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Yamaha YZ 250 1994 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Year: 1994 Type: Motorcycle Category: Dirt Bike / Motocross Codes Chassis Code: 4JW 👋 Introduction Market Position Segment: High-performance 250cc motocross Target...
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZ250
Year:
1994
Type:
Motorcycle
Category:
Dirt Bike / Motocross
Codes
Chassis Code:
4JW
👋 Introduction
Market Position
Segment:
High-performance 250cc motocross
Target Audience:
Motocross racers, performance enthusiasts, mechanics
Competitive Analysis
Key Competitors 1994:
Honda CR250R, Kawasaki KX250, Suzuki RM250
Key Features
Performance Focus:
Renowned for its potent 2-stroke powerband and agile handling
Engine Type:
Liquid-cooled, reed-valve induction, 2-stroke
Suspension Design:
Advanced KYB suspension for superior control and comfort
📋 Manual Details
Coverage Areas
Primary Focus:
Service, Repair, Workshop
Engine Coverage:
Complete overhaul, tuning, lubrication, cooling system
Transmission Coverage:
Clutch, gearbox, final drive maintenance and repair
Chassis Coverage:
Frame, suspension (front and rear), steering, wheels, brakes
Electrical Coverage:
Ignition system, lighting, wiring diagrams, troubleshooting
Bodywork Coverage:
Fuel tank, seat, fenders, plastics, graphics
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Top end (cylinder, piston, rings, head), bottom end (crankshaft, bearings, seals)
Fuel System:
Carburetor (VM26SS type), fuel lines, fuel tank maintenance
Ignition System:
CDI (Capacitor Discharge Ignition), spark plug specifications, timing
Cooling System:
Air-cooled system, heat dissipation analysis
Exhaust System:
Expansion chamber, muffler maintenance and inspection
Suspension Front:
KYB 43mm conventional forks, oil levels, seal replacement, damping adjustment
Suspension Rear:
Monocross (linkage-driven) rear suspension, shock absorber service, spring preload adjustment
Brakes Front:
Hydraulic disc brake, caliper service, pad replacement, fluid bleeding
Brakes Rear:
Hydraulic disc brake, caliper service, pad replacement, fluid bleeding
Wheels And Tires:
Spoke inspection, rim service, tire pressure, replacement
Steering:
Headset bearing service, steering stem adjustments
Electrical Components:
Magneto, rectifier/regulator, lighting coils
Procedures Included
Maintenance:
Regular checks, lubrication points, filter cleaning/replacement, chain adjustment
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues
Engine Rebuild:
Complete engine disassembly, inspection, component replacement, reassembly torque specifications
Carburetor Service:
Disassembly, cleaning, jetting adjustments, float height settings
Suspension Service:
Fork seal replacement, fork oil changes, shock absorber fluid replacement
Brake System Service:
Brake pad replacement, brake fluid flush and bleed, caliper maintenance
Electrical Diagnostics:
Wiring diagram interpretation, component testing (e.g., CDI, stator, coil)
Wheel And Tire Service:
Tire mounting/dismounting, spoke tensioning
Technical Depth
Diagnostic Capability:
Advanced diagnostics for engine performance and electrical systems
Rebuild Capability:
Comprehensive procedures for complete engine and transmission rebuilds
Specifications Detail:
Detailed torque specifications, clearances, fluid capacities, and wear limits
Diagrams Illustrations:
Clear, step-by-step diagrams and illustrations for all procedures
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality:
High-resolution for clear viewing and printing
Print Quality
Image Clarity:
Crisp and detailed images and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
Single-cylinder, 2-stroke
Displacement:
249 cc
Bore X Stroke:
67.0 mm x 70.0 mm
Compression Ratio:
7.6:1 (Nominal)
Cooling System:
Liquid-cooled
Induction System:
Reed valve
Performance
Horsepower:
~47-49 HP (Est. at Crank)
Torque:
~27-29 lb-ft (Est. at Crank)
Fuel System
Carburetor Model:
Keihin VM26SS
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Mixing:
Pre-mix (100:1 ratio recommended in manual for optimum performance and longevity)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch Type:
Wet, multi-disc, cable-actuated
Features
Final Drive:
Chain drive (520 pitch)
Gear Ratios:
1st: 2.538, 2nd: 1.875, 3rd: 1.500, 4th: 1.250, 5th: 1.045
Transmission Oil Type:
Yamalube 2-stroke engine oil (or equivalent API-SE, JASO-FB or higher)
Transmission Oil Capacity:
0.65 Liters (0.69 US qt)
📐 Dimensions
Exterior
Length:
2,160 mm (85.0 in)
Width:
825 mm (32.5 in)
Height:
1,250 mm (49.2 in)
Wheelbase:
1,460 mm (57.5 in)
Ground Clearance:
330 mm (13.0 in)
Seat Height:
975 mm (38.4 in)
Weights
Dry Weight:
100 kg (220.5 lbs)
Wet Weight:
~108 kg (238 lbs) (Est. with fluids)
Fuel Tank Capacity:
8.0 Liters (2.1 US gal)
Wheels And Tires
Front Tire Size:
80/100-21 51M
Rear Tire Size:
100/90-19 57M
Front Wheel Size:
21 x 1.60
Rear Wheel Size:
19 x 2.15
🛡️ Safety Features
Ratings
Safety Certification:
Not Applicable (Off-road vehicle)
Active Features
Braking System:
Powerful hydraulic disc brakes front and rear for decisive stopping power.
Suspension Performance:
KYB suspension designed to absorb impacts and maintain tire contact for control.
Passive Features
Frame Construction:
Durable steel frame designed for rigidity and rider feedback.
Ergonomics:
Motocross-specific riding position for optimal rider control and weight distribution.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Performance Motocross Motorcycle)
Driver Assistance
Electronic Aids:
N/A (No electronic rider aids present)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15-20 hours of riding, or annually
Air Filter Cleaning:
After every few rides, or as needed based on conditions
Spark Plug Inspection:
Every 10-15 hours of riding
Chain Lubrication Adjustment:
Every 5-10 hours of riding
Fluid Specifications
Engine Oil Premix:
Yamalube 2-stroke oil (or equivalent API-SE, JASO-FB or higher) at 100:1 ratio
Fork Oil Type:
SAE 0W-20 or SAE 5W (refer to manual for specific viscosity recommendations)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant Type:
Distilled water and Yamaha's recommended anti-freeze (50/50 mix)
Known Issues
Common Wear Items:
Piston rings, clutch plates, brake pads, fork seals, swingarm bearings
Engine Performance Tips:
Proper jetting for atmospheric conditions and exhaust modifications is crucial for optimal power delivery.
Suspension Tuning Notes:
Fork and shock settings can be adjusted to suit rider weight and track conditions.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha has a long and successful history in motocross, with the YZ line being a cornerstone of their off-road performance.
Model Evolution
Yz250 Lineage:
The YZ250 has been a dominant force in the 250cc motocross class for decades, constantly evolving with technological advancements.
1994 Updates:
The 1994 model saw refinements in suspension, engine tuning, and chassis geometry to maintain its competitive edge.
Production
Manufacturing Country:
Japan
🏆 Awards & Recognition
Recognitions
Motocross Class Performance:
The YZ250 series has consistently been recognized as a top contender in the 250cc motocross class throughout its production.