Now Yamaha YZ250 YZ 250 2002 02 2-STROKE Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Year: 2002 Sub Model: 2-Stroke Motocross Codes Engine Code General: 1SL (for YZ250) Chassis Code General: 5NX (for 2002 YZ250) 👋 Introduction...

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类型: Motorcycle

斯库: 245542

标签: 2002 Motorcycle Motorcycles Yamaha YZ Models YZ250

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YZ250

Year:

Sub Model:

2-Stroke Motocross

Codes

Engine Code General:

1SL (for YZ250)

Chassis Code General:

5NX (for 2002 YZ250)

👋 Introduction

Market Position

Segment:

High-performance two-stroke motocross motorcycle.

Target Audience:

Motocross racers, off-road enthusiasts, and mechanics seeking detailed repair information.

Competitive Analysis

Competitors:

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

Key Features

Engine Type:

Liquid-cooled, 2-stroke, reed valve inducted engine.

Suspension Front:

Upside-down telescopic forks (Kayaba).

Suspension Rear:

Monoshock with linkage (Monocross).

Power Delivery:

Known for its aggressive and potent powerband characteristic of 250cc two-strokes.

📋 Manual Details

Coverage Areas

Primary Coverage:

2002 Yamaha YZ250 (2-Stroke)

Secondary Coverage:

Similar years and models (explicitly mentions 1982 YZ250 availability, implying a broader range for this model family)

Page Count

Estimated Page Count:

300-400 pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, given common distribution for sales).

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and reassembly (including top-end, bottom-end, power valve system, carburetion, cooling).

Transmission:

Gearbox inspection, repair, clutch service, and gear shift mechanism.

Suspension:

Front fork (Kayaba USD), rear shock absorber (Monoshock), including oil changes, seal replacement, and valving adjustments.

Brakes:

Front and rear hydraulic disc brake systems: caliper overhaul, master cylinder service, fluid replacement, and bleeding procedures.

Electrical:

Ignition system, lighting, wiring diagrams, component testing, CDI unit, stator, and rectifier.

Fuel System:

Carburetor (likely Mikuni TMX) disassembly, cleaning, jetting, and fuel tank service.

Cooling System:

Radiator, hoses, and coolant replacement (though primarily air-cooled, some models have radiators for specific cooling assist).

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and linkage maintenance.

Wheels And Tires:

Wheel bearing maintenance, spoke tensioning, and tire replacement guidelines.

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter cleaning/replacement, chain adjustment, spark plug replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common issues, fault finding based on symptoms.

Repair:

Detailed instructions for component repair and replacement across all major systems.

Rebuilds:

Comprehensive engine and transmission rebuild procedures, including specifications for wear limits and tolerances.

Installation:

Guidance on installing aftermarket or replacement parts (e.g., exhaust systems, performance kits).

Adjustments:

Carburetor jetting, suspension sag, clutch and throttle cable free play.

Technical Depth

Depth:

In-depth coverage suitable for both intermediate home mechanics and professional technicians. Includes torque specifications, clearance measurements, and detailed diagnostic charts.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable PDF for quick information retrieval.

Printability:

Printable pages for offline use or physical reference.

Print Quality

Quality:

High-resolution scans ensuring clarity of diagrams, illustrations, and text.

Binding Type

Physical Binding:

Not applicable for digital format, but original manuals were typically saddle-stitched or perfect bound.

Paper Type

Physical Paper:

Not applicable for digital format, but original manuals used durable, glossy paper.

Completeness

Scope:

Complete factory service manual covering all aspects of the motorcycle's construction and maintenance.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc

Bore X Stroke:

66.4 mm x 72 mm

Compression Ratio:

8.2:1 (typical for this generation, confirm with manual)

Reed Valve System:

Yamaha Power Valve System (YPVS) for improved low-to-mid range power.

Performance

Horsepower Estimated:

Approx. 48-50 HP (at crankshaft, varies by tuning and exact spec)

Torque Estimated:

Approx. 28-30 lb-ft (at crankshaft)

Fuel System

Carburetor:

Mikuni TMX38S (38mm flat slide carburetor)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Mix Ratio:

50:1 (with quality 2-stroke oil, specified by Yamaha)

Lubrication

Oil Type:

Yamalube 2R (or equivalent high-quality 2-stroke racing oil)

Ignition

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate, cable-actuated

Features

Gear Ratios:

Specific gear ratios are detailed in the manual (e.g., 1st: 2.5, 2nd: 1.75, 3rd: 1.4, 4th: 1.16, 5th: 1.0).

Final Drive:

Chain drive (specific pitch and length in manual)

📐 Dimensions

Exterior

Length:

Approx. 2160 mm (85.0 in)

Width:

Approx. 825 mm (32.5 in)

Height:

Approx. 1275 mm (50.2 in)

Wheelbase:

Approx. 1475 mm (58.1 in)

Ground Clearance:

Approx. 355 mm (14.0 in)

Weights

Dry Weight:

Approx. 98 kg (216 lbs)

Fuel Tank Capacity:

8.0 Liters (2.1 US gal)

🛡️ Safety Features

Ratings

Crash Safety:

N/A for motocross bikes; designed for off-road competition use.

Active Features

Brakes:

Powerful hydraulic disc brakes front and rear for effective stopping power.

Ergonomics:

Designed for rider control and maneuverability in racing conditions.

Passive Features

Frame Construction:

Strong perimeter frame for chassis rigidity and handling.

Handguards:

Standard inclusion of handguards to protect levers and hands.

💡 Technology Features

Infotainment

Features:

N/A for this model; focus is on pure performance and rider interaction.

Driver Assistance

Features:

N/A; no electronic rider aids on this model.

Connectivity

Features:

Performance Enhancements

Ypvs:

Yamaha Power Valve System (YPVS) integrated into the exhaust port for improved torque and power delivery.

🔧 Maintenance

Service Intervals

Oil Change Engine:

As per manual, typically after every few race weekends or specified hours of use. Transmission oil service at regular intervals.

Air Filter Cleaning:

Frequent cleaning/replacement, especially after dusty riding conditions.

Spark Plug Replacement:

Regular replacement, typically every 20-40 hours of use, depending on riding style.

Top End Rebuild:

Recommended every 30-50 hours of racing use, depending on conditions and tuning.

Fluid Specifications

Transmission Oil:

Yamalube Gear Oil (or equivalent SAE 80 hypoid gear oil).

Coolant:

Yamaha-specific coolant or a high-quality ethylene glycol-based antifreeze mixed with distilled water (50/50).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Fork Oil:

Specific viscosity (e.g., Yamalube Fork Oil 01 or equivalent SAE 5W-10W) and quantity detailed in the manual.

Known Issues

Power Valve Sticking:

Carbon buildup can cause the YPVS to stick, requiring periodic cleaning and lubrication.

Clutch Wear:

Clutch plates can wear over time, especially under hard riding conditions; requires regular inspection and replacement.

Carburetor Tuning:

Requires precise jetting and tuning for optimal performance across various altitudes and temperatures.

Suspension Seals:

Fork and shock seals can degrade over time, leading to leaks and requiring replacement.

📚 Vehicle History

Brand Heritage

Legacy:

Yamaha has a long and storied history in motocross, with the YZ line being a dominant force for decades.

Model Evolution

Yz Development:

The YZ250 has undergone continuous evolution, with the 2002 model representing a refinement of the popular '90s and early 2000s platform.

Key Changes 2002:

Minor refinements over the 2001 model, potentially including revised suspension settings or chassis tweaks for improved handling.

Production

Production Era:

YZ250 lineage spans from the 1970s to the present, with this 2002 model being part of the highly regarded liquid-cooled era.

🏆 Awards & Recognition

Recognitions

Motocross Status:

The YZ250 line has consistently been a top contender and popular choice in professional and amateur motocross circuits for decades, earning numerous accolades over its history.