Product Type:
Service Repair Manual
Applicable Years Range:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Segment:
Motocross / Off-Road Competition
Target Audience:
Motocross racers, off-road enthusiasts, mechanics
Competitors:
Honda CR250R, KTM 250 EXC, Suzuki RM250, Kawasaki KX250
Vehicle Design:
Lightweight, powerful two-stroke engine, agile handling, competition-focused chassis
Manual Benefit:
Enables owners and technicians to perform all necessary maintenance, diagnostics, and repairs to factory specifications, ensuring optimal performance and longevity.
Engine:
Top-end, Bottom-end, Cooling, Lubrication, Fuel Injection/Carburetion
Transmission:
Clutch, Gearbox Internals, Shifting Mechanism
Chassis:
Frame, Suspension (Front & Rear), Steering, Swingarm
Brakes:
Hydraulic Front & Rear Brake Systems, Calipers, Master Cylinders, Hoses
Electrical:
Ignition System, Wiring Diagrams, Lighting, CDI Unit
Bodywork And Trim:
Body panels, Seat, Handlebars, Footpegs
Maintenance:
Routine checks, Oil changes, Filter replacements, Chain adjustment, Spark plug service
Troubleshooting:
Diagnostic flowcharts, Common problem identification and solutions
Repair:
Engine rebuild, Transmission overhaul, Suspension servicing, Brake system repairs
Disassembly And Assembly:
Step-by-step instructions for major component removal and reinstallation
Technical Specifications:
Torque values, Clearances, Fluid capacities, Electrical specifications
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Engine Type:
2-Stroke, Single Cylinder, Liquid-Cooled
Bore X Stroke:
66.4 mm x 72.0 mm
Compression Ratio:
8.2:1 (typically, can vary slightly by year)
Induction:
Carburetor (e.g., Keihin PWK 38)
Ignition:
CDI (Capacitor Discharge Ignition)
Horsepower:
Approx. 45-50 HP (depending on year and tuning)
Torque:
Approx. 28-30 lb-ft (depending on year and tuning)
Fuel Type:
Unleaded Gasoline (91-98 Octane Recommended)
Fuel Oil Mixture:
50:1 ratio with high-quality 2-stroke oil
Fuel Tank Capacity:
Approx. 2.37 US gallons (9 Liters)
Overall Length:
Approx. 83.3 inches (2115 mm)
Overall Width:
Approx. 32.1 inches (815 mm)
Overall Height:
Approx. 50.2 inches (1275 mm)
Seat Height:
Approx. 39.2 inches (995 mm)
Wheelbase:
Approx. 58.1 inches (1475 mm)
Dry Weight:
Approx. 219 lbs (99.4 kg)
Wet Weight:
Approx. 234 lbs (106 kg)
Crash Test Ratings:
N/A (Motorcycle, not subject to automotive crash tests)
Braking System:
Hydraulic disc brakes front and rear
Suspension:
Adjustable front (Kayaba USD) and rear (Kayaba Monoshock) suspension for optimal control
Frame Construction:
Lightweight aluminum perimeter frame
Infotainment System:
N/A (Competition Motocross Bike)
Electronic Aids:
N/A (No electronic rider aids like traction control or ABS)
Connectivity Features:
N/A (No connectivity features)
Power Valves:
Yamaha Power Valve System (YPVS) for optimized power delivery across the rev range.
Oil Change:
Every 10-15 hours of use (or as per manual recommendations)
Air Filter Cleaning:
After every few rides, or as needed based on conditions
Spark Plug Replacement:
Every 20-30 hours of use, or as needed
Top End Rebuild:
Every 50-75 hours of hard riding (piston, rings, possibly cylinder)
Transmission Oil Capacity:
Approx. 0.75 Liters (0.80 US qt)
Coolant Type:
Pre-mixed motorcycle coolant (e.g., Yamalube Coolant, 50/50 mix)
Common Wear Items:
Piston and rings, clutch plates, wheel bearings, swingarm pivot bearings, fork seals
Potential Problems:
Overheating if coolant is low, carburetor jetting sensitivity to altitude/temperature, transmission seal leaks.
Recommended Upgrades:
Aftermarket exhaust systems, different carburetor jetting, enhanced clutch components, suspension revalving for specific rider weight/style.
Brand History:
Yamaha has a long and successful history in motorcycle racing, particularly in motocross and off-road disciplines, known for performance and innovation.
Yz250 Legacy:
The YZ250 is a legendary model in motocross, continuously refined for decades. The 2000-2009 generation represents a highly competitive and well-regarded era for the bike, focusing on power delivery, suspension performance, and chassis dynamics.
Manufacturing Location:
Japan
Motocross Wins:
The YZ250 platform has numerous professional motocross race wins and championships across various series.
Industry Reputation:
Highly regarded for its potent engine, tunable suspension, and durable chassis, making it a favorite among serious motocross and off-road riders.
Emissions Compliance:
Designed for closed-course competition use, not for street legality or EPA emissions compliance.
