Yamaha YZ250 YZ250T YZ250T1 2002-2008 Service Manual

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

19 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 66428

Etiquetas: 2002 2003 2004 2005 2006 2007 2008 Misc Motorcycle Motorcycles Yamaha YZ250 YZ250T YZ250T1

Variantes de producto

Descripción

The Yamaha YZ250, including the YZ250T and YZ250T1 variants produced between 2002 and 2008, stands as a formidable machine in the high-performance motocross and off-road competition segment. Renowned for its potent 249cc liquid-cooled two-stroke engine featuring the Yamaha Power Valve System (YPVS), this model delivers exceptional power and torque. Its agility and handling are further enhanced by an aluminum bilateral beam frame and industry-leading Kayaba Speed Sensitive System (SSS) front forks coupled with a refined Monocross rear suspension system. This generation saw significant refinements, solidifying the YZ250's reputation for reliability, engineering quality, and its engaging riding experience, making it a consistent choice against competitors like Honda CR250R, Kawasaki KX250, and Suzuki RM250. This comprehensive 589-page workshop service and repair manual provides essential information for owners, mechanics, and technicians. It covers all aspects of the Yamaha YZ250 from 2002-2008, including detailed procedures for engine disassembly, assembly, and tuning, as well as maintenance and repair of the fuel, ignition, cooling, and electrical systems. The manual also details the 6-speed transmission, clutch, front and rear suspension, braking systems, wheels, tires, and frame. With in-depth troubleshooting guides, adjustment procedures, and rebuild instructions, this manual is an indispensable resource for maintaining and repairing the YZ250, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YZ250

Model Variant:

YZ250T, YZ250T1

Year Range:

2002-2008

Codes

Chassis Codes:

4SP, 4SR, 5XC, 5XJ, 1S7

👋 Introduction

Market Position

Segment:

High-performance motocross and off-road competition motorcycle.

Target Audience:

Motocross racers, off-road enthusiasts, and general maintenance users seeking in-depth technical knowledge.

Competitive Analysis

Competitors:

Honda CR250R, Kawasaki KX250, Suzuki RM250.

Key Features

Engine Type:

Renowned for its potent 2-stroke power delivery and lightweight chassis.

Chassis Design:

Aluminum bilateral beam frame, contributing to agility and handling.

Suspension Advancements:

Industry-leading Kayaba (KYB) Speed Sensitive System (SSS) forks and a refined Monocross rear suspension system for superior damping and adjustability.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive service, maintenance, troubleshooting, and repair information for Yamaha YZ250, YZ250T, and YZ250T1 models from 2002 to 2008.

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, tuning, and troubleshooting for the 249cc liquid-cooled 2-stroke engine.

Fuel System:

Carburetor (Keihin PWK38S) specifications, adjustment, cleaning, and troubleshooting; fuel tank and lines.

Ignition System:

CDI ignition system, troubleshooting, component testing, and specifications.

Cooling System:

Radiator, hoses, water pump, thermostat, coolant specifications, and bleeding procedures.

Transmission:

6-speed gearbox, clutch assembly (wet multi-plate), maintenance, disassembly, assembly, and lubrication.

Suspension Front:

Inverted telescopic fork (Kayaba), disassembly, assembly, oil change, seal replacement, compression/rebound adjustment, and spring rates.

Suspension Rear:

Monocross suspension, shock absorber, linkage system, bearing maintenance, and adjustment procedures.

Brakes Front:

Hydraulic disc brake system, caliper, master cylinder, brake fluid specifications (DOT 4), pad replacement, bleeding, and rotor inspection.

Brakes Rear:

Hydraulic disc brake system, caliper, master cylinder, brake fluid specifications (DOT 4), pad replacement, bleeding, and rotor inspection.

Wheels And Tires:

Wheel bearing inspection and replacement, spoke tension adjustment, tire pressure recommendations, and wheel alignment checks.

Electrical System:

Wiring diagrams, lighting system, ignition coil, stator, rectifier, and battery maintenance (if applicable for ignition).

Frame And Bodywork:

Frame inspection, subframe, footpegs, fuel tank, seat, fenders, and plastics removal/installation.

Procedures Included

Maintenance:

Scheduled maintenance, routine checks, lubrication points, and cleaning procedures.

Troubleshooting:

Diagnostic charts for common problems, symptoms, causes, and corrective actions.

Repair:

Detailed step-by-step instructions for component repair and replacement.

Rebuilds:

Engine and transmission rebuild procedures, including torque specifications and critical measurements.

Adjustments:

Carburetor jetting, ignition timing, clutch play, suspension settings, and throttle cable adjustment.

Technical Depth

Depth:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and chassis overhauls.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Likely, depending on the original scanning quality. Typically, official service manuals are OCR'd.

Print Quality

Print Quality:

Digital, allowing for high-resolution printing of individual pages or the entire manual.

Binding Type

Binding Type:

Not applicable (digital download)

Paper Type

Paper Type:

Not applicable (digital download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, reed valve induction, YPVS (Yamaha Power Valve System)

Displacement:

249 cc

Bore X Stroke:

66.4 mm x 72.0 mm

Compression Ratio:

8.8:1 (typical, may vary slightly by year)

Performance

Horsepower:

Approx. 45-50 HP (at crankshaft, manufacturer claims vary)

Torque:

Approx. 27-30 lb-ft (at crankshaft, manufacturer claims vary)

Fuel System

Carburetor:

Keihin PWK38S, CDI controlled YPVS

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Lubrication

Oil Mixture:

Yamalube 2R or equivalent 2-stroke oil, pre-mix ratio 50:1 (gasoline:oil)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet, multi-plate

Features

Gear Ratios:

Refer to manual for specific year/model gear ratios. Typically includes: 1st: 2.615, 2nd: 1.933, 3rd: 1.556, 4th: 1.333, 5th: 1.182, 6th: 1.000

Final Drive:

Chain drive, 520 O-ring type

Transmission Oil Type:

Yamalube Gear Oil 10W-30 or equivalent API SE, SF, SG type.

Transmission Oil Capacity:

0.75 L (0.79 US qt)

📐 Dimensions

Exterior

Length:

Approx. 81.7 inches (2075 mm)

Width:

Approx. 32.5 inches (825 mm)

Height:

Approx. 50.0 inches (1270 mm)

Wheelbase:

Approx. 57.7 inches (1465 mm)

Weights

Dry Weight:

Approx. 217 lbs (98.5 kg)

Wet Weight:

Approx. 232 lbs (105 kg) (with fluids)

Fuel Capacity:

2.4 US gal (9.0 L)

Seat Height:

Approx. 38.6 inches (980 mm)

🛡️ Safety Features

Ratings

Safety Standards:

Not applicable for competition off-road vehicles in the same way as street-legal vehicles. Designed for off-road use only.

Active Features

Braking System:

Powerful dual hydraulic disc brakes front and rear for effective stopping power.

Passive Features

Frame Strength:

Rigid aluminum frame provides stability and control.

Ergonomics:

Optimized rider triangle for control and comfort during aggressive riding.

💡 Technology Features

Infotainment

Features:

Not applicable to this competition-oriented off-road motorcycle.

Driver Assistance

Features:

Not applicable. Focus is on rider control and mechanical systems.

Connectivity

Features:

Not applicable.

Powertrain Technology

Ypvs:

Yamaha Power Valve System enhances low-to-mid range torque and broadens the powerband.

Suspension Technology

Kayaba Sss Forks:

Speed Sensitive System (SSS) forks offer superior damping characteristics and adjustability for different terrain and riding styles.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 10-15 hours of riding or annually. Refer to manual for detailed recommendations.

Air Filter Cleaning:

After every few rides or as needed depending on conditions.

Spark Plug Inspection:

Every 10-15 hours of riding.

Brake Fluid Flush:

Every 12 months or as per manual recommendations.

Suspension Service:

Fork oil change every 20-30 hours; rear shock service as needed or per manual.

Fluid Specifications

Engine Oil Premix:

Yamalube 2R or equivalent 2-stroke racing oil (50:1 ratio)

Transmission Oil:

Yamalube Gear Oil 10W-30 or equivalent API SE, SF, SG

Coolant:

Yamaha All Weather Motor Oil (liquid cooled) or equivalent permanent type anti-freeze coolant (50% mixture)

Brake Fluid:

DOT 4

Known Issues

Clutch Wear:

Can experience rapid clutch wear with aggressive use; proper adjustment and timely replacement of plates and springs are crucial.

Power Valve Sticking:

YPVS mechanism can accumulate carbon and stick if not regularly cleaned and serviced, affecting powerband.

Suspension Seals:

Fork and shock seals can degrade over time and require replacement to prevent oil leaks.

Carburetor Tuning:

Requires precise jetting and adjustment based on altitude, temperature, and riding style for optimal performance.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha has a long and successful history in motocross and off-road racing, consistently producing competitive and innovative machinery.

Model Evolution

Yz250 Lineage:

The YZ250 has been a dominant force in the 250cc 2-stroke class for decades, undergoing continuous refinement and updates.

02-08 Updates:

This generation saw significant updates including revised suspension (Kayaba SSS forks), updated styling, chassis refinements, and engine tuning improvements to maintain its competitive edge.

Production

Manufacturing Location:

Japan

Significance:

The YZ250 remains a popular choice for riders who prefer the simplicity, power, and engaging nature of a 2-stroke engine.

🏆 Awards & Recognition

Recognitions

Motocross Championships:

The YZ250 platform has been a staple in professional motocross and supercross racing for decades, accumulating numerous championship titles across various classes.

Ratings

Industry Reviews:

Consistently praised in industry reviews for its powerful engine, nimble handling, and durable construction.