Now Yamaha YZ250 YZ 250 1999 99 2-STROKE Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Year: 1999 Engine Type: 2-Stroke Product Name: Now Yamaha YZ250 YZ 250 1999 99 2-STROKE Service Repair Workshop Manual 👋 Introduction Market...

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Mots clés: 1999 Motorcycle Motorcycles Yamaha YZ Models YZ250

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YZ250

Year:

Engine Type:

2-Stroke

Product Name:

Now Yamaha YZ250 YZ 250 1999 99 2-STROKE Service Repair Workshop Manual

👋 Introduction

Market Position

Segment:

High-performance motocross motorcycle, competitive within the 250cc two-stroke class of its era.

Competitive Analysis

Competitors:

Competed directly with models like the Honda CR250R, Kawasaki KX250, and Suzuki RM250.

Key Features

Features:

Renowned for its potent powerband, agile handling, and robust Yamaha build quality. The 1999 model represented an evolution of Yamaha's successful YZ platform.

📋 Manual Details

Coverage Areas

Coverage:

Complete service, repair, and workshop information for the 1999 Yamaha YZ250. Also compatible with similar year models within the YZ250 lineage.

Page Count

Pages:

Estimated 300-400 pages (typical for a comprehensive workshop manual of this era).

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF inferred from online sales, but physical copies exist)

📖 Manual Coverage

Systems Covered

Engine:

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

Transmission:

Gearbox inspection, repair, clutch service, and lubrication procedures.

Cooling System:

Radiator, hoses, water pump, and coolant specifications and servicing (though YZ250 is typically liquid-cooled).

Fuel System:

Carburetor (Mikuni VM series typical) disassembly, cleaning, adjustment, and jetting information. Fuel tank and petcock service.

Ignition System:

CDI ignition system, spark plug selection, troubleshooting, and stator/coil testing.

Exhaust System:

Exhaust pipe and silencer maintenance, decarbonizing, and installation.

Suspension Front:

Kayaba (KYB) front fork service, including oil type, level, seal replacement, and damping adjustments.

Suspension Rear:

Monocross rear shock absorber service, including spring preload, damping adjustments, and rebuild procedures.

Brakes Front:

Hydraulic front brake system service, including caliper, master cylinder, and brake fluid replacement.

Brakes Rear:

Hydraulic rear brake system service, including caliper, master cylinder, and brake fluid replacement.

Wheels And Tires:

Spoke tightening, hub maintenance, tire pressure, and recommended tire sizes.

Electrical System:

Basic lighting circuit (if applicable), wiring diagrams, and troubleshooting of electrical components.

Frame And Bodywork:

Chassis inspection, swingarm lubrication, seat removal, and plastics maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter cleaning/replacement, chain adjustment, spark plug checks, and general lubrication.

Engine Rebuild:

Complete engine overhaul, including piston replacement, ring gap, cylinder inspection, and crankshaft service.

Suspension Tuning:

Adjustment of compression, rebound, and preload for optimal performance based on riding conditions.

Carburetor Tuning:

Jetting changes for altitude and temperature variations, idle speed adjustment.

Troubleshooting:

Systematic diagnosis of common problems, including starting issues, poor running, and component failures.

Component Replacement:

Detailed instructions for replacing wear items and specific components like bearings, seals, cables, and levers.

Torque Specifications:

Precise torque values for all critical fasteners, essential for correct assembly and preventing damage.

Technical Depth

Depth:

Comprehensive, covering everything from basic rider maintenance to full engine and suspension rebuilds.

📊 Manual Specifications

File Format

Format:

Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature of quality digital manuals.

Print Quality

Quality:

High-resolution scans/reproductions of original factory documentation, ensuring clarity of diagrams and text.

Binding Type

Binding:

If physical: Spiral-bound for lay-flat use in a workshop environment.

Paper Type

Paper:

If physical: Durable, often glossy paper to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Code:

Likely 4SS or similar Yamaha designation for the YZ250 engine (specific code not provided but discoverable within the manual).

Displacement:

249cc

Bore X Stroke:

66.4 mm x 72.0 mm (typical for this generation YZ250)

Compression Ratio:

Approximately 8.8:1 (may vary slightly based on tuning and specific model details within the manual).

Engine Layout:

Single-cylinder, liquid-cooled, 2-stroke, reed valve induction.

Power Output:

Estimated 45-50 HP (peak, at the crankshaft - specific figures will be in the manual).

Torque:

Estimated 28-30 lb-ft (peak, at the crankshaft - specific figures will be in the manual).

Performance

Ignition Timing:

Specific BTDC (Before Top Dead Center) values will be detailed for various RPM ranges.

Spark Plug Gap:

Typically 0.6 - 0.7 mm (e.g., NGK BR9ES or equivalent, specific part number in manual).

Fuel System

Carburetor Model:

Mikuni VM38SS (typical for this model, specific part number will be confirmed in the manual).

Fuel Type:

Unleaded gasoline, 91 octane (octane rating may be adjusted based on tuning).

Premix Ratio:

Typically 32:1 or 50:1 (Yamalube 2R or equivalent 2-stroke oil, specified in manual).

🔧 Transmission

Standard

Type:

5-speed constant mesh sequential manual transmission.

Clutch Type:

Wet, multiple-disc, cable-operated.

Gear Ratios:

Specific ratios for 1st through 5th gear and final drive will be listed in the manual.

Features

Lubrication:

Transmission oil type and capacity (e.g., Yamalube Gear Oil or equivalent SAE 80/90, specific API GL-4 specification).

📐 Dimensions

Exterior

Overall Length:

Approximately 83.7 inches (2125 mm).

Overall Width:

Approximately 32.3 inches (820 mm).

Overall Height:

Approximately 50.6 inches (1285 mm).

Wheelbase:

Approximately 58.1 inches (1475 mm).

Ground Clearance:

Approximately 13.2 inches (335 mm).

Weights

Dry Weight:

Approximately 227 lbs (103 kg).

Wet Weight:

Will be higher due to fluids, exact figure not specified but typical for class.

Fuel Capacity:

8.0 Liters (2.1 US gal).

Coolant Capacity:

Approximately 0.7 Liters (0.74 US qt).

Transmission Oil Capacity:

Approximately 0.8 Liters (0.85 US qt).

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable for off-road motorcycles; focus is on rider protection and machine integrity.

Active Features

Braking System:

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

Suspension Performance:

High-quality Kayaba suspension components designed for excellent control and rider feedback.

Passive Features

Frame Construction:

Durable aluminum alloy frame designed for strength and rigidity.

Ergonomics:

Designed for optimal rider positioning and control during demanding off-road riding.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable; this is a performance motocross motorcycle focused on functionality.

Driver Assistance

Driver Assistance Features:

Not applicable.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Transmission oil to be checked regularly and changed per riding hours or annually. Engine oil is mixed with fuel.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (typically every few rides).

Chain Lubrication Adjustment:

Lubricate chain every 500 km (300 miles) or more frequently based on riding conditions. Adjust tension as needed (typically 10-20 mm slack).

Spark Plug Replacement:

Inspect every 1000 km (600 miles), replace as needed or per manual's recommendation.

Piston Ring Replacement:

Recommended every 300-500 hours of operation or based on performance degradation, as detailed in the manual.

Top End Rebuild:

Full top-end rebuild (piston, rings, gasket) often recommended every 100-200 hours of aggressive use.

Fluid Specifications

Transmission Fluid:

Yamalube Gear Oil SAE 80 API GL-4 or equivalent.

Coolant:

Permanent type antifreeze coolant (ethylene glycol based) mixed with distilled water (50/50 ratio), or specific Yamaha coolant.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

2-Stroke Oil:

Yamalube 2R or equivalent high-performance 2-stroke injector oil.

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, swingarm bushings, and suspension seals are common wear items that require regular inspection and replacement.

Carburetor Cleaning:

The Mikuni carburetor can be prone to clogging from debris or stale fuel, requiring regular cleaning and proper fuel storage practices.

Suspension Seals:

Front fork seal leaks are common due to the demanding nature of off-road riding; the manual provides replacement procedures.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha has a long and storied history in motocross and off-road racing, known for innovation and performance.

Model Evolution

Evolution:

The YZ250 has been a cornerstone of Yamaha's motocross lineup for decades, with continuous improvements in engine technology, chassis design, and suspension.

Production

Production Years:

The YZ250 has been in continuous production for many years, with the 1999 model representing a significant iteration in its development.

🏆 Awards & Recognition

Recognitions

Motocross Awards:

While specific awards for the '99 model aren't detailed here, the YZ250 platform has historically been a championship-winning machine across various racing disciplines.

Ratings

Editorial Ratings:

Contemporary reviews often lauded the YZ250 for its potent engine and well-balanced chassis, contributing to its strong market presence.