Yamaha YZ250F(R) Manuale utente

YZ250FR

5UL-28107-10

ASSEMBLY MANUAL

LIT-11666-16-39

YZ250FR

ASSEMBLY MANUAL

First Edition, August 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11666-16-39

EAA00002

FOREWORD

This Assembly Manual contains the information required for the correct reassembly of this Yamaha

machine prior to delivery to the customer. Since some external parts of the machine have been

removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is

required. It should be noted that the assembled machine should be thoroughly cleaned, inspected, and

adjusted prior to delivery to the customer.

EAA00005

NOTICE

The service specifications given in this assembly manual are based on the model as manufactured.

Yamaha Motor Company, Ltd. is continually striving to improve all of its model. Modifications and signifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will

appear in future editions of this manual where applicable.

The procedures below are described in the order that the procedures are carried out correctly and com-

pletely. Failure to do so can result in poor performance and possible harm to the machine and/or rider.

wFailure to follow WARNING instructions could result in severe injury or death to

the machine operator, a bystander, or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid damage to

the machine.

CAUTION:

A NOTE provides key information to make procedures easier or clearer.NOTE:

CONCERNING CRATE DAMAGE:

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED!

Particularly important information is distinguished in this manual by the following notations.

EAA00001

EAA00008

SYMBOLS USED IN

ASSEMBLY MANUAL

In order to simplify descriptions in this

assembly manuals, the following symbols

are used:

(1) Coat with lithium-soap-based-grease.

(2) Tighten to 10 Nm.

(10 Nm = 1.0mdkg = 7.2 ftdlb)

(3) Towards the front of the machine.

(4) Clearance required.

(5) Install so that the arrow mark faces

upward.

(6) Apply a motor oil.

(7) Made of rubber or plastics.

(8)

A: Ref No. (indicating the order of opera-

tions.)

B: Part name

C: Quantity of parts per machine.

D: Place where parts are held.

V: Stored in vinyl bag.

C: Stored in carton box.

S: Fixed inside the steel frame,

and/or contained in the styrofoam

tray (upper or lower).

*: Temporarily installed or secured.

E: Size or material of parts.

d/D: Diameter of part.

l: Length of part.

ex, D = 5 (0.2) = 5mm (0.2 in)

(1) (2)

(3) (4)

(5) (6)

(7)

(8)

(1) (2)

(3) (4)

EAA00040

PREPARATION

To assemble the machine correctly, sup-

plies (e.g. oils, greases, and shop rags) and

sufficient working space are required.

Workshop

The workshop where the machine is assem-

bled, should be clean, specious, and have a

level floor.

Self-protection

Protect your eyes with suitable safety glass-

es or goggles when using compressed air,

when grinding or when doing any operation

which may cause particles to fly off.

Protect hands and feet by wearing safety

gloves and shoes.

EAA00050

SYMBOLS USED ON

CRATE CARTON

(1) Contents of the transport package are frag-

ile, therefore the package must be handled

with care.

(2) Indicates correct upright position of the

transport package.

(3) Transport package must be kept away

from rain.

(4) Insertion of the forklift arm from this side

will cause damage.

(5) Yellow label

Lift arm insertion position

If the forklift arms cannot be inserted

under the transport package in align-

ment with the two yellow labels, adjust

the arms so that they are positioned

evenly in relation to these marks while

taking care not to damage the package

contents.

(5) (5)

EAA00060

UNPACKING

1. Remove the frame cover (1).

NOTE:

To remove the frame cover, cut the vinyl

bands around the cover using a cutter or

scissors.

2. Remove the carton boxes (2), front tire

(3).

3. Remove the packing frame bolt (4), and

handlebar holder bolts (5).

4. Remove the packing frames (in order of

sideways (6), upward (7), and front/back

(8)).

NOTE:

Hold the frame while removing the frame

bolts.

5. Remove the bolts (9). (front axle fixed

plate (10)).

NOTE:

Before starting the assembly, check for

damaged or missing parts. Check the parts

contained in the carton boxes and on the

machine for damage, scratches and other

defects.

EAA00070

PARTS LOCATION

1. Front wheel

2. Front fender

3. Carton Box 1

4. Carton Box 2

Packing frame

1. Front wheel

2. Front fender

EAA00080

Carton Box 1

3. Handlebar

4. Side stand

5. Plastic bag

6. Handlebar upper holder

7. Flange bolt [d=8, l=35 (1.38)]

8. Master cylinder bracket

9. Flange bolt [d=6 (0.24), l=22 (0.87)]

10.Engine stop button holder (Upper and

lower)

11.Panhead screw with spring washer

[d=3 (0.12), l=14 (0.55)]

12.Collar

Carton Box 2

13.Number plate

14.Owner’s service manual

15.Plastic bag

16.Hose cover

17.Fuel tank breather hose

18.Spark plug wrench

19.Nipple wrench

20.Boots

21.Handlebar clamp

22.Boots

23.Hexagon bolt with plain washer (front fender)

[d=6 (0.24), l=20 (0.78)]

24.Collar (front fender)

25.Flange bolt (brake hose cover)

[d=6 (0.24), l=12 (0.47)]

26.Plain washer (brake hose cover)

[d=8 (0.31)]

27.Flange bolt (brake hose cover)

[d=8 (0.31), l=20 (0.79)]

28.Flange bolt (number plate)

[d=6 (0.24), l=14 (0.55)]

29.Clamp (brake hose)

30.Hexagon socket bolt. (brake hose clamp)

[d=6 (0.24), l=14 (0.55)]

EAA00100

SETUP PROCEDURES

Perform the setup procedures in the order indicated by the numbers.

Always follow the order as shown.

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