🏷️ Basic Information

Make:

Yamaha

Model:

YZ 250

Product Type:

Service Repair Manual

Applicable Years Range:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

👋 Introduction

Segment:

Motocross / Off-Road Competition

Target Audience:

Motocross racers, off-road enthusiasts, mechanics

Competitors:

Honda CR250R, KTM 250 EXC, Suzuki RM250, Kawasaki KX250

Vehicle Design:

Lightweight, powerful two-stroke engine, agile handling, competition-focused chassis

Manual Benefit:

Enables owners and technicians to perform all necessary maintenance, diagnostics, and repairs to factory specifications, ensuring optimal performance and longevity.

📋 Manual Details

Primary Focus:

Service, Repair, Maintenance, Troubleshooting

Estimated Pages:

300+

Type:

Factory Service Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Top-end, Bottom-end, Cooling, Lubrication, Fuel Injection/Carburetion

Transmission:

Clutch, Gearbox Internals, Shifting Mechanism

Chassis:

Frame, Suspension (Front & Rear), Steering, Swingarm

Brakes:

Hydraulic Front & Rear Brake Systems, Calipers, Master Cylinders, Hoses

Electrical:

Ignition System, Wiring Diagrams, Lighting, CDI Unit

Bodywork And Trim:

Body panels, Seat, Handlebars, Footpegs

Maintenance:

Routine checks, Oil changes, Filter replacements, Chain adjustment, Spark plug service

Troubleshooting:

Diagnostic flowcharts, Common problem identification and solutions

Repair:

Engine rebuild, Transmission overhaul, Suspension servicing, Brake system repairs

Disassembly And Assembly:

Step-by-step instructions for major component removal and reinstallation

Technical Specifications:

Torque values, Clearances, Fluid capacities, Electrical specifications

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

📊 Manual Specifications

File Type:

PDF

Resolution:

High-resolution, clear images and text

Searchability:

Searchable text for quick information retrieval

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness:

Complete Factory Service Manual

⚙️ Engine Specifications

Engine Type:

2-Stroke, Single Cylinder, Liquid-Cooled

Bore X Stroke:

66.4 mm x 72.0 mm

Displacement:

249 cc

Compression Ratio:

8.2:1 (typically, can vary slightly by year)

Induction:

Carburetor (e.g., Keihin PWK 38)

Ignition:

CDI (Capacitor Discharge Ignition)

Horsepower:

Approx. 45-50 HP (depending on year and tuning)

Torque:

Approx. 28-30 lb-ft (depending on year and tuning)

Fuel Type:

Unleaded Gasoline (91-98 Octane Recommended)

Fuel Oil Mixture:

50:1 ratio with high-quality 2-stroke oil

Fuel Tank Capacity:

Approx. 2.37 US gallons (9 Liters)

🔧 Transmission

Transmission Type:

5-Speed Manual

Optional Gearboxes:

N/A (Standard 5-speed)

Clutch Type:

Wet, Multi-plate

Transmission Oil Type:

Yamalube 10W-30 or equivalent (check manual for specific part number like 90793-28018-00)

📐 Dimensions

Overall Length:

Approx. 83.3 inches (2115 mm)

Overall Width:

Approx. 32.1 inches (815 mm)

Overall Height:

Approx. 50.2 inches (1275 mm)

Seat Height:

Approx. 39.2 inches (995 mm)

Wheelbase:

Approx. 58.1 inches (1475 mm)

Dry Weight:

Approx. 219 lbs (99.4 kg)

Wet Weight:

Approx. 234 lbs (106 kg)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle, not subject to automotive crash tests)

Braking System:

Hydraulic disc brakes front and rear

Suspension:

Adjustable front (Kayaba USD) and rear (Kayaba Monoshock) suspension for optimal control

Frame Construction:

Lightweight aluminum perimeter frame

💡 Technology Features

Infotainment System:

N/A (Competition Motocross Bike)

Electronic Aids:

N/A (No electronic rider aids like traction control or ABS)

Connectivity Features:

N/A (No connectivity features)

Power Valves:

Yamaha Power Valve System (YPVS) for optimized power delivery across the rev range.

🔧 Maintenance

Oil Change:

Every 10-15 hours of use (or as per manual recommendations)

Air Filter Cleaning:

After every few rides, or as needed based on conditions

Spark Plug Replacement:

Every 20-30 hours of use, or as needed

Top End Rebuild:

Every 50-75 hours of hard riding (piston, rings, possibly cylinder)

Transmission Oil Capacity:

Approx. 0.75 Liters (0.80 US qt)

Coolant Type:

Pre-mixed motorcycle coolant (e.g., Yamalube Coolant, 50/50 mix)

Common Wear Items:

Piston and rings, clutch plates, wheel bearings, swingarm pivot bearings, fork seals

Potential Problems:

Overheating if coolant is low, carburetor jetting sensitivity to altitude/temperature, transmission seal leaks.

Recommended Upgrades:

Aftermarket exhaust systems, different carburetor jetting, enhanced clutch components, suspension revalving for specific rider weight/style.

📚 Vehicle History

Brand History:

Yamaha has a long and successful history in motorcycle racing, particularly in motocross and off-road disciplines, known for performance and innovation.

Yz250 Legacy:

The YZ250 is a legendary model in motocross, continuously refined for decades. The 2000-2009 generation represents a highly competitive and well-regarded era for the bike, focusing on power delivery, suspension performance, and chassis dynamics.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Motocross Wins:

The YZ250 platform has numerous professional motocross race wins and championships across various series.

Industry Reputation:

Highly regarded for its potent engine, tunable suspension, and durable chassis, making it a favorite among serious motocross and off-road riders.

Emissions Compliance:

Designed for closed-course competition use, not for street legality or EPA emissions compliance.