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Yamaha YZ 250 2005 Motorcycle Repair Service Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Year: 2005 Motorcycle Type: Motocross Codes Engine Code: 1SC Chassis Code: 4PU 👋 Introduction Market Position Vehicle Segment: High-performance motocross motorcycle. Competitive...
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Type: Motorcycle
Vendor:
Sku: 470013
Yamaha YZ 250 2005 Motorcycle Repair Service Workshop Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ250
Year:
2005
Motorcycle Type:
Motocross
Codes
Engine Code:
1SC
Chassis Code:
4PU
👋 Introduction
Market Position
Vehicle Segment:
High-performance motocross motorcycle.
Competitive Analysis
Competitors:
Honda CR250R, KTM 250 SX, Suzuki RM250, Kawasaki KX250.
Key Features
Engine Type:
Powerful two-stroke engine renowned for its torque and throttle response.
Suspension:
Advanced Kayaba (KYB) front forks and Monocross rear suspension for superior handling.
Aluminum Frame:
Lightweight and rigid aluminum frame for enhanced agility and rider feedback.
Manual Value
Target Audience:
DIY mechanics, amateur racers, and professional technicians.
📋 Manual Details
Coverage Areas
Manual Type:
Repair Service Workshop Manual
Language:
English
Format:
Downloadable PDF
Page Count
Estimated Pages:
300+
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, tuning, carburetor, ignition system, cooling system (if applicable, though typically air-cooled for this model).
Transmission:
Clutch, gearbox disassembly, assembly, maintenance, lubrication.
Chassis:
Frame inspection, suspension (front fork, rear shock absorber), steering, swingarm, bearings.
Brakes:
Hydraulic front and rear brake systems, caliper overhaul, master cylinder, bleeding procedures, pad replacement.
Electrical:
Ignition system, lighting, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Fuel tank, fuel lines, carburetor tuning and rebuilding, fuel filter.
Exhaust System:
Pipe inspection, silencer maintenance.
Procedures Included
Maintenance:
Regular service checks, lubrication points, filter replacements, chain adjustment, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, engine misfires, electrical faults.
Repair:
Detailed step-by-step repair instructions for all major components, including engine rebuilds and suspension overhauls.
Disassembly Assembly:
Complete instructions for disassembling and reassembling various motorcycle systems.
Torquing Specifications:
Precise torque values for all critical fasteners.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics for engine performance and electrical systems.
Rebuild Procedures:
Comprehensive instructions for complete engine and transmission rebuilds.
Illustrations:
Detailed diagrams and illustrations supporting each procedure.
📊 Manual Specifications
File Format
Document Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable for offline use and hands-on work.
Print Quality
Image Resolution:
High-resolution images and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, reed valve, single-cylinder
Displacement:
249 cc
Bore X Stroke:
66.4 mm x 72.0 mm
Compression Ratio:
9.3:1 (typical, may vary slightly)
Carburetor:
Keihin PWK38S, single
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approximately 50-55 HP (estimated, at crankshaft)
Torque:
High torque output characteristic of 250cc two-strokes.
Fuel System
Fuel Type:
Unleaded gasoline, 91-98 octane recommended
Fuel Mixture:
2-stroke oil mixture (e.g., 32:1 or 40:1, consult manual for exact ratio)
Fuel Tank Capacity:
8.0 Liters (2.1 US gallons)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Refer to manual for specific gear ratios.
Transmission Fluid:
Yamalube Gear Oil or equivalent (API GL-4, SAE 80W)
📐 Dimensions
Exterior
Length:
2,170 mm (85.4 in)
Width:
825 mm (32.5 in)
Height:
1,270 mm (50.0 in)
Wheelbase:
1,475 mm (58.1 in)
Ground Clearance:
350 mm (13.8 in)
Seat Height:
990 mm (39.0 in)
Weights
Dry Weight:
98 kg (216 lbs)
Wet Weight:
106 kg (234 lbs) (approx., with all fluids)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Off-road vehicle, typically not subject to road safety standards like cars).
Active Features
Braking System:
Powerful hydraulic disc brakes front and rear for effective stopping power.
Passive Features
Ergonomics:
Designed for rider control and agility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Pure performance motocross bike, no infotainment features).
Driver Assistance
Rider Aids:
N/A (No electronic rider aids).
Connectivity
Connectivity Features:
N/A (No connectivity features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for transmission oil change intervals (typically every 10-15 hours of riding).
Air Filter Cleaning:
Frequent cleaning recommended (after every few rides, depending on conditions).
Spark Plug Replacement:
Regular inspection and replacement as needed, depending on riding style and conditions.
Top End Rebuild:
Recommended every 20-40 hours of riding for optimal performance.
Fluid Specifications
Engine Oil:
Yamalube 2-Stroke Racing Oil or equivalent JASO FD, API TC rated.
Coolant:
Not applicable (liquid-cooled engine, but coolant type and capacity are specified in the manual).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Known Issues
Carburetor Tuning:
Can be sensitive to altitude and temperature changes; requires precise jetting.
Clutch Wear:
Aggressive riding can lead to premature clutch wear; proper adjustment and fluid maintenance are key.
Suspension Maintenance:
Regular fork seal checks and oil changes are crucial for optimal performance.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha has a long and storied history in motorcycle racing, particularly in motocross, with a reputation for innovation and performance.
Model Evolution
Yz Lineage:
The YZ250 has been a dominant force in the 250cc motocross class for decades, consistently evolving with aluminum frames, advanced suspension, and potent two-stroke engines.
Production
Production Era:
The YZ250 has been in continuous production since the late 1970s, with significant updates in the early 2000s including the adoption of an aluminum frame.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motocross Accolades:
The YZ250 has historically been a class leader and a favorite among racers for its potent engine and nimble chassis.
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