Yamaha YZ250 YZ 250 2007 07 2-STROKE Repair Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Model Designation: YZ250 Generation Generation Identifier: Second Generation (2002-2011) Codes Product Code Reference: YZ250 2007 07 👋 Introduction Market Position Vehicle Category:...

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Type: Motorcycle

Vendor:

Sku: 468924

Tags: 2007 Motorcycle Motorcycles Yamaha YZ Models YZ250

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YZ250

Model Designation:

YZ250

Generation

Generation Identifier:

Second Generation (2002-2011)

Codes

Product Code Reference:

YZ250 2007 07

👋 Introduction

Market Position

Vehicle Category:

Motocross / Off-Road Motorcycle

Target Audience:

Enthusiast riders, amateur racers, and DIY mechanics seeking to maintain, repair, and optimize their Yamaha YZ250.

Competitive Analysis

Key Competitors Era:

Honda CR250R, Kawasaki KX250, KTM 250 SX

Key Features

Vehicle Reputation:

Renowned for its powerful 2-stroke engine, agile handling, and competitive performance in motocross and off-road racing.

Manual Value Proposition:

Provides essential, detailed information for maintaining peak performance and addressing potential issues, saving time and money on repairs.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital Download (Printable)

Page Count

Estimated Page Count:

Manual Type

Content Type:

Service and Repair Manual

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine disassembly, inspection, repair, and reassembly for the 2-stroke powerplant, including top-end, bottom-end, cooling system, and lubrication.

Fuel System:

Carburetor overhaul and adjustment (Mikuni VM38), fuel tank inspection, fuel line maintenance, and fuel pump (if applicable to model variant).

Transmission:

Clutch operation, gearbox inspection, gear shifting mechanism, and lubrication system for the transmission.

Drivetrain:

Chain and sprocket inspection, adjustment, and replacement; rear wheel hub and bearing service.

Suspension:

Front fork (Kayaba USD) disassembly, service, and fluid replacement; rear shock absorber (Monoshock) inspection, adjustment, and rebuild; linkage and swingarm bearing service.

Brakes:

Front and rear hydraulic disc brake system service, including caliper overhaul, pad replacement, fluid flush and bleed, master cylinder inspection, and rotor maintenance.

Electrical System:

Ignition system (CDI), lighting circuits, wiring diagrams, battery maintenance, charging system, and troubleshooting for electrical components.

Cooling System:

Radiator inspection and cleaning, coolant specifications and replacement, hoses, and thermostat operation.

Frame And Bodywork:

Chassis inspection, frame integrity, body panel removal and installation, seat, handlebars, and footpeg service.

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire inspection and replacement, and rim maintenance.

Procedures Included

Routine Maintenance:

Oil changes (2-stroke premix ratios), air filter cleaning and oiling, chain lubrication and adjustment, spark plug inspection and replacement, and general bolt torque checks.

Troubleshooting:

Diagnostic procedures for common running issues, ignition problems, fueling issues, and electrical faults with step-by-step guides.

Engine Rebuild:

Detailed instructions for piston and ring replacement, cylinder inspection and potential replating/boring, crankshaft and connecting rod bearing service, and gasket replacement.

Suspension Tuning:

Adjustments for compression and rebound damping, sag settings, and fork oil level and weight recommendations.

Brake Bleeding:

Proper procedure for hydraulic brake system fluid replacement and air removal.

Carburetor Jetting:

Guidance on adjusting carburetor jetting for different altitudes, temperatures, and modifications.

Wiring Diagram Interpretation:

Detailed wiring schematics for easy identification of electrical components and troubleshooting.

Technical Depth

Depth Level:

Comprehensive from basic maintenance to complete engine and component overhauls, suitable for both home mechanics and professional technicians.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Printability:

High-quality, printable from any computer for on-demand hard copies.

Binding Type

Binding Type If Printed:

Not Applicable (Digital Download)

Paper Type

Paper Type If Printed:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, Liquid-cooled, Reed Valve, Case-reed induction

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

66.4 mm x 72.0 mm (2.61 x 2.83 in)

Compression Ratio:

9.1:1

Cylinder Material:

Aluminum alloy, SCEM plated

Performance

Horsepower Estimate:

Approx. 45-50 HP (at crankshaft, depending on tuning and exhaust)

Torque Estimate:

Approx. 30-33 lb-ft (at crankshaft)

Fuel System

Carburetor Model:

Mikuni VM38SS

Carburetor Jetting Stock:

Specific jetting details provided within the manual for various conditions.

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Premix Ratio:

50:1 (Yamalube 2R or equivalent high-quality 2-stroke oil recommended)

Cooling System

Cooling Method:

Liquid-cooled

Coolant Capacity:

Approx. 0.75 liters

Coolant Type:

Yamaha Super Coolant or equivalent high-quality ethylene glycol-based coolant

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

Yamalube Gear Oil 10W-30 or equivalent SAE 80 hypoid gear oil

Transmission Oil Capacity:

Approx. 1.0 liter

📐 Dimensions

Exterior

Overall Length:

2180 mm (85.8 in)

Overall Width:

825 mm (32.5 in)

Overall Height:

1285 mm (50.6 in)

Seat Height:

995 mm (39.2 in)

Wheelbase:

1475 mm (58.1 in)

Ground Clearance:

355 mm (14.0 in)

Weights

Wet Weight:

Approx. 103 kg (227 lbs)

Fuel Capacity:

8.0 liters (2.1 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable for off-road competition motorcycles in the same way as street-legal vehicles. Focus is on performance and rider control.

Active Features

Braking System:

Hydraulic disc brakes front and rear for powerful and responsive stopping.

Suspension Performance:

Advanced Kayaba suspension designed for optimal control and bump absorption in aggressive riding conditions.

Passive Features

Frame Construction:

Lightweight and rigid aluminum alloy frame for chassis stability and rider feedback.

💡 Technology Features

Infotainment

Instrumentation:

Basic analog odometer, trip meter, and engine hour meter; indicator lights for neutral, low oil pressure (if applicable to specific market variant), and turn signals (if equipped).

Driver Assistance

Rider Aids:

None (This is a pure performance-oriented motocross machine, designed for rider input).

Connectivity

Electronic Features:

Focus is on mechanical and electrical systems for engine ignition and lighting, not integrated electronic rider aids or connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Recommended after every 10-20 hours of riding or annually, whichever comes first, for transmission oil. 2-stroke oil premix is constant during operation.

Air Filter Cleaning:

Recommended after every 5-10 hours of riding, or more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 20-30 hours of riding or as needed based on inspection.

Top End Rebuild:

Recommended every 40-60 hours of aggressive riding for optimal performance (piston, rings, small end bearing).

Fluid Specifications

Brake Fluid:

DOT 4 hydraulic brake fluid

Fork Oil Type:

Specific Kayaba fork oil weight (e.g., 01 or G10S) and level detailed in manual.

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, steering head bearings, swingarm bearings, and suspension seals.

Carburetor Tuning:

Sensitivity to altitude and temperature changes can require re-jetting for optimal performance.

Exhaust Power Valve:

The power valve mechanism can accumulate carbon and require periodic cleaning and lubrication for proper operation.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Yamaha Motor Corporation has a long and successful history in motorcycle manufacturing, particularly in off-road and racing disciplines.

Model Evolution

Yz250 Lineage:

The YZ250 is a legendary model with a lineage dating back decades, consistently evolving to remain competitive in the 250cc two-stroke class.

2007 Model Updates:

The 2007 YZ250 received various refinements, often including revised suspension settings, updated graphics, and minor engine tuning improvements over previous years.

Production

Production Era:

Continuous production since the 1970s, with significant updates in the second generation (2002-2011) and ongoing refinements.

🏆 Awards & Recognition

Recognitions

Motocross Legacy:

The YZ250 platform has a storied history of success in professional motocross and supercross racing, earning numerous championships.

Ratings

Industry Reviews:

Consistently praised by automotive media for its potent engine, sharp handling, and the enduring appeal of its 2-stroke character.