REAR WHEEL
EAM20096
REAR WHEEL
EAM30022
REMOVING THE REAR WHEEL

1. Use a maintenance stand to raise the rear
wheel off the ground.
EWA13120
WARNING
G088904
2. Remove: b. Correct
• Rear wheel axle nut “1” 1. Drive chain roller
3. Loosen: 2. Rear wheel sprocket
• Locknut “2”
4. Tighten: 2. Replace:
• Adjusting bolt “3” • Rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces that
2 contact the sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket nut
3 42 N·m (4.2 kgf·m, 31 lb·ft)
T.
R.
1
TIP
5. Remove: Tighten the self-locking nuts in stages and in a
• Rear wheel axle crisscross pattern.
• Rear wheel
EAM30027
TIP INSTALLING THE REAR WHEEL
• Push the rear wheel forward and remove the 1. Install:
drive chain from the rear wheel sprocket. • Rear wheel
• Do not depress the brake pedal with the rear
TIP
wheel removed.
Install the brake disc “1” between the brake pads
“2” correctly.
EAM30025
CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket as
a set.
Bent tooth  Replace the rear wheel sprock-
et and the drive sprocket as a set.
2. Install:
• Drive chain “1”
TIP
Push the rear wheel “2” forward and install the
drive chain.
4-3
REAR WHEEL
Refer to “DRIVE CHAIN SLACK” on page

3-16.
3. Install:
• Left drive chain puller “1”
• Rear wheel axle “2” 6. Tighten:
TIP • Rear wheel axle nut “1”
• Install the left drive chain puller, and insert the Rear wheel axle nut
rear wheel axle from the left side. 125 N·m (12.5 kgf·m, 92 lb·ft)
• Apply the lithium-soap-based grease to the
T.
R.
rear wheel axle. • Locknut “2”
Drive chain puller locknut
19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
1
2 1
2
4. Install:
• Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the rear wheel axle nut at
this point.
3 1
5. Adjust:
• Drive chain slack “a”
Drive chain slack (Maintenance
stand)
48.0–58.0 mm (1.89–2.28 in)
4-4
FRONT BRAKE
EAM20097
FRONT BRAKE Brake pad lining thickness limit

1.0 mm (0.04 in)
EAM30519
REPLACING THE FRONT BRAKE PADS

TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- a
ble the brake caliper.
1. Remove:
• Brake pad
a. Remove the pad pin plug “1”.
3. Install:
• Brake pad
a. Connect the plastic hose “1” to the bleed
screw “2” and place a container under the
end of the plastic hose.
2
b. Loosen the pad pin “2”. 1

c. Remove the brake caliper “3” from the
front fork.
b. Loosen the bleed screw and push the

brake caliper piston in.
EWA19160
WARNING
Do not reuse the drained brake fluid.
c. Tighten the bleed screw.
d. Remove the pad pin and brake pads “4”. Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
4
R.
d. Install the brake pads “3” and the pad pin.

TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
2. Measure:
• Brake pad wear limit “a”
Out of specification  Replace the brake
pads as a set.
4-5
FRONT BRAKE
b a
e. Install the brake caliper “4” and tighten the

pad pin “5”.
Front brake caliper bolt
28 N·m (2.8 kgf·m, 21 lb·ft)
T.
Brake pad pin

R.
17 N·m (1.7 kgf·m, 13 lb·ft)
f. Install the pad pin plug “6”.

Brake pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
4. Check:
• Brake fluid level
5. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
4-6
REAR BRAKE
EAM20098
pads as a set.
REAR BRAKE
Brake pad lining thickness limit
EAM30523
1.0 mm (0.04 in)
REPLACING THE REAR BRAKE PADS
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
• Brake pad
a
a. Remove the protector “1” and the pad pin
plug “2”.
3. Install:
• Brake pad
a. Connect the plastic hose “1” to the bleed
screw “2” and place a container under the
end of the plastic hose.
b. Loosen the pad pin “3”.

c. Remove the rear wheel “4” and the brake
caliper “5”. 2
Refer to “REAR WHEEL” on page 4-3. 1
b. Loosen the bleed screw and push the

brake caliper piston in.
EWA19170
WARNING
Do not reuse the drained brake fluid.
c. Tighten the bleed screw.
Brake caliper bleed screw
d. Remove the pad pin “6” and the brake 6 N·m (0.6 kgf·m, 4.4 lb·ft)
pads “7”.
T.
R.
6 7 d. Install the brake pad “3” and the pad pin

“4”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
2. Measure:
• Brake pad wear limit “a”
Out of specification  Replace the brake
4-7
REAR BRAKE
Refer to “BLEEDING THE HYDRAULIC

4 3 BRAKE SYSTEM” on page 3-15.
a
b
e. Install the brake caliper “5” and the rear

wheel “6”.
f. Tighten the pad pin “7”.
Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
g. Install the pad pin plug “8” and the

protector “9”.
Brake pad pin plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
Rear brake caliper protector bolt

R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
4. Check:
• Brake fluid level
5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
4-8
HANDLEBAR
EAM20099 EAM30054
HANDLEBAR INSTALLING THE HANDLEBAR

1. Stand the vehicle upright on a level surface.
EAM30052 EWA13120
REMOVING THE HANDLEBAR WARNING

1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is
EWA13120
WARNING
Securely support the vehicle so that there is 2. Install:
no danger of it falling over. • Lower handlebar holder “1”
• Washer “2”
2. Remove: • Lower handlebar holder nut “3”
• Grip “1”
TIP
TIP • Install the lower handlebar holders with them
Blow in compressed air between the handlebar side having the greater distance “a” from the
or tube guide and the grip. Then remove the grip mounting bolt center facing forward.
which has become loose. • Apply the lithium soap base grease on the
thread of the lower handlebar holders.
1 • Installing the lower handlebar holders in the re-
verse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• Do not tighten the nuts yet.
1
G088916
3. Remove:
• Throttle cable housing “1”
• Throttle grip “2” 2
TIP
While removing the throttle cable housing, pull 3
back the rubber cover “3”.
2 1 3
EAM30053
3. Install:
CHECKING THE HANDLEBAR
• Handlebar “1”
1. Check:
• Upper handlebar holder “2”
• Handlebar
• Upper handlebar holder bolt “3”
Bends/cracks/damage  Replace.
Upper handlebar holder bolt
EWA13690
WARNING
28 N·m (2.8 kgf·m, 21 lb·ft)
Do not attempt to straighten a bent handle-
T.
R.
bar as this may dangerously weaken it. TIP

• The upper handlebar holders should be in-
4-9
HANDLEBAR
stalled with the punch marks “a” facing for-

ward. Lower handlebar holder nut
40 N·m (4.0 kgf·m, 30 lb·ft)
• Install the handlebar so that the marks “b” are
T.
R.
in place on both sides.
• Install the handlebar so that the projection “c”
of the upper handlebar holders is positioned at
the mark on the handlebar as shown.
• First tighten the bolts on the front side of the
upper handlebar holder, and then tighten the
bolts on the rear side.
5. Install:
• Left grip “1”
Apply the adhesive to the handlebar “2”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the handlebar surface “a” with a lac-
quer thinner.
• Install the left grip to the handlebar so that the
line “b” between the two arrow marks faces
straight upward.
6. Install:
• Engine stop switch “1”
Engine stop switch screw
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.
• Clutch lever holder “2”

• Clutch lever holder bolt “3”
Clutch lever holder bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
Clutch lever nut

R.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
• Clamp “4”
TIP
• The engine stop switch, clutch lever holder and
4. Tighten: clamp should be installed according to the di-
• Lower handlebar holder nut “1” mensions shown.
4-10
HANDLEBAR
• Pass the engine stop switch lead in the middle

of the clutch lever holder.
0 mm
(0 in)
0 mm
(0 in)
10.Install:
• Grip cap (upper) “1”
• Grip cap (lower) “2”
7. Install: • Grip cap bolt “3”
• Clutch cable “1” TIP
TIP Temporarily tighten the grip cap bolts.
Apply the lithium soap base grease on the clutch
cable end.
11.Install:
• Collar “1”
8. Adjust: • Grip cap cover “2”
• Clutch lever free play • Throttle grip “3”
Refer to “ADJUSTING THE CLUTCH LEVER TIP
FREE PLAY” on page 3-7. • Apply the lithium soap base grease on the
9. Install: throttle grip sliding surface.
• Right grip “1” • Tighten the grip cap bolts temporarily without
Apply the adhesive on the tube guide “2”. the throttle being fixed to the handlebar.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Align the mating mark “b” on the right grip with
the slot “c” in the tube guide.
4-11
HANDLEBAR
Throttle cable cap screw

2
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.
1 3
12.Install:
• Throttle cable “1”
(to tube guide “2”)
TIP 15.Adjust:
Apply the lithium soap base grease on the throt-
• Throttle grip free play
tle cable end and tube guide cable winding por-
Refer to “CHECKING THE THROTTLE
tion.
GRIP” on page 3-5.
16.Install:
1 • Cap cover “1”
13.Install:
• Roller “1”
• Collar “2” 17.Install:
TIP • Brake master cylinder “1”
• Apply the lithium soap base grease on the roll- • Brake master cylinder holder “2”
er sliding surface and cable guide. • Front brake master cylinder holder bolt “3”
• Install the roller so that the “UPPER” mark “a” Front brake master cylinder hold-
faces upward. er bolt
• Pass the throttle cable in the groove “b” in the
T.
9 N·m (0.9 kgf·m, 6.6 lb·ft)

R.
roller.
TIP
2 1 • Install the holder so that the arrow mark “a” fac-
es upward.
• First tighten the bolt on the upper side of the
brake master cylinder holder, and then tighten
b the bolt on the lower side.
14.Install:
• Throttle cable cap “1”
• Throttle cable cap screw “2”
4-12
HANDLEBAR
18.Install:
• Grip cap bolt “1”
Grip cap bolt
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
EWA21080
WARNING
After tightening the bolts, check that the
throttle grip “2” moves smoothly. If it does
not, retighten the bolts for adjustment.
4-13
FRONT FORK
EAM20100
TIP
FRONT FORK • While compressing the inner tube “2”, set the
EAM30055
cap bolt ring wrench “4” between the inner tube
REMOVING THE FRONT FORK LEGS and locknut “3”.
1. Use a maintenance stand to raise the front • Hold the locknut and remove the adjuster.
wheel off the ground. ECA24520
EWA13120
NOTICE
WARNING
Do not remove the locknut as the damper rod
Securely support the vehicle so that there is may go into the damper assembly and not be
no danger of it falling over. taken out.
TIP
Record the adjusting screw setting position be- Cap bolt ring wrench
fore loosening the adjuster and the base valve. 90890-01501
Cap bolt ring wrench
2. Loosen: YM-01501
• Upper bracket pinch bolt
• Damper assembly
• Lower bracket pinch bolt
EWA20350
WARNING
1
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
TIP 4
Before removing the front fork leg from the vehi- 3
cle, loosen the damper assembly “1” with the 2
cap bolt ring wrench “2”.
3. Remove:
Cap bolt ring wrench • Dust seal “1”
90890-01501 • Stopper ring “2”
Cap bolt ring wrench (with a flat-head screwdriver)
YM-01501 ECA14180
NOTICE
Do not scratch the inner tube.
1 2
2
3. Remove: G088920
• Front fork leg 4. Remove:
EAM30056 • Inner tube “1”
DISASSEMBLING THE FRONT FORK LEGS a. Push in slowly “a” the inner tube just be-
1. Drain: fore it bottoms out and then pull it back
• Fork oil quickly “b”.
2. Remove: b. Repeat this step until the inner tube can be
• Adjuster “1” pulled out from the outer tube.
(from the inner tube)
4-14
FRONT FORK
dial gauge reading.

EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tube
Scratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”
5. Remove: Out of specification  Replace.
• Base valve “1”
(from the damper assembly) Fork spring free length limit
TIP 449.0 mm (17.68 in)
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to re-
move the base valve.
Cap bolt wrench

90890-01500
Cap bolt wrench
YM-01500
90890-01501
Cap bolt ring wrench G088921
YM-01501 4. Check:
• Damper assembly “1”
3 Bend/damage  Replace.
• O-ring “2”
2 Wear/damage  Replace.
ECA14200
1 NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
EAM30057
front fork leg, do not allow any foreign ma-
CHECKING THE FRONT FORK LEGS terial to enter the front fork.
1. Check:
• Inner tube surface
Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace. 1
• Inner tube bends
2
Out of specification  Replace.
Use the dial gauge.
Inner tube bending limit
0.2 mm (0.01 in)
5. Check:
TIP • Base valve “1”
The bending value is shown by one half of the Wear/damage  Replace.
4-15
FRONT FORK
Contamination  Clean. legs are equal.

• O-ring “2” New • Uneven oil levels can result in poor han-
Wear/damage  Replace. dling and a loss of stability.
• Piston metal “3”
TIP
Wear/damage  Replace. • When assembling the front fork leg, be sure to
• Fork spring “4”
replace the following parts:
Damage/fatigue  Replace base valve.
• Inner tube bushing
• Air bleed screw “5”
• Slide metal
Wear/damage  Replace. • Oil seal
• Copper washer
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill:
• Damper assembly
Recommended oil
Yamaha Suspension Oil S1
Standard oil amount
6. Check: 205 cm³ (6.93 US oz, 7.21 Imp.oz)
• Upper spring seat “1” ECA24530
(contacting surface “a”) NOTICE
Wear/damage  Replace.
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
1 fork performance.
a • When disassembling and assembling the
front fork leg, take care not to allow any for-
eign material to enter the front fork.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper as-
sembly of air.
TIP
7. Check:
Avoid excessive full stroke. A stroke of 200 mm
• Adjuster “1”
(7.9 in) or more will cause air to enter. In this
• O-ring “2” New
case, repeat the steps (1) to (3).
Wear/damage  Replace.
1
2 New
1
EAM30058 4. Measure:
ASSEMBLING THE FRONT FORK LEGS • Oil level (left and right) “a”
EWA13660
Out of specification  Regulate.
WARNING
• Make sure the oil levels in both front fork
4-16
FRONT FORK
Standard oil level

145–148 mm (5.71–5.83 in)
From top of fully stretched
damper assembly.
7. Install:
(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releasing
the damper rod pressure.
5. Tighten:
• Locknut “1”
TIP 8. Check:
Fully finger tighten the locknut onto the damper • Damper assembly
assembly. Not fully stretched  Repeat the steps (1) to
(7).
9. Tighten:
Base valve (front fork)
29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
TIP
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to
tighten the base valve.
6. Loosen:
• Compression damping force adjuster “1” Cap bolt wrench
TIP 90890-01500
• Before loosening the damping force adjuster, Cap bolt wrench
record the setting position. YM-01500
• Unless the damping force adjuster is fully loos-
90890-01501
ened, correct damping characteristic cannot be Cap bolt ring wrench
obtained after installation. YM-01501
4-17
FRONT FORK
3 a
2
1
10.After filling, pump the damper assembly “1” 13.Check:

slowly up and down more than 10 times to • Damper assembly smooth movement
distribute the fork oil. Tightness/binding/rough spots  Repeat the
steps (1) to (12).
11.While protecting the damper assembly “1”

with a cloth and compressing fully, allow ex- 14.Install:
cessive oil to overflow on the base valve side. • Dust seal “1” New
ECA24540
• Stopper ring “2”
NOTICE • Oil seal “3” New
Take care not to damage the damper assem- • Washer “4”
bly. • Slide metal “5” New
(to the inner tube “6”)
ECA24550
NOTICE
Make sure that the numbered side of the oil
seal faces bottom side.
TIP
1 • Apply the lithium-soap-based grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat with
fork oil applied to protect the oil seal lip.
12.Allow the overflowing oil to escape at the hole
“a” in the damper assembly.
TIP
The overflow measures about 10 cm³ (0.34
US oz, 0.35 Imp.oz).
LS
4-18
FRONT FORK
1
G088922 G088923
15.Install: 18.Install:
• Piston metal “1” New • Oil seal “1” New
TIP TIP
Install the piston metal onto the slot on inner Using a fork seal driver “2”, press the oil seal in
tube. until the stopper ring groove fully appears.
Fork seal driver

90890-01502
Fork seal driver (48)
YM-A0948
16.Install: 1
• Outer tube “1”
(to the inner tube “2”)
G088924
19.Install:
• Stopper ring “1”
TIP
Fit the stopper ring correctly in the groove in the
outer tube.
17.Install: 1
• Slide metal “1” New
• Washer “2”
(to the outer tube)
TIP
Press the slide metal into the outer tube with fork G088925
seal driver “3”.
20.Install:
Fork seal driver • Dust seal “1” New
90890-01502 TIP
Fork seal driver (48) Apply lithium-soap-based grease on the inner
YM-A0948 tube.
4-19
FRONT FORK
1 2
3 a
21.Check: 24.Install:
• Inner tube smooth movement • Damper assembly “1”
Tightness/binding/rough spots  Repeat the (to the inner tube “2”)
steps (14) to (20). ECA24560
NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
1
22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
Distance “a” 2
16 mm (0.63 in) or more
Between the damper assembly 25.Loosen:
“1” bottom and locknut “2” bot- • Rebound damping force adjuster “1”
tom. TIP
• Before loosening the damping force adjuster,
record the setting position.
• Unless the damping force adjuster is fully loos-
ened, correct damping characteristic cannot be
obtained after installation.
2 1
1 a
23.Install:
• Upper spring seat “1”
• Fork spring “2”
(to the damper assembly “3”)
TIP
Install the upper spring seat with its larger dia. 26.Install:
end “a” facing the fork spring. • Damper adjusting rod “1”
• Copper washer “2” New
4-20
FRONT FORK
(to the damper assembly “4”) TIP

TIP Hold the locknut “2” and tighten the adjuster.
• While compressing the inner tube “5”, set the
cap bolt ring wrench “7” between the inner tube
and locknut “6”.
• Fully finger tighten the adjuster onto the damp-
er assembly.

90890-01501
YM-01501
29.Install:
(to the inner tube)
Inner tube and adjuster
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
LOCTITE®
R.
27.Measure: 1
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and readjust
the locknut.
Gap “a” between the adjuster and
the locknut
0.5–1.0 mm (0.02–0.04 in) 30.Fill:
• Front fork leg
TIP
If it is installed with a gap out of specification, Recommended oil
correct damping force cannot be obtained. Yamaha Suspension Oil S1
Standard oil amount
320 cm³ (10.8 US oz, 11.3 Imp.oz)
1 Extent of adjustment
300–365 cm³ (10.1–12.3 US oz,
10.6–12.9 Imp.oz)
a
ECA24570
NOTICE
• Be sure to use the recommended oil. Other
2
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
28.Tighten: front fork leg, do not allow any foreign ma-
• Adjuster (damper assembly) “1” terial to enter the front fork.
Adjuster (damper assembly)
29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
4-21
FRONT FORK
31.Install: 2. Tighten:
• Damper assembly “1” • Damper assembly “1”
(to the outer tube)
Damper assembly (front fork)
TIP
30 N·m (3.0 kgf·m, 22 lb·ft)
Temporarily tighten the damper assembly.
T.
R.
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.

90890-01501
YM-01501
1
32.Install:
• Protector guide “1”
3. Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
EAM30059
0 mm (0.0 in)
INSTALLING THE FRONT FORK LEGS
1. Install:
• Front fork “1” a
TIP
• Temporarily tighten the pinch bolts (lower
bracket).
• Do not tighten the pinch bolts (upper bracket)
yet.
4. Tighten:
• Upper bracket pinch bolt “1”
4-22
FRONT FORK
Upper bracket pinch bolt

T.
R.
21 N·m (2.1 kgf·m, 15 lb·ft)
• Lower bracket pinch bolt “2” 1

Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EWA19320
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause the 7. Adjust:
front fork to malfunction. • Compression damping force
TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.
5. Install:
• Protector “1”
• Front fork protector bolt “2”
Front fork protector bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
2
6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.
4-23
STEERING HEAD
EAM20101
c. Install a new bearing race.
STEERING HEAD ECA14270
NOTICE
EAM30060
REMOVING THE LOWER BRACKET If the bearing race is not installed properly,
1. Use a maintenance stand to raise the front the steering head pipe could be damaged.
wheel off the ground. TIP
EWA13120
Always replace the bearing and the bearing race
WARNING
as a set.
2. Remove:
• Ring nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
Steering nut wrench

90890-01403 G088933
Exhaust flange nut wrench
YU-A9472
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
G088934
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAM30062
INSTALLING THE STEERING HEAD

EAM30061
1. Install:
CHECKING THE STEERING HEAD • Lower bearing “1”
1. Wash with kerosene:
TIP
• Bearing
Apply the lithium-soap-based grease on the dust
• Bearing race seal lip and bearing inner circumference.
2. Check:
• Bearing
• Bearing race
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing race
a. Remove the bearing race from the steer-
ing head pipe “1” with a long rod “2” and a
hammer.
b. Remove the bearing race from the lower
bracket “3” with a chisel “4” and a hammer.
4-24
STEERING HEAD
2. Install:
• Bearing race
• Upper bearing “1”
• Bearing race cover “2”
TIP
Apply the lithium-soap-based grease on the
bearing and bearing race cover lip.
5. Check the steering stem by turning this lock

to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.
3. Install:
• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.
6. Install:
• Washer “1”
LS
a
LS
4. Install:
• Steering ring nut “1”
Steering ring nut 7. Install:
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Front fork “1”
T.
• Upper bracket “2”

R.
TIP TIP
Install the steering ring nut with its stepped side • Temporarily tighten the lower bracket pinch
“a” facing downward. bolts.
Tighten the steering ring nut with a steering • Do not tighten the upper bracket pinch bolts
nut wrench “2”. yet.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-17.
4-25
STEERING HEAD
Upper bracket pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
• Lower bracket pinch bolt “2”
Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EWA19330
WARNING
Tighten the lower bracket to specified
8. Install: torque. If torqued too much, it may cause the
• Steering stem nut “1” front fork to malfunction.
Steering stem nut
145 N·m (14.5 kgf·m, 107 lb·ft)
T.
R.
TIP
Apply the lithium-soap-based grease to the con-
tact surface of the steering stem nut when in-
stalling.
9. After tightening the nut, check the steering for

smooth movement. If not, adjust the steering
by loosening the steering ring nut little by lit-
tle.
10.Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
0 mm (0.0 in)
11.Tighten:
• Upper bracket pinch bolt “1”
4-26
REAR SHOCK ABSORBER ASSEMBLY
EAM20102
REAR SHOCK ABSORBER AS-

SEMBLY
EAM30065
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
EWA13120
WARNING
2. Remove:
• Rear shock absorber assembly lower bolt “1”
TIP
While removing the rear shock absorber assem-
bly lower bolt, hold the swingarm so that it does
not drop down.
3. Remove:
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAM30067
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear shock
absorber assembly.
• Spring
Damage/wear  Replace.
• Spring guide
• Bearing
• Bolt
Bends/damage/wear  Replace.
4-27
SWINGARM
EAM20103
SWINGARM
EAM30071
REMOVING THE SWINGARM

EWA13120
WARNING
2. Measure:
• Swingarm side play
• Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
b. Check the swingarm side play “A” by mov-

ing the swingarm from side to side.
If the swingarm has side-to-side play,
check the bushings, the bearings and the
collars.
c. Check the swingarm vertical movement
“B” by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
bushings, the bearings and the collars.
B
A
G088936
4-28
CHAIN DRIVE
EAM20104
tween the outer sides of the pins on a 15-
CHAIN DRIVE link section of the drive chain as shown in
EAM30556
the illustration.
REMOVING THE DRIVE CHAIN (for YZ250)
EWA13120
WARNING
2. Remove:
• Master link clip G088937
• Master link “1”
• Master link plate “2” b. Calculate the length “c” of the 15-link sec-
• Drive chain “3” tion of the drive chain using the following
formula.
1 Drive chain 15-link section length “c” =
(length “a” between pin inner sides +
3 length “b” between pin outer sides)/2
G089068
EAM30559
REMOVING THE DRIVE CHAIN (for YZ250X)

1. Stand the vehicle on a level surface. G088938
EWA13120
WARNING TIP
Securely support the vehicle so that there is • When measuring a 15-link section of the drive
no danger of it falling over. chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
TIP location each time.
Place the vehicle on a maintenance stand so
that the rear wheel is elevated. 2. Check:
• Drive chain
2. Remove:
Stiffness  Clean, lubricate, or replace.
• Drive chain
TIP
Cut the drive chain with the drive chain cut & riv-
et tool. (Use goods on the market.)
EAM30557
CHECKING THE DRIVE CHAIN (for YZ250)

1. Measure:
• 15-link section of the drive chain
Out of specification  Replace the drive G088939
chain.
3. Clean:
15-link length limit • Drive chain
242.9 mm (9.56 in) (YZ250) a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and re-
a. Measure the length “a” between the inner move any remaining dirt.
sides of the pins and the length “b” be-
4-29
CHAIN DRIVE
c. Remove the drive chain from the kerosene

and completely dry it.
G088937
b. Calculate the length “c” of the 15-link sec-

G088940
tion of the drive chain using the following
4. Check: formula.
• Drive chain roller “1” Drive chain 15-link section length “c” =
Damage/wear  Replace the drive chain. (length “a” between pin inner sides +
• Drive chain side plate “2” length “b” between pin outer sides)/2
Damage/wear  Replace the drive chain.
G088938
G088942
TIP
5. Lubricate: • When measuring a 15-link section of the drive
• Drive chain chain, make sure that the drive chain is taut.
EAM30560
• Perform this procedure 2–3 times, at a different
CHECKING THE DRIVE CHAIN (for YZ250X) location each time.
1. Measure: 2. Check:
• 15-link section of the drive chain • Drive chain
Out of specification  Replace the drive Stiffness  Clean, lubricate, or replace.
chain.
15-link length limit
239.3 mm (9.42 in) (YZ250X)
a. Measure the length “a” between the inner

sides of the pins and the length “b” be-
tween the outer sides of the pins on a 15-
link section of the drive chain as shown in
the illustration.
G088939
3. Clean:
• Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and re-
move any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
4-30
CHAIN DRIVE
ECA19090
5. Lubricate:
NOTICE • Drive chain
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain Recommended lubricant
side plates. Never use high-pressure water Chain lubricant suitable for O-
or air, steam, gasoline, certain solvents ring chains
(e.g., benzine), or a coarse brush to clean
EAM30077
the drive chain. High-pressure methods CHECKING THE DRIVE SPROCKET
could force dirt or water into the drive 1. Check:
chain’s internals, and solvents will deterio- • Drive sprocket
rate the O-rings. A coarse brush can also More than 1/4 tooth wear “a”  Replace the
damage the O-rings. Therefore, use only drive sprocket and the rear wheel sprocket as
kerosene to clean the drive chain. a set.
• Do not soak the drive chain in kerosene for Bent tooth  Replace the drive sprocket and
more than ten minutes, otherwise the O- the rear wheel sprocket as a set.
rings can be damaged.
G088904
G088940
b. Correct
1. Drive chain roller

2. Drive sprocket
EAM30078
CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-3.
EAM30558
G088941
INSTALLING THE DRIVE CHAIN (for YZ250)
1. Install:
4. Check: • Master link “1”
• O-ring “1” • Master link plate “2”
Damage  Replace the drive chain. • Master link clip “3” New
• Drive chain roller “2” ECA14310
Damage/wear  Replace the drive chain. NOTICE

• Drive chain side plate “3” • The closed end of the master link clip must
Damage/wear  Replace the drive chain. face in the direction of drive chain rotation.
• Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain’s life.
G088943
4-31
CHAIN DRIVE
EAM30561
INSTALLING THE DRIVE CHAIN (for YZ250X)

1
1. Install:
• Drive chain
ECA17410
NOTICE
Be sure to put on safety goggles when work-
ing.
2 TIP
G089069 Install the master link with the drive chain cut &
rivet tool. (Use goods on the market.)
a. When press fitting the master link plate
“1”, make sure the space “a” between the
end of the connecting pin “2” and the mas-
ter link plate is 1.2–1.4 mm (0.05–0.06 in).
3
G089070
2. Lubricate:
• Drive chain
3. Install:
• Drive sprocket
• Lock washer New
• Drive sprocket nut
b. After riveting, make sure the diameter be-
Drive sprocket nut tween the edges “b” of the connecting pin
75 N·m (7.5 kgf·m, 55 lb·ft) “2” is 5.5–5.8 mm (0.22–0.23 in).
T.
R.
ECA14300
NOTICE
Never install a new drive chain onto worn
4. Adjust:
• Drive chain slack
3-16.
Drive chain slack (Maintenance c. After riveting, make sure the space “c”,
stand) which is inside of the master link “3” and
48.0–58.0 mm (1.89–2.28 in) inside of the master link plate “1”, is 12.1–
12.3 mm (0.476–0.484 in).
ECA24590
NOTICE
its.
4-32
CHAIN DRIVE
2. Lubricate:
• Drive chain
Chain lubricant suitable for O-
ring chains
3. Install:
• Drive sprocket
• Lock washer New
• Drive sprocket nut
Drive sprocket nut
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.
ECA14300
NOTICE
Never install a new drive chain onto worn
4. Adjust:
• Drive chain slack
3-16.
Drive chain slack (Maintenance
stand)
48.0–58.0 mm (1.89–2.28 in)
ECA24590
NOTICE
its.
4-33
CHAIN DRIVE
4-34
ENGINE
CLUTCH............................................................................................................5-1
REMOVING THE CLUTCH ........................................................................5-1
CHECKING THE FRICTION PLATES ........................................................5-1
CHECKING THE CLUTCH PLATES ..........................................................5-1
CHECKING THE CLUTCH SPRINGS ........................................................5-1
1
CHECKING THE CLUTCH HOUSING .......................................................5-1
CHECKING THE CLUTCH BOSS ..............................................................5-2
CHECKING THE PRESSURE PLATE .......................................................5-2
CHECKING THE PUSH LEVER SHAFT ....................................................5-2
CHECKING THE PUSH RODS ..................................................................5-2
2
CHECKING THE PRIMARY DRIVE GEAR ................................................5-2
CHECKING THE PRIMARY DRIVEN GEAR..............................................5-2
INSTALLING THE CLUTCH .......................................................................5-2
3
4
5
6
7
8
9
10
CLUTCH
EAM20111
2. Measure:
CLUTCH • Clutch plate warpage
EAM30108
(with a surface plate and thickness gauge)
REMOVING THE CLUTCH Out of specification  Replace the clutch
1. Remove: plates as a set.
• Clutch boss nut “1” Thickness gauge
• Lock washer 90890-03268
• Clutch boss “2” Feeler gauge set
TIP YU-26900-9
• While holding the clutch boss with the univer-
sal clutch holder “3”, loosen the clutch boss
nut. Clutch plate thickness
1.50–1.70 mm (0.059–0.067 in)
• Do not use an impact wrench for removing the
Warpage limit
clutch boss nut. 0.20 mm (0.008 in)
Universal clutch holder EAM30111
90890-04086 CHECKING THE CLUTCH SPRINGS

Universal clutch holder 1. Check:
YM-91042 • Clutch spring
Damage  Replace the clutch springs as a
set.
2. Measure:
3 1 • Clutch spring free length
Out of specification  Replace the clutch
springs as a set.
Clutch spring free length
2 44.00 mm (1.73 in) (YZ250X)
50.00 mm (1.97 in) (YZ250)
G088993 Clutch spring free length limit
EAM30109
41.80 mm (1.65 in) (YZ250X)
CHECKING THE FRICTION PLATES 48.00 mm (1.89 in) (YZ250)
1. Check:
EAM30112
• Friction plate CHECKING THE CLUTCH HOUSING
Damage/wear  Replace the friction plates 1. Check:
as a set. • Clutch housing dogs
2. Measure: Damage/pitting/wear  Deburr the clutch
• Friction plate thickness housing dogs or replace the clutch housing.
Out of specification  Replace the friction
TIP
plates as a set. Pitting on the clutch housing dogs will cause er-
TIP ratic clutch operation.
Measure it at four points on the friction plate.
Friction plate thickness

2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.80 mm (0.110 in)
EAM30110
CHECKING THE CLUTCH PLATES

1. Check:
• Clutch plate G088994
Damage  Replace the clutch plates as a
set.
5-1
CLUTCH
EAM30113
CHECKING THE CLUTCH BOSS

1. Check:
• Clutch boss splines
Damage/pitting/wear  Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
2. Measure:
• Push rod 2 bending limit
Out of specification  Replace.
Push rod bending limit
0.30 mm (0.012 in)
EAM30117
G088995 CHECKING THE PRIMARY DRIVE GEAR

EAM30114
1. Check:
CHECKING THE PRESSURE PLATE • Primary drive gear
1. Check: Damage/wear  Replace the primary drive
• Pressure plate and primary driven gears as a set.
Crack/damage  Replace. Excessive noise during operation  Replace
the primary drive and primary driven gears as
EAM30115
CHECKING THE PUSH LEVER SHAFT a set.

1. Check: 2. Check:
• Push lever shaft • Primary-drive-gear-to-primary-driven-gear
Wear/damage  Replace. free play
Free play exists  Replace the primary drive
and primary driven gears as a set.
EAM30118
CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
• Primary driven gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Replace
the primary drive and primary driven gears as
a set.
EAM30484
CHECKING THE PUSH RODS EAM30121
1. Check: INSTALLING THE CLUTCH

• Push rod 1 “1” 1. Install:
• Bearing “2” • Push lever shaft “1”
• Washer “3” • Copper washer “2” New
• Push rod 2 “4” • Push lever shaft bolt “3”
Cracks/damage/wear  Replace.
Push lever shaft bolt
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
5-2
CLUTCH
Universal clutch holder

2 90890-04086
Universal clutch holder
YM-91042
3
2. Install:
• Thrust washer [D = ø42 mm (1.65 in)] “1”
• Spacer “2”
• Bearing “3”
• Primary driven gear “4”
TIP 5. Bend the lock washer “1” tab.
Apply the transmission oil on the bearing, spacer
and primary driven gear inner circumference.
6. Install:
• Friction plate “1”
3. Install: • Clutch plate “2”
• Thrust washer [D = ø44 mm (1.73 in)] “1” TIP
• Clutch boss “2” • Install the clutch plates and friction plates alter-
nately on the clutch boss, starting with a friction
plate and ending with a friction plate.
• Apply the transmission oil on the friction plates
and clutch plates.
4. Install:
• Lock washer “1” New
• Clutch boss nut “2”
Clutch boss nut 7. Install:
75 N·m (7.5 kgf·m, 55 lb·ft)
• Bearing “1”
T.
R.
• Washer “2”
TIP
Use the universal clutch holder “3” to hold the • Circlip “3” New
clutch boss. (to push rod 1 “4”)
5-3
CLUTCH
TIP TIP
Apply the lithium soap base grease on the bear- Tighten the bolts in stage, using a crisscross pat-
ing, washer and push rod 1. tern.
11.Install:
(to clutch cover)
3
2
1
4
8. Install:
• Push rod 2 “1”
• Push rod 1 “2”
TIP 12.Install:
• Apply the transmission oil on the ends of the • Clutch cover
push rod 2. • Clutch cover bolt
• Install the push rod 2 with its smaller end “a” to-
ward you. Clutch cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the bolts in stage, using a crisscross pat-
tern.
13.Install:
• Clutch cable “2”
TIP
Apply the lithium soap base grease on the O-
ring.
9. Install:
• Pressure plate “1” 1
10.Install:
• Clutch spring
• Clutch spring bolt
Clutch spring bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-4
CLUTCH
5-5
ELECTRICAL SYSTEM
WIRING DIAGRAM ...........................................................................................6-1

COLOR CODE............................................................................................6-1
1
2
3
4
5
6
7
8
9
10
WIRING DIAGRAM
EAM20195
WIRING DIAGRAM
1. CDI unit
2. Engine stop switch
3. Ignition coil
4. Throttle position sensor
5. Solenoid valve
6. Neutral switch
7. CDI magneto
8. Spark plug
EAM30608
COLOR CODE
B Black
L Blue
O Orange
R Red
Sb Sky blue
Y Yellow
B/L Black/Blue
B/R Black/Red
B/W Black/White
G/L Green/Blue
G/W Green/White
W/L White/Blue
W/R White/Red
6-1
TROUBLESHOOTING
TROUBLESHOOTING ......................................................................................7-1
GENERAL INFORMATION ........................................................................7-1
TROUBLESHOOTING OF ENGINE ...........................................................7-1
TROUBLESHOOTING OF CLUTCH ..........................................................7-6
TROUBLESHOOTING OF TRANSMISSION .............................................7-7
1
TROUBLESHOOTING OF COOLING SYSTEM ........................................7-8
TROUBLESHOOTING OF BRAKE ............................................................7-9
TROUBLESHOOTING OF SUSPENSION .................................................7-9
TROUBLESHOOTING OF STEERING/HANDLING.................................7-11 2
3
4
5
6
7
8
9
10
TROUBLESHOOTING
EAM20148
TROUBLESHOOTING
EAM30309
GENERAL INFORMATION
TIP
• Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter
for detailed information on checking, adjustment, and replacement.
• The following guide for troubleshooting represent quick and easy procedures for checking these vital
systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer,
whose skilled technicians have the necessary tools, experience, and know-how to service the motor-
cycle properly.
EAM30612
TROUBLESHOOTING OF ENGINE
Engine will not start or is difficult to start, but it cranks.
Symptom Possible cause Actions
Spark plug does not produce a

Have a Yamaha dealer check the electrical system.
spark
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather
Clean the fuel tank cap.
hole
Clogged or damaged fuel hose Clean, repair, or replace the fuel

hose.
Check the fuel passage. Repair or
Fuel leakage replace as necessary.
Clean or replace the fuel cock
Clogged fuel cock strainer strainer.
Clogged fuel cock Clean or replace the fuel cock.
Fuel not supplied Cracked, damaged or worn fuel
Replace the fuel cock.
cock
Clogged carburetor fuel passage Clean the carburetor.
Clogged needle valve or needle Clean the needle valve or needle
valve seat valve seat.
Damaged float Replace the float.
Clogged pilot jet Clean the pilot jet.
Clogged starter jet Clean the starter jet.
Bent or damaged starter plunger Replace the starter plunger.
Incorrectly adjusted starter cable Adjust the starter cable.
Water or foreign material in fuel,
— Change fuel.
degraded fuel
7-1
TROUBLESHOOTING
Measure the compression pres-

—
sure.
Loose spark plug Tighten the spark plugs to the

specified torque.
Tighten bolts or nuts on cylinder
Loose cylinder head or cylinder head and cylinder to the specified
torque.
Compression pressure is low Damaged cylinder head gasket Replace the cylinder head gasket.
Worn, damaged, or stuck piston Replace the piston and piston
ring rings as a set.
Replace the piston and piston
Seized or damaged piston
rings as a set.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.
Incorrect idling speed or mid-to-high speed

Incorrect spark plug gap Adjust the spark plug gap.

Worn or damaged spark plug Replace the spark plug.
Spark plug does not produce a Defective spark plug cap Replace the spark plug cap.
spark
Defective ignition coil Replace the ignition coil.
CDI unit failure Replace the CDI unit.
Fuel leakage
replace as necessary.
Fuel not supplied
Change fuel.
degraded fuel
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Incorrectly adjusted idling speed Adjust the throttle stop screw.
(throttle stop screw)
Incorrectly adjusted pilot screw Adjust the pilot screw.
— Incorrectly adjusted pilot air screw Adjust the pilot air screw.
Tighten the pilot jet to the specified
Loose pilot jet
torque.
Damaged or worn needle valve
Replace the needle valve seat.
seat
Loose needle valve seat Tighten the needle valve seat to

the specified torque.
7-2
TROUBLESHOOTING
Damaged or worn needle valve Replace the needle valve.

Adjust the fuel level to the proper
Incorrect fuel level
level.
Bent, worn, or damaged starter
Replace the starter plunger.
plunger
Clogged or damaged carburetor Clean, repair, or replace the car-
breather hose buretor breather hose.
Incorrect throttle position sensor Adjust the throttle position sensor
angle angle.
—
Check the air induction system.
Failed air induction system
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum
hose Replace the vacuum hose.
Damaged carburetor joint Replace the carburetor joint.

Tighten the carburetor joint bolts
Loose carburetor joint
to the specified torque.
Clean or replace the air filter ele-
Clogged air filter element
ment.
Incorrect mid-high speed

Incorrect spark plug gap Adjust the spark plug gap.

Worn or damaged spark plug Replace the spark plug.
Spark plug does not produce a
Defective spark plug cap Replace the spark plug cap.
spark
Defective ignition coil Replace the ignition coil.
CDI unit failure Replace the CDI unit.
Fuel leakage
replace as necessary.
Fuel not supplied
7-3
TROUBLESHOOTING

Change fuel.
degraded fuel
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Improperly synchronized carbure- Adjust synchronization of carbure-
tors tors.
Incorrectly adjusted pilot screw Adjust the pilot screw.
Incorrectly adjusted pilot air screw Adjust the pilot air screw.
Tighten the pilot jet to the specified
Loose pilot jet
torque.
Clogged main nozzle Clean the main nozzle.
Tighten the main nozzle to the
Loose main nozzle
specified torque.
Clogged main jet Clean the main jet.
Tighten the main jet to the speci-
Loose main jet
fied torque.
— Bent, damaged, or worn jet needle Replace the jet needle.
Cracks or damage in the piston Replace the piston valve dia-
valve diaphragm phragm.
Problem with piston valve move- Replace the piston valve.
ment (movement is not smooth)
Damaged or worn needle valve
Replace the needle valve seat.
seat
Tighten the needle valve seat to
Loose needle valve seat
Damaged or worn needle valve Replace the needle valve.
Adjust the fuel level to the proper
Incorrect fuel level level.
Bent, worn, or damaged starter
Replace the starter plunger.
plunger
Clogged or damaged carburetor Clean, repair, or replace the car-
breather hose buretor breather hose.
Incorrect throttle position sensor Adjust the throttle position sensor
angle angle.
7-4
TROUBLESHOOTING
Check the air induction system.

Failed air induction system
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum
Replace the vacuum hose.
hose
—
Damaged carburetor joint Replace the carburetor joint.
Loose carburetor joint Tighten the carburetor joint bolts

Clogged air filter element ment.
Excessive noise from engine

Worn or damaged piston ring Replace the piston and piston

rings as a set.
Replace the piston and piston
Worn or damaged piston rings as a set.
Replace the piston and piston pin
Worn piston (piston pin hole) as a set.
Noise heard from around piston
Worn or damaged piston pin Replace the piston pin.
Replace the cylinder, piston, and
Worn or damaged cylinder bore
piston rings as a set.
Carbon buildup in piston head and Clean the piston head and com-
combustion chamber bustion chamber.
Worn or damaged crankshaft jour-
Replace the crankshaft.
nal or crank pin
Worn or damaged big end bearing Replace the big end bearing.
Noise heard from around crank-
shaft Worn or damaged crankshaft jour- Replace the crankshaft journal
nal bearing bearing.
Worn or damaged balancer shaft Replace the balancer shaft journal
journal bearing bearing.
7-5
TROUBLESHOOTING
EAM30510
TROUBLESHOOTING OF CLUTCH
Manual clutch
Improperly assembled clutch Reassemble the clutch.

Improperly adjusted clutch cable Adjust the clutch lever free play.
Tighten the clutch spring bolts to
Loose clutch spring
Fatigued clutch spring Replace the clutch springs as a

set.
Warped pressure plate Replace the pressure plate.
Clutch slippage Replace the friction plates as a
Worn friction plate
set.
Warped or worn clutch plate Replace the clutch plates as a set.
Incorrect oil level Adjust the engine oil level to the

specified level.
Change to recommended engine
Incorrect oil viscosity (low)
oil.
Deteriorated oil oil.
Replace the clutch springs as a
Faulty clutch spring
set.
Warped pressure plate Replace the pressure plate.
Replace the friction plates as a
Swollen friction plate
set.
Warped clutch plate Replace the clutch plates as a set.
Bent pull rod (outer pull type) Replace the pull rod.
Worn pull rod tooth (outer pull Replace the pull rod and pull lever
type) shaft as a set.
Bent push rod (inner push type) Replace the push rod.
Clutch drags
Damaged or worn clutch boss Replace the clutch boss.
Seized clutch housing bushing Replace the clutch housing.
Align the match mark on the pull
Improperly installed pull lever
lever before installation.
Adjust the engine oil level to the
Incorrect oil level
specified level.
Incorrect oil viscosity (high)
oil.
Deteriorated oil
oil.
7-6
TROUBLESHOOTING
Replace the primary drive gear or

Damaged or worn primary driven
gear crankshaft, and the clutch housing
as a set.
Tighten the clutch boss nut to the
Loose clutch boss nut
specified torque.
Clutch noise
Fatigued clutch damper Replace the clutch housing.
Replace the clutch housing bear-
Worn clutch housing bearing
ing.
Worn pressure plate bearing Replace the pressure plate bear-

ing.
EAM30511
TROUBLESHOOTING OF TRANSMISSION
Clutch drags Refer to “Clutch drags”.
Improperly adjusted shift rod Adjust the shift rod installation

length.
Bent shift shaft Replace the shift shaft.
Foreign object in a shift drum Remove foreign object from shift
groove drum groove.
Damaged shift drum Replace the shift drum.
Difficult or impossible to shift Replace the shift fork and shift fork
transmission gear Seized shift fork
guide bar as a set.
Bent shift fork guide bar Replace the shift fork guide bar.
Foreign object between transmis- Remove foreign object from trans-
sion gears mission gears.
Replace the seized gear and the
Seized transmission gear
axle as a set.
Improperly assembled transmis- Reassemble the transmission axle
sion assembly.
Incorrect shift pedal position Adjust the shift pedal position.
Improperly returned stopper lever Replace the stopper lever spring.
Bent or worn shift fork Replace the shift fork.
Jumps out of gear
Shift drum incorrect axial play Replace the shift drum.
Worn shift drum groove Replace the shift drum.
Worn transmission gear dog Replace the transmission gear.
Damaged or worn transmission
Replace the transmission gear.
gear
Transmission noise Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Worn bearing Replace the bearing.
7-7
TROUBLESHOOTING
EAM30512
TROUBLESHOOTING OF COOLING SYSTEM

Carbon buildup in piston head and Clean the piston head and com-
combustion chamber bustion chamber.
Clogged engine cooling water Check and clean the engine cool-
passages ing water passages.
Damaged or leaking radiator Replace the radiator.
Faulty radiator cap Replace the radiator cap.
Clogged radiator fin Clean the radiator fin.
Repair the radiator fin or replace
Bent or damaged radiator fin
the radiator.
Damaged or faulty water pump Replace the water pump.
Overheating Damaged hoses or pipes Replace the hose or pipe.
Improperly connected hoses or Connect the hoses and pipes
pipes properly.
Clogged air filter element
ment.
Check the brake system and
Brake drags repair or replace faulty parts as
necessary.
Adjust to the specified spark plug
Incorrect spark plug gap
gap.
Incorrect spark plug heat range Replace the spark plug with the
one of the specified type.
Contact between the water pump Disassemble the water pump and
housing cover and impeller replace faulty parts.
Noise from water pump
Replace the water pump housing
Worn water pump housing bearing bearing.
7-8
TROUBLESHOOTING
EAM30513
TROUBLESHOOTING OF BRAKE
Worn brake pad Replace the brake pads as a set.

Worn or deflected brake disc Replace the brake disc.
Air in hydraulic brake system Bleed the hydraulic brake system.
Check the hydraulic brake system
Brake fluid leakage and repair or replace faulty parts
as necessary.
Add brake fluid to the specified
Incorrect brake fluid level (low)
level.
Stuck brake caliper piston Replace the caliper piston seal.
Poor performance of disc brake
Stuck brake caliper and slide pin Lubricate the caliper slide pin.
Tighten the union bolt to the speci-
Loose union bolt fied torque.
Damaged brake hose and brake Replace the brake hose and brake
pipe pipe.
Oil or grease on the brake disc or
Clean the brake disc or brake pad.
brake pad
Insufficient lubrication of brake Lubricate the brake lever or brake
lever or brake pedal pivot pedal pivot.
EAM30514
TROUBLESHOOTING OF SUSPENSION
Bent or damaged inner tube Replace the inner tube.

Bent or damaged outer tube Replace the outer tube.
Damaged or worn slide metal Replace the slide metal.
Bent or damaged damper rod Replace the damper rod.
Bent wheel axle Replace the wheel axle.
Incorrect oil viscosity (high) Change to recommended fork oil.
Front fork is hard
Incorrect oil level (high) Adjust to the specified oil level.
Improperly adjusted spring pre- Adjust the spring preload.
load (hard)
Improperly adjusted rebound
Adjust the rebound damping.
damping (hard)
Improperly adjusted compression
Adjust the compression damping.
damping (hard)
7-9
TROUBLESHOOTING
Fatigued or broken fork spring Replace the fork spring.

Incorrect oil viscosity (low) Change to recommended fork oil.
Incorrect oil level (low) Adjust to the specified oil level.
Improperly adjusted spring pre-
Front fork is soft load (soft) Adjust the spring preload.
Improperly adjusted rebound

damping (soft)
Improperly adjusted compression
Adjust the compression damping.
damping (soft)
Bent, damaged, or corroded inner
Replace the inner tube.
tube
Cracked or damaged outer tube Replace the outer tube.
Improperly installed oil seal Replace the oil seal.
Damaged oil seal lip Replace the oil seal.
Leaking oil from front fork Incorrect oil level (high) Adjust to the specified oil level.
Tighten the damper rod assembly
Loose damper rod assembly bolt
bolt to the specified torque.
Damaged damper rod assembly Replace the damper rod assembly
bolt copper washer bolt copper washer.
Cracked or damaged cap bolt O-
Replace the cap bolt O-ring.
ring
Bent or damaged rear shock
Replace the rear shock absorber.
absorber rod
Bent swingarm pivot shaft Replace the swingarm pivot shaft.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
Damaged or worn relay arm bear-
Replace the relay arm bearing.
ing
Rear suspension is hard Damaged or worn connecting arm Replace the connecting arm bear-
bearing ing.
Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (hard)
absorber rebound damping (hard)
absorber compression damping Adjust the compression damping.
(hard)
7-10
TROUBLESHOOTING
Oil leaking from rear shock

absorber Replace the rear shock absorber.
Gas leaking from rear shock

absorber
Fatigued or damaged rear shock
absorber spring
Rear suspension is soft Improperly adjusted rear shock
Adjust the spring preload.
absorber spring preload (soft)
absorber rebound damping (soft)
absorber compression damping Adjust the compression damping.
(soft)
Bent, damaged, or corroded rear Replace the rear shock absorber.
Oil leaking from rear shock shock absorber rod
absorber
Damaged oil seal lip Replace the rear shock absorber.
EAM30515
TROUBLESHOOTING OF STEERING/HANDLING
Tighten the steering ring nut to the

Loose steering ring nut specified torque.
Replace the bearing and bearing
Worn bearing or bearing race
race as a set.
Handlebar wobble Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
Worn, deformed, or incorrect tire Replace the tire.
Steering ring nut is tightened too Tighten the steering ring nut to the
tight. specified torque.
Bent lower bracket Replace the lower bracket.
Heavy steering Replace the bearing and bearing
Broken bearing or bearing race
race as a set.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
7-11
TROUBLESHOOTING
Incorrect wheel balance Adjust the wheel balance.

Tighten the spoke and adjust the
Loose spoke
runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Front wheel vibration
Loose wheel axle or wheel axle Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Loose wheel axle pinch bolt Tighten the wheel axle pinch bolt
Adjust to the specified front fork oil
Incorrect front fork oil level level.
Incorrect wheel balance Adjust the wheel balance.
Tighten the spoke and adjust the
Loose spoke
runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Rear wheel vibration Loose wheel axle nut Tighten the wheel axle nut to the
specified torque.
Loose swingarm pivot shaft Tighten the swingarm pivot shaft

Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm bear- Replace the swingarm bearing or
ing or bushing bushing.
7-12
TROUBLESHOOTING
7-13
TUNING
ENGINE.............................................................................................................8-1
CARBURETOR SETTING ..........................................................................8-1
ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS ............8-1
TEST RUN ..................................................................................................8-1
EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE
1
OPENING ..................................................................................................8-2
MAIN JET ADJUSTMENT ..........................................................................8-2
ADJUSTING THE POWER JET .................................................................8-2
PILOT AIR SCREW ADJUSTMENT ...........................................................8-2
PILOT JET ADJUSTMENT .........................................................................8-3
2
JET NEEDLE ADJUSTMENT .....................................................................8-3
JET NEEDLE GROOVE POSITION ADJUSTMENT ..................................8-4
RELATIONSHIP WITH THROTTLE OPENING..........................................8-4
CARBURETOR SETTING PARTS .............................................................8-5
ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING.......8-6
3
EXAMPLES OF CARBURETOR SETTING DEPENDING ON
4
SYMPTOM.................................................................................................8-6
CHANGE OF THE HEAT RANGE OF SPARK PLUGS..............................8-8
CHASSIS ..........................................................................................................8-9
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET).............................................................................................8-9
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS...................8-9
TIRE PRESSURE .......................................................................................8-9
5
FRONT FORK SETTING ..........................................................................8-10
6
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ..........8-10
SETTING OF SPRING AFTER REPLACEMENT.....................................8-10
FRONT FORK SETTING PARTS .............................................................8-11
REAR SUSPENSION SETTING...............................................................8-11
CHOOSING SET LENGTH.......................................................................8-11
7
SETTING OF SPRING AFTER REPLACEMENT.....................................8-12
REAR SHOCK ABSORBER SETTING PARTS .......................................8-12
SUSPENSION SETTING (FRONT FORK) ...............................................8-14
SUSPENSION SETTING (REAR SHOCK ABSORBER)..........................8-15
8
9
10
ENGINE
EAM20198
• Lower atmospheric pressure (at a high alti-
ENGINE tude) reduces the density of the air.
EAM30590 EAM30592
CARBURETOR SETTING TEST RUN

• The role of fuel is to cool the engine, and in the After warming up the engine equipped with the
case of a 2-stroke engine, to lubricate the en- standard type carburetor(s) and spark plug(s),
gine in addition to power generation. Accord- run two or three laps of the circuit and check the
ingly, if a mixture of air and fuel is too lean, smooth operation of the engine and discolor-
abnormal combustion will occur, and engine ation of spark plug(s).
seizure may result. If the mixture is too rich,
spark plugs will get wet with oil, thus making it Discoloration Condition of spark plug
impossible to bring the engine into full play or if Insulator is dry and burnt
Normal
the worst comes to the worst, the engine may brown.
stall. Over burned
• The richness of the air-fuel mixture required for Insulator is whitish.
(too lean)
the engine will vary with atmospheric condi-
Oil fouled
tions of the day and therefore, the settings of (too rich) Insulator is sooty and wet.
the carburetor must be properly suited to the
atmospheric conditions (air pressure, humidity A
and temperature).
• Finally, the rider himself must make a test run
and check his vehicle for conditions (pick-up of
engine speed, road surface conditions) and for
the discoloration of the spark plug(s).
After taking these into consideration, he must
select the best possible carburetor settings.
TIP
It is advisable to make a note of settings, atmo-
spheric conditions, road surface condition, lap- B
time, etc. so that the memorandum can be used
as a reference useful for future.
EAM30591
ATMOSPHERIC CONDITIONS AND

CARBURETOR SETTINGS
Air
Air
Humidity pressure Mixture Setting
temp.
(altitude) C
Low
High High Richer Leaner
(high)
High
Low Low Leaner Richer
(low)
The air density (i.e., concentration of oxygen in

the air) determines the richness or leanness of
the air/fuel mixture. Therefore, refer to the above
table for mixture settings.
That is: A. Normal
• Higher temperature expands the air with its re- B. Over burned (too lean)
sultant reduced density. C. Oil fouled (too rich)
• Higher humidity reduces the amount of oxygen
in the air by so much of the water vapor in the
same air.
8-1
ENGINE
EAM30593
EFFECTS OF THE SETTING PARTS ON THE

THROTTLE VALVE OPENING
EAM30604
ADJUSTING THE POWER JET

The richness of air-fuel mixture under 8500 r/min
to the extent of 1/2 to full opened throttle can be
set by changing the power jet “1”. A larger size
jet results in a richer mixture, and a smaller size
in a leaner mixture.
Standard power jet #50
A. Closed
B. Full-open
1. Pilot jet
2. Pilot air screw
3. Jet needle
4. Diameter of straight portion
5. Clip position EAM30595
6. Throttle valve PILOT AIR SCREW ADJUSTMENT

7. Power jet The richness of the air-fuel mixture with the
8. Main jet throttle fully closed to 1/8 open can be set by
turning the pilot air screw “1”.
TIP Turning in the pilot air screw will make the mix-
The power jet closes at 8500 r/min of the engine, ture enrich at low speeds, and turning it out will
after which only the main jet dominates. lean it.
Standard pilot air
EAM30594
screw position 1-1/4 turns out
MAIN JET ADJUSTMENT
The richness of air-fuel mixture with 3/4–4/4
throttle can be set by changing the main jet “1”.
Standard main jet #178
1. Spark plug is too hot.

Select a main jet having higher calibrating
No. than standard. (To be enriched)
2. Spark plug is wet.
Select a main jet having lower calibrating No.
than standard. (To be leaned out)
8-2
ENGINE
EAM30596
PILOT JET ADJUSTMENT

The richness of air-fuel mixture with the throttle
fully closed to 1/2 open can be set by turning the
pilot jet “1”. It is changed when adjustment can-
N3EG
not be made by the pilot air screw alone.
N3EH
A larger size jet results in a richer mixture at low
N3EW
speeds, and a smaller size in a leaner mixture. N3EJ
Standard pilot jet #50 N3EK
N8RW
N3EW
N3CW
N89W
EAM30597
JET NEEDLE ADJUSTMENT

A. Difference in straight portion diameter
On the carburetors used in the YZ250/YZ250X,
B. Difference in taper starting position
the main nozzle is press-fitted, so it can not be
replaced. Therefore, carburetor setting requires a. Diameter of the straight portion
the change of the jet needle. b. Taper starting position
1. The jet needle setting parts, having the same c. Rich
taper angle, are available in different straight d. Lean
portion diameters and in different taper start-
2. Effects of changing the jet needle (reference)
ing positions.
• Diameter of straight portion
Standard jet needle N3EW Changing the diameter of the straight portion
adjusts the air-fuel mixture when the throttle
is 1/8 to 1/4 open.
• Taper starting position
Changing the taper starting position produc-
es the same effect as changing the clip posi-
tion by 0.5 groove.
Example:
In case of being 0.5 groove leaner in relation
to N3EW-3rd groove, choose N3CW-3rd
groove.
8-3
ENGINE
EAM30605
RELATIONSHIP WITH THROTTLE OPENING

The flow of the fuel through the carburetor main
system is controlled by the main jet and then, it
is further regulated by the area between the
main nozzle and the jet needle. On the relation-
ship between the fuel flow and the throttle open-
ing, the fuel flow relates to the jet needle straight
portion diameter around 1/8 to 1/4 throttle open-
ing, whereas around 1/4 to 1/1 throttle opening it
relates to the taper starting position and to the
A. In case of being 0.5 groove leaner in relation clip position.
to N3EW-3rd groove. Therefore, the fuel flow is balanced at each
a. Difference of 0.5 groove
stage of throttle opening by the combination of
the jet needle straight portion diameter, taper
EAM30598
starting position and clip position.
JET NEEDLE GROOVE POSITION
ADJUSTMENT
Should the engine be hard to run smoothly at in-
termediate speeds, the jet needle “1” must be
adjusted. If the mixture is too rich or too lean at
intermediate speed operation, irregular engine
operation and poor acceleration will result.
Whether or not the richness of the mixture is
proper is hard to be determined by means of the
spark plug and therefore, it should be judged
from your feeling of actual engine operation.
Example:
Standard clip position No. 2 groove
N3EW-3 N3EJ-3
1. Too rich at intermediate speeds
Rough engine operation is felt and the engine N3EW-4 N8RW-3
will not pick up speed smoothly.
In this case, step up the jet needle clip by one A. Lean (larger diameter)
groove and move down the needle to lean out B. Rich (smaller diameter)
the mixture.
1. 1/8 throttle
2. Too lean at intermediate speeds
2. 1/4 throttle
The engine breathes hard and will not pick up
3. 1/2 throttle
speed quickly.
4. 1/1 throttle
In this case, step down the jet needle clip by
one groove and move up the needle to enrich a. Main nozzle
the mixture.
8-4
ENGINE
EAM30599
CARBURETOR SETTING PARTS

Part name Size Part number
Main jet “1” Rich #190 4MX-14943-45

#188 4MX-14943-95
#185 4MX-14943-44
#182 4MX-14943-94
#180 4MX-14943-43
(STD) #178 4MX-14943-93
#175 4MX-14943-42
#172 4MX-14943-92
#170 4MX-14943-41
#168 4MX-14943-91
#165 4MX-14943-40
Lean #162 4MX-14943-90
Pilot jet “2” Rich #62 4MX-14948-12
#60 4MX-14948-11
#58 4MX-14948-10
#55 4MX-14948-09
#52 4MX-14948-08
(STD) #50 4MX-14948-07
#48 4MX-14948-06
#45 4MX-14948-05
#42 4MX-14948-04
#40 4MX-14948-03
Lean #38 4MX-14948-02
Jet needle Rich N8RH 4SR-14916-RH
“3”
N3EH 4SR-14916-EH
N8RW 4SR-14916-RW
(STD) N3EW 4SR-14916-EW
N3CW 4SR-14916-CW
N3EJ 4SR-14916-EJ
Lean N3CJ 4SR-14916-CJ
Power Jet Rich #65 4JT-1494F-13
“4”
#60 4JT-1494F-11
#55 4JT-1494F-09
(STD) #50 4JT-1494F-07
Lean #40 4JT-1494F-03
8-5
ENGINE
EAM30601
ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING

General condition Sandy condition
15–25 C 15–25 C
Under 10 C (59–77 F) Over 25 C Under 10 C Over 25 C
(59–77 F)
(50 F) (Spring, (77 F) (50 F) (Spring, (77 F)
(Winter) (Summer) (Winter) (Summer)
Autumn) Autumn)
Main jet #178 #178 #178 #182 #180 #178

N3CW-3 N3EW-2 N3EJ-2 N3CW-3 N3CW-3 N3CW-3
Jet needle
N3EW-3 N3CW-3 N3EW-2 N3CW-4 N3EW-3 N3EW-3
Pilot jet #50 #50 #50 #52 #52 #52
Pilot air screw -1/4 0 0 0 0 +1/4
Power jet #50 #50 #50 #50 #50 #50
TIP
Optimum pilot air screw setting can be obtained by adding the ex-factory number of the same screw
back-out turns to any required value provided in the chart. For example, if the ex-factory number is “1”,
add “1” to the value chosen in the chart.
EAM30602
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM

Symptom Setting Checking
• At full throttle Increase main jet calibration no. • Discoloration of spark plug 
Stall at high speeds (Gradually) If tan color, it is in good condition.
*Hard breathing • If cannot be corrected:
Shearing noise Clogged float valve seat
Whitish spark plug Clogged fuel hose
 Clogged fuel cock
Lean mixture
• At full throttle Decrease main jet calibration no. • Discoloration of spark plug 
Speed pick-up stops (Gradually) If tan color, it is in good condition.
Slow speed pick-up *In case of racing slight enrichment of • If cannot be corrected:
Slow response mixture reduces engine trouble. Clogged air filter
Sooty spark plug Fuel overflow from carburetor

Rich mixture
8-6
ENGINE
Symptom Setting Checking
Lean mixture Lower jet needle clip position. (1

groove down)
Rich mixture Raise jet needle clip position. (1
groove up)
• 1/4–3/4 throttle Lower jet needle clip position. (1 Leaner
*Hard breathing groove down)
Lack of speed (Standard)
1. Groove 1 Richer
2. Groove 2
3. Groove 3
4. Groove 4
5. Groove 5
6. Jet needle
7. Clip
• 1/4–1/2 throttle The clip position is the jet needle
Slow speed pick-up Raise jet needle clip position. (1 groove on which the clip is installed.
White smoke groove up) The positions are numbered from the
Poor acceleration top.
• Closed to 1/4 throttle Use jet needle having a smaller diam-
*Hard breathing eter.
Speed down
• Closed to 1/4 throttle Use jet needle with a larger diameter.
Poor acceleration
White smoke
• Unstable at low speeds Lower jet needle clip position. (1
Pinking noise groove down)
Turn in pilot air screw.
Poor response at extremely Reduce pilot jet calibration No. Dragging brake
low speed Turn out pilot air screw. Overflow from carburetor
If not effect, reverse the above proce-
dures.
Poor response in the low to Raise jet needle clip position.
intermediate speeds If no effect, reverse the above proce-
dures.
Poor response when throt- Check overall settings. Check air filter for fouling.
tle is opened quickly Use main jet having lower calibration
No.
Raise jet needle clip position. (1
groove up)
If no effect, reverse the above proce-
dures.
Poor engine operation Turn in pilot air screw. Check throttle valve operation.
* marked: In case of hard breathing, check the carburetor breather hoses for clogging.
This should be taken simply for an example. It is necessary to set the carburetor while checking the
operating conditions of the engine and discoloration of spark plugs.
Normally, carburetor setting is made by means of the main jet, jet needle clip position, pilot jet and pilot
air screw.
8-7
ENGINE
EAM30603
CHANGE OF THE HEAT RANGE OF SPARK

PLUGS
Judging from the discoloration of spark plugs, if
they are found improper, it can be corrected by
the following two methods; changing carburetor
settings and changing the heat range of spark
plug.
BR8EG
Standard spark plug
(resistance type)
• In principle, it is advisable to first use spark

plugs of standard heat range, and judging from
the discoloration of spark plugs, adjust carbu-
retor settings.
• If the calibration No. of the main jet must be
changed by ±30, it is advisable to change the
heat range of spark plugs and newly select the
proper main jet.
TIP
• When checking the discoloration of spark
plugs, be sure to stop the engine immediately
after a run and check.
• Avoid racing.
• When changing the heat range of spark plugs,
never attempt to change it more than ±1 rank.
• When using a spark plug other than standard,
check its heat range against the standard and
check that it is a resistance type.
• Note that even if the discoloration seems prop-
er, it may slightly vary with the spark plug mak-
er and oil in use.
8-8
CHASSIS
EAM20119 EAM30169
CHASSIS DRIVE AND REAR WHEEL SPROCKETS

SETTING PARTS
EAM30168
SELECTION OF THE SECONDARY Part name Type Part number

REDUCTION RATIO (SPROCKET)
Drive 13T 9383E-13216
sprocket “1”
Secondary reduction ratio = Number of (STD) 14T 9383E-14215
rear wheel sprocket teeth/Number of
drive sprocket teeth Rear wheel 47T 17D-25447-50
sprocket “2”
48T 17D-25448-50
Secondary reduction ratio 49T 17D-25449-50
3.571 (50/14) (STD) 50T 17D-25450-50
<Requirement for selection of secondary gear 51T 17D-25451-50
reduction ratio> 52T 17D-25452-50
• It is generally said that the secondary gear ratio
should be reduced for a longer straight portion
of a speed course and should be increased for
a course with many corners. Actually, howev-
er, as the speed depends on the ground condi-
tion of the day of the race, be sure to run
through the circuit to set the machine suitable
for the entire course.
• In actuality, it is very difficult to achieve settings
suitable for the entire course and some set-
tings may be sacrificed. Thus, the settings
should be matched to the portion of the course
that has the greatest effect on the race result.
In such a case, run through the entire course
while making notes of lap times to find the best
balance; then, determine the secondary reduc-
tion ratio.
• If a course has a long straight portion where a
machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving. EAM30170
TIP TIRE PRESSURE

Riding technique varies from rider to rider and Tire pressure should be adjusted to suit the road
the performance of a machine also vary from surface condition of the circuit.
machine to machine. Therefore, do not imitate
other rider’s settings from the beginning but Standard tire pressure
choose your own setting according to the level of 100 kPa (1.00 kgf/cm², 15 psi)
your riding technique.
• Under a rainy, a muddy, a sandy, or a slippery
condition, the tire pressure should be lower for
a larger area of contact with the road surface.
Extent of adjustment
60–80 kPa (0.60–0.80 kgf/cm², 9–
12 psi)
• Under a stony or a hard road condition, the tire
8-9
CHASSIS
pressure should be higher to prevent a flat tire.

Extent of adjustment
100–120 kPa (1.00–1.20 kgf/cm²,
15–18 psi)
EAM30171
FRONT FORK SETTING

The front fork setting should be made depending
on the rider’s feeling of an actual run and the cir-
cuit conditions.
The front fork setting includes the following three
factors:
1. Setting of air spring characteristics
• Change the fork oil amount.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.
The spring acts on the load and the damping
force acts on the cushion travel speed.
EAM30172 A. Air spring characteristics in relation to oil
CHANGE IN AMOUNT AND amount change
CHARACTERISTICS OF FORK OIL B. Load
Damping characteristic near the final stroke can C. Stroke
be changed by changing the fork oil amount. 1. Max. oil amount
EWA19190
WARNING 2. Standard oil amount

3. Min. oil amount
Adjust the oil amount in 5 cm³ (0.2 US oz, 0.2
Imp.oz) increments or decrements. Too EAM30173
small oil amount causes the front fork to pro- SETTING OF SPRING AFTER
duce a noise at full rebound or the rider to REPLACEMENT
feel some pressure on his hands or body. Al- As the front fork setting can be easily affected by
ternatively, too large oil amount will cause the rear suspension, take care so that the front
the air spring characteristics to have a ten- and the rear are balanced (in position etc.) when
dency to be stiffer with the consequent dete- setting the front fork.
riorated performance and characteristics. 1. Use of soft spring
Therefore, adjust the front fork within the • Change the rebound damping force.
specified range. Turn out one or two clicks.
Recommended oil Turn in one or two clicks.
Yamaha Suspension Oil S1 TIP
Standard oil amount Generally a soft spring gives a soft riding feeling.
320 cm³ (10.8 US oz, 11.3 Imp.oz) Rebound damping tends to become stronger
Extent of adjustment and the front fork may sink deeply over a series
300–365 cm³ (10.1–12.3 US oz, of gaps.
10.6–12.9 Imp.oz)
2. Use of stiff spring
Turn in one or two clicks.
Turn out one or two clicks.
8-10
CHASSIS
EAM30175
TIP
Generally a stiff spring gives a stiff riding feeling. REAR SUSPENSION SETTING
Rebound damping tends to become weaker, re- The rear shock absorber setting should be made
sulting in lack of a sense of contact with the road depending on the rider’s feeling of an actual run
surface or in a vibrating handlebar. and the circuit conditions.
The rear suspension setting includes the follow-
EAM30174
ing two factors:
FRONT FORK SETTING PARTS 1. Setting of spring preload
• Front fork spring “1” • Change the set length of the spring.
• Change the spring.
STD spring rate
(N/mm)
4.3 2. Setting of damping force
Spring I.D. • Change the compression damping force.
Type rate Part number mark
(N/mm) (slits) EAM30176
SOFT 3.9 1C3-23141-A1 I

CHOOSING SET LENGTH
1. Place a stand or a block under the engine to
4.0 1C3-23141-B1 II put the rear wheel above the floor, and mea-
4.1 1C3-23141-C1 III sure the length “a” between the rear wheel
axle center and the rear fender holding bolt.
4.2 1C3-23141-D1 IIII
4.3 1C3-23141-E1 IIIII
4.4 1C3-23141-F1 I-I
4.5 1C3-23141-G1 I-II
4.6 1C3-23141-H1 I-III
STIFF 4.7 1C3-23141-J1 I-IIII
TIP
The I.D. mark (slits) “a” is proved on the end of
the spring. 2. Remove the stand or block from the engine
and, with a rider astride the seat, measure the
a sunken length “b” between the rear wheel
axle center and the rear fender holding bolt.
3. Loosen the locknut “1” and make adjustment

by turning the adjuster “2” to achieve the
standard figure from the subtraction of the
length “b” from the length “a”.
Standard figure
1 90–100 mm (3.5–3.9 in)
TIP
• If the machine is new and after it is broken in,
8-11
CHASSIS
the same set length of the spring may change

because of the initial fatigue, etc. of the spring.
Therefore, be sure to make reevaluation.
• If the standard figure cannot be achieved by
adjusting the adjuster and changing the set
length, replace the spring with an optional one
and make readjustment.
EAM30178
REAR SHOCK ABSORBER SETTING PARTS

• Rear shock spring “1”
[Equal-pitch steel spring]
STD spring rate
48
(N/mm)
Spring
I.D.
Type rate Part number
EAM30177 mark/Q’ty
SETTING OF SPRING AFTER (N/mm)
REPLACEMENT SOFT 42 5UN-22212-00 Brown/1
After replacement, be sure to adjust the spring to
44 5UN-22212-10 Green/1
the set length [sunken length 90–100 mm (3.5–
3.9 in)] and set it. 46 5UN-22212-20 Red/1
1. Use of soft spring 48 5UN-22212-30 Black/1
• Adjust to decrease rebound damping force to
compensate for less spring load. Run with the 50 5UN-22212-40 Blue/1
rebound damping force adjuster one or two 52 5UN-22212-50 Yellow/1
clicks turned out, and readjust it to suit your
54 5UN-22212-60 Pink/1
preference.
2. Use of stiff spring STIFF 56 5UN-22212-70 White/1
• Adjust to increase rebound damping force to
compensate for greater spring load. Run with [Unequal-pitch steel spring]
the rebound damping force adjuster one or Spring
I.D.
two clicks turned in, and readjust it to suit your Type rate Part number
(N/mm) mark/Q’ty
preference.
TIP SOFT 44 5UN-22212-A0 Green/2
Adjusting the rebound damping force will be fol- 46 5UN-22212-B0 Red/2
lowed more or less by a change in the compres-
sion damping force. For correction, adjust to 48 5UN-22212-C0 Black/2
decrease compression damping force. 50 5UN-22212-D0 Blue/2
EWA19200
52 5UN-22212-E0 Yellow/2
WARNING
When using a rear shock absorber other 54 5UN-22212-F0 Pink/2
than currently installed, use the one whose STIFF 56 5UN-22212-G0 White/2
overall length “a” does not exceed the stan-
dard as it may result in faulty performance. TIP
Never use one whose overall length is great- • The unequal-pitch spring is softer in initial char-
er than standard. acteristic than the equal-pitch spring and is dif-
ficult to bottom out under full compression.
Length “a” of standard shock • The I.D. mark “a” is marked at the end of the
490 mm (19.29 in) spring.
• Spring specification varies according to the
8-12
CHASSIS
color and quantity of I.D. marks.
• Spring preload adjusting positions

Spring preload adjusting positions
Minimum
its free length.
Standard
its free length.
Maximum
its free length.
TIP
For the spring preload adjustment, refer to “AD-
JUSTING THE REAR SHOCK ABSORBER AS-
SEMBLY” on page 3-21.
8-13
CHASSIS
EAM30179
SUSPENSION SETTING (FRONT FORK)

TIP
• If any of the following symptoms is experienced with the standard position as the base, make resetting
by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap
Turn adjuster counterclockwise

Compression
damping force (about 2 clicks) to decrease
damping.
Stiff over entire
   Decrease oil amount by about 5–
range
Oil amount 10 cm³ (0.2–0.3 US oz, 0.2–0.4
Imp.oz).
Spring Replace with soft spring.
Check for any bends, dents, other
Outer tube
noticeable scars, etc. If any,
Inner tube
replace affected parts.
Unsmooth move- Replace with a new one for

Slide metal
ment over entire     extended use.
range Replace with a new one for
Piston metal
extended use.
Lower bracket
Retighten to specified torque.
tightening torque
Rebound damp-
Poor initial move- (about 2 clicks) to decrease
 ing force
ment damping.
Oil seals Apply grease in oil seal wall.
Compression Turn adjuster clockwise (about 2
damping force clicks) to increase damping.
Soft over entire
Increase oil amount by about 5–
range, bottoming  
out
Imp.oz).
Spring Replace with stiff spring.
Stiff toward Decrease oil amount by about 5
 Oil amount
stroke end cm³ (0.2 US oz, 0.2 Imp.oz).
Soft toward
Increase oil amount by about 5
stroke end, bot-  Oil amount
toming out cm³ (0.2 US oz, 0.2 Imp.oz).

Stiff initial move- Compression
    (about 2 clicks) to decrease
ment damping force
damping.
8-14
CHASSIS
Section
Large Medium Small
Jump gap gap gap
Compression Turn adjuster clockwise (about 2

damping force clicks) to increase damping.
Rebound damp-
(about 2 clicks) to decrease
ing force
Low front, tend- damping.
ing to lower front   Set sunken length for 95–100
posture Balance with rear mm (3.7–3.9 in) when one pas-
end senger is astride seat (lower rear
posture).
Increase oil amount by about 5
Oil amount
cm³ (0.2 US oz, 0.2 Imp.oz).
Compression
damping force (about 2 clicks) to decrease
damping.
Set sunken length for 90–95 mm
“Obtrusive” front, Balance with rear (3.5–3.7 in) when one passenger
tending to upper   end is astride seat (upper rear pos-
front posture ture).
Decrease oil amount by about 5–
Imp.oz).
EAM30180
SUSPENSION SETTING (REAR SHOCK ABSORBER)

TIP
• If any of the following symptoms is experienced with the standard position as the base, make resetting
by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Section
Large Medium Small
Jump
gap gap gap

Rebound damp-
ing force
Stiff, tending to damping.
sink  
Set sunken length for 90–100
Spring set length mm (3.5–3.9 in) when one pas-
senger is astride seat.
Rebound damp- Turn adjuster clockwise (about 2
ing force clicks) to increase damping.
Spongy and
  Low compres- Turn adjuster clockwise (about 1
unstable
sion damping click) to increase damping.
8-15
CHASSIS
Section
Large Medium Small
Jump
gap gap gap

Rebound damp-
Heavy and drag- (about 2 clicks) to decrease
  ing force damping.
ging
Rebound damp-
ing force
damping.
Low compres- Turn adjuster clockwise (about 1
sion damping click) to increase damping.
Poor road grip-
ping  High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
High compres- Turn adjuster clockwise (about
sion damping 1/6 turn) to increase damping.
Bottoming out  
Rebound damp- Turn adjuster clockwise (about 2
Bouncing   ing force clicks) to increase damping.
High compres-
sion damping (about 1/6 turn) to decrease
damping.
Stiff travel   Set sunken length for 90–100
8-16
CHASSIS
8-17
For your best ownership experience, think Genuine Yamaha!
Genuine Yamaha Parts text
EAM20160
Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones
originally equipped on your vehicle, providing you with the performance and durability you have come
to expect. Why settle for aftermarket parts that may not provide full confidence and satisfaction?
Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for
quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right
and perform right – right out of the box.
Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
They’re formulated and approved by the toughest judges we know: the Yamaha engineering teams that
know your Yamaha from the inside out.
Genuine Yamaha Service Manuals – Get the same factory manual for your vehicle that the techni-
cians at your authorized Yamaha dealer use. Service manuals are available through your Yamaha
dealer or you can order them directly through yamahapubs.com.
Genuine Yamaha products are available only from your Yamaha dealer.
Operating, servicing and Find out more at yamaha-motor.com

maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more
information go to
www.P65Warnings.ca.gov/passenger-vehicle
Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle
if it is sold.
BF1-28199-10_cover.indd 4-6 2020/03/10 13:38:50

2021
OWNER’S MANUAL
YZ250
YZ250X
Read this manual carefully before operating this vehicle.
YZ250M2
PRINTED IN JAPAN
YZ250XM
2020.04-0.9×1 ! LIT-11626-34-11 BF1-28199-10
(E)
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Operating, servicing and Find out more at yamaha-motor.com

BF1-28199-10_cover.indd 4-6 2020/03/10 13:38:50

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED

SAFETY INFORMATION ..................................................................................1-1

LOCATION OF IMPORTANT LABELS.............................................................1-4 1

INCLUDED PARTS ...........................................................................................1-7

IMPORTANT INFORMATION ...........................................................................1-8

MAINTENANCE AFTER BREAK-IN ..............................................................1-13

Aftermarket Tires and Rims

LOCATION OF IMPORTANT LABELS

1. Clutch lever 11.Check bolt (Transmission oil level)

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

SIDESTAND (for YZ250)

2. During disassembly, check and measure the

3. During disassembly, clean each of the parts,

INSTRUMENT AND CONTROL

ENGINE STOP SWITCH

FRONT BRAKE LEVER

REAR BRAKE PEDAL

EAM30537 SIDESTAND (for YZ250X)

has the three positions: WARNING

STARTER KNOB (CHOKE)

Recommended fuel WARNING

Lubrication system NOTICE

2. Start and warm up the engine.

of cables, free play of the brake, stretch of the

Plastic cover Tightening of front fender

6. Touch up minor paint damage caused by

exhaust system. (Even the thermally induced NOTICE

GENERAL SPECIFICATIONS ..........................................................................2-1

Adjustment value from the start position 12

GENERAL TIGHTENING TORQUE

A. Distance between flats

General tightening torques

ENGINE TIGHTENING TORQUES

Spark plug M14S 1 20 N·m (2.0 kgf·m, 15 lb·ft)

Link rod screw M5 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)

Silencer bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Fiber bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Crankcase bolt M6 11 14 N·m (1.4 kgf·m, 10 lb·ft)

Bearing plate cover bolt (main axle

Holder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Oil drain bolt M12 1 23 N·m (2.3 kgf·m, 17 lb·ft)

Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Tension spring (shift shaft) stopper

Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft)

CHASSIS TIGHTENING TORQUES

Upper bracket pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) 

Base valve (front fork) M42 2 29 N·m (2.9 kgf·m, 21 lb·ft)

Front brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Rear brake disc bolt M6 6 12 N·m (1.2 kgf·m, 8.9 lb·ft) / LT

Footrest bracket bolt M10 4 55 N·m (5.5 kgf·m, 41 lb·ft) LT