🏷️ Basic Information

Make:

Yamaha

Model:

YZ250

Year:

2006

Product Name:

2006 Yamaha YZ250 Service Manual Repair

Engine Code:

YZ250K

Chassis Code:

36C

👋 Introduction

Market Segment:

Performance Motocross / Off-Road Motorcycle

Target Audience:

Motocross racers, off-road enthusiasts, mechanics, owners performing their own maintenance and repairs.

Key Competitors:

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

Vehicle Key Features:

Powerful two-stroke engine, lightweight chassis, advanced suspension, race-proven performance

Manual Key Value:

Provides essential factory specifications and procedures to maintain and repair the YZ250, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Scope:

Complete tear down and rebuild, maintenance, troubleshooting, part diagrams, torque specifications

Page Count:

269

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Engine Systems:

Engine assembly/disassembly, lubrication, cooling, fuel system (carburetor), ignition system, exhaust system, power valve system

Drivetrain Systems:

Clutch, transmission, gearbox, final drive (chain)

Suspension Systems:

Front forks (KYB SSS or similar for the era), rear shock absorber (Monocross system)

Braking Systems:

Front and rear hydraulic disc brakes, brake caliper overhaul, master cylinder service

Electrical Systems:

Ignition system, lighting, wiring diagrams, troubleshooting electrical faults

Chassis Systems:

Frame, handlebars, footpegs, seat, bodywork, plastics, subframe

Maintenance Procedures:

Pre-ride inspection, oil changes, filter cleaning/replacement, chain maintenance, spark plug service, air filter service, brake bleeding, suspension adjustments

Repair Procedures:

Engine rebuild (top end, bottom end), transmission overhaul, clutch replacement, suspension fork service and seal replacement, rear shock rebuild, brake system repair, carburetor cleaning and adjustment, power valve maintenance

Troubleshooting Procedures:

Diagnostic flowcharts for common problems, ignition issues, fuel delivery problems, starting difficulties, performance issues, suspension tuning

Installation Procedures:

Guidance for replacing key components and ensuring correct assembly

Technical Depth:

Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Includes complete disassembly, inspection, measurement, and reassembly instructions.

Special Tools:

Lists of required special tools and their applications for specific procedures.

Diagrams Illustrations:

Extensive use of exploded views, part diagrams, and step-by-step illustrations to clarify procedures.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely text-searchable for quick information retrieval.

Print Quality:

High-resolution scans for clear viewing of text and diagrams.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, 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)

Valve Mechanism:

Reed valve intake, Yamaha Power Valve System (YPVS)

Horsepower:

Approx. 48-50 HP (claimed, at crankshaft)

Torque:

Approx. 30-32 lb-ft (claimed, at crankshaft)

Carburetor Type:

Keihin PWK38S (38mm) flat slide carburetor

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Mixture:

Pre-mix (50:1 ratio with high-quality 2-stroke oil)

Engine Oil Type:

Yamalube 2R or equivalent high-performance 2-stroke racing oil

Transmission Oil Type:

Yamalube 10W-40 API SG or higher

Transmission Oil Capacity:

Approx. 0.80 liters (0.85 US qt)

🔧 Transmission

Transmission Type:

Constant-mesh, 5-speed

Clutch Type:

Wet, multiple-disc

Gear Ratios:

1st: 2.166, 2nd: 1.705, 3rd: 1.333, 4th: 1.090, 5th: 0.913 (approximate)

Clutch Actuation:

Hydraulic

📐 Dimensions

Overall Length:

2175 mm (85.6 in)

Overall Width:

825 mm (32.5 in)

Overall Height:

1280 mm (50.4 in)

Wheelbase:

1475 mm (58.1 in)

Ground Clearance:

355 mm (14.0 in)

Seat Height:

995 mm (39.2 in)

Dry Weight:

96 kg (211.6 lbs)

Wet Weight:

Approx. 107 kg (236 lbs) (with all fluids)

Fuel Tank Capacity:

8.0 liters (2.1 US gal)

Oil Tank Capacity:

0.7 liters (0.74 US qt)

🛡️ Safety Features

Safety Ratings:

N/A (Off-road vehicle, not subject to typical road safety ratings)

Active Safety Features:

Powerful hydraulic disc brakes, responsive suspension geometry

Passive Safety Features:

Robust frame construction, durable bodywork designed for off-road impact

💡 Technology Features

Infotainment System:

N/A (Performance off-road motorcycle)

Driver Assistance Features:

N/A (Performance off-road motorcycle)

Connectivity Features:

N/A (Performance off-road motorcycle)

Power Delivery:

Known for its strong mid-range and top-end powerband, characteristic of potent 250cc two-strokes.

🔧 Maintenance

Oil Change Interval:

Recommended every 10-15 hours of riding, or as per manual's specific recommendations.

Air Filter Cleaning:

Frequent cleaning, typically after every few rides, depending on conditions.

Spark Plug Replacement:

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

Top End Rebuild:

Depending on usage and riding style, a top-end rebuild (piston, rings) is often recommended between 40-60 hours for optimal performance.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment (check before every ride).

Engine Oil Spec:

Yamalube 2R or equivalent premium 2-stroke premix oil

Transmission Oil Spec:

Yamalube 10W-40 API SG or higher

Coolant Spec:

Yamaha's recommended coolant or equivalent ethylene glycol-based antifreeze mixed with distilled water (50:50 ratio)

Common Wear Items:

Piston rings, clutch plates, wheel bearings, steering head bearings, brake pads, chain and sprockets, fork seals

Power Valve Maintenance:

Carbon buildup in the power valve system can affect performance; requires periodic cleaning as outlined in the manual.

Carburetor Tuning:

May require jetting adjustments based on altitude, temperature, and modifications.

📚 Vehicle History

Yamaha Motorcycles:

Yamaha has a long and distinguished history in motorsports, particularly in motocross and off-road racing, with numerous championship wins.

Yz Series:

The YZ250 has been a staple in Yamaha's motocross lineup for decades, evolving through numerous technological advancements while retaining its core two-stroke performance identity.

2006 Updates:

The 2006 model saw refinements over previous years, potentially including updated suspension valving, carburetor tuning, and minor chassis or aesthetic changes to maintain competitiveness.

Manufacturing Location:

Japan (typical for Yamaha performance motorcycles)

🏆 Awards & Recognition

Motocross Magazine Awards:

The YZ250 platform consistently received praise and accolades from motocross publications for its performance and handling throughout its production runs.

Track Performance Rating:

Highly rated for its competitive performance on the motocross track.

Factory Certification:

This manual represents factory-certified repair information.