Yamaha 2002 YZ250FR Assembly Manual Download Page 1 | Manualshive

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Summary of Contents for 2002 YZ250FR

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Page 3: ...YZ250FR 5UL 28107 10 ASSEMBLY MANUAL LIT 11666 16 39 ...

Page 4: ...ontinually 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 p...

Page 5: ...all 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 ...

Page 6: ...s 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 I...

Page 7: ...acking 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 1 ...

Page 8: ...EAA00070 PARTS LOCATION 1 Front wheel 2 Front fender 3 Carton Box 1 4 Carton Box 2 2 ...

Page 9: ...x 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 ...

Page 10: ...EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers Always follow the order as shown 4 ...

Page 11: ...lts on the front side of the handlebar holder and then tighten the bolts on the rear side to spec ification Bolt 28 Nm 2 8 mdkg 20 ftdlb EAA00020 3 FRONT WHEEL A Clean the brake disc B Clean the front wheel axle C Clean the collars NOTE Install the collars with the flared ends a facing the wheel D W Take care not to get grease on the brake disc or inner surface of the brake pads If you do so clean...

Page 12: ... hose holder bolts to specification Bolt 10 Nm 1 0 mdkg 7 2 ftdlb D Slide the front fork cover to its original position E Tighten the front fork cover bolts to specification Bolt 10 Nm 1 0 mdkg 7 2 ftdlb 1 Brake hose holder 2 V 2 Hexagon socket bolt 2 V d 6 0 24 l 14 0 55 EAA00031 5 BRAKE HOSE COVER A Tighten the bolts to specifica tion Bolt M8 16 Nm 1 6 mdkg 11 ftdlb Bolt M6 7 Nm 0 7 mdkg 5 1 ftd...

Page 13: ...ABLE ROUTING 1 Front fender 1 S 2 Hexagon bolt with plain washer 4 V d 6 0 24 l 20 0 78 3 Collar 4 V d 6 0 24 1 Collar 1 2 Front brake master cylinder 1 3 Master cylinder bracket 1 V 4 Flange bolt 2 V d 6 0 24 l 22 0 87 EAA00049 8 CLUTCH CABLE A Install the boot and lever cover to the clutch cable B Lubricate the pivoting part of the clutch lever Recommended lubricants Yamaha cable lube or motor o...

Page 14: ...lever for smooth action Refer to ADJUSTMENTS AND PREDE LIVERY SERVICE W Proper cable routing is essen tial to assure safe machine operation Refer to CABLE ROUTING EAA00207 10 ENGINE STOP SWITCH A W Proper cable and hose routing are essential to assure safe motorcycle operation Refer to CABLE ROUTING 1 Hot starter choke lever 1 2 Boot 1 1 Engine stop button 1 2 Panhead screw with spring washer 1 V ...

Page 15: ...THER HOSE A Connect one end of the breather hose to the fuel tank filler cap and insert the other end into the hole of the num ber plate NOTE Refer to CABLE ROUTING CAUTION Install the hose joint with its arrow mark facing the TANK side 1 Number plate 1 C 2 Flange bolt 1 V d 6 0 24 l 14 0 55 1 Fuel tank breather hose 1 V ...

Page 16: ...ose between the handlebar and tension bar then insert its end into the hole of the number plate B Pass the hot starter choke cable between the cylinder head breather hose oil tank breather hose and ignition coil then on the outside of the left engine bracket 10 EAA00900 CABLE ROUTING C Pass the clutch cable throught the cable guides D Pass the clutch cable in front of the radiator mounting boss E ...

Page 17: ...e 5 Ignition coil A Pass the hot starter choke cable and throttle cables through the cable guides B Pass the hot starter choke cable and throttle cables between the radiator and frame then under the radiator mounting boss C Pass the throttle cables on the outside of the ignition coil 11 ...

Page 18: ...rter choke cable 6 ENGINE STOP button lead 7 Brake hose 8 Hose guide A Fasten the ENGINE STOP button lead to the handlebar with the plastic band B Pass the brake hose in front of the number plate C Pass the hot starter choke cable and throttle cables through the cable guide 12 ...

Page 19: ...EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters Always follow the order as shown 13 ...

Page 20: ...ght With oil coolant and full fuel tank 101 5 kg 224 lb Cold tire pressure Front 100 kPa 1 0 kgf cm2 15 psi Rear 100 kPa 1 0 kgf cm2 15 psi EAA01019 C CHECKING THE COOLANT LEVEL 1 Stand the machine on a level surface NOTE D Place the machine on a suitable stand D Make sure that the machine is upright 2 Remove Dradiator cap W Do not remove the radiator cap when the engine is hot 3 Check Dcoolant le...

Page 21: ...btained c Tighten the locknut Locknut 5 Nm 0 5 mdkg 3 6 ftdlb Direction a Brake lever distance is increased Direction b Brake lever distance is decreased W A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will considerably reduce braking perfor...

Page 22: ...vel surface NOTE D Place the machine on a suitable stand D Make sure that the machine is upright 2 Check Dbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Recommended brake fluid DOT 4 A Front brake B Rear brake W D Use only designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake perfor...

Page 23: ...amalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At 15mC 60mF or lower B Yamalube 4 10W 30 or SAE 10W 30 type SG motor oil Non Friction modified or Yamalube 4 R 15W 50 Non Friction modified W D D Do not add any chemical additives or use oils with a grade of CD a or higher D D Do not use oils labeled ENERGY CONSERVING II b or higher Engine oil also lubricates the clutch and ad...

Page 24: ...EE PLAY 1 Measure Dclutch cable free play a Out of specification Adjust Clutch cable free play 8 13 mm 0 31 0 51 in 2 Adjust Dclutch cable free play a Loosen the locknuts 1 b Adjust the free play by changing their tightening position EAA01069 L ADJUSTING THE HOT STARTER CHOKE CABLE FREE PLAY 1 Measure Dhot starter choke cable free play c Out of specification Adjust Hot starter choke cable free pla...

Page 25: ...k is obtained Direction a Drive chain is tightened Direction b Drive chain is loosened NOTE To maintain the proper wheel alignment adjust both sides evenly c Tighten the wheel axle nut to specifica tion Wheel axle nut 125 Nm 12 5 mdkg 90 ftdlb d Tighten the locknuts to specification Locknut 16 Nm 1 6 mdkg 11 ftdlb EAA01049 N ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Spring preload W Securely supp...

Page 26: ...er Direction b Low compression damping is decreased suspension is softer Adjusting positions Standard 7 turns out Minimum 0 turns out Maximum 20 turns out from the fully turned in position Dhigh compression damping a Turn the adjusting nut 5 in direction a or b Direction a High compression damping is increased suspension is harder Direction b High compression damping is decreased suspension is sof...

Page 27: ...ion damping a Turn the adjusting screw 2 in direction a or b Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Adjusting positions Standard 12 clicks out Minimum 0 clicks out Maximum 20 clicks out from the fully turned in position 3 Install Drubber cap ...

Page 28: ...with a research octane number of 95 or higher Fuel tank capacity 7 0L 1 54 lmp gal 1 85 US gal Valve clearance cold IN 0 10 0 15 mm 0 0039 0 0059 in EX 0 17 0 22 mm 0 0067 0 0087 in Tire air pressure Front 100 kPa 1 0kgf cm2 15 psi measured on cold tires Rear100 kPa 1 0kgf cm2 15 psi EAA10100 STANDARD EQUIPMENT Owner s service manual X 1 22 EAA10200 OWNER S TOOL KIT Nipple wrench X 1 Spark plug wr...

Page 29: ...1 0 6 0 6 4 3 Brake lever mounting nut M 6x1 0 6 0 6 4 3 Brake lever position locknut M 6x1 0 5 0 5 3 6 Cable guide front brake hose and guide stay M 5x0 8 4 0 4 2 9 Front brake hose union bolt master cylinder M10x1 25 30 3 0 22 Front brake hose union bolt caliper M10x1 25 30 3 0 22 Front brake caliper and front fork M 8x1 25 23 2 3 17 Brake caliper front and rear and pad pin plug M10x1 0 3 0 3 2 ...

Page 30: ...M10x1 25 56 5 6 40 Rear shock absorber and relay arm M10x1 25 53 5 3 38 Rear frame and frame upper M 8x1 25 32 3 2 23 Rear frame and frame lower M 8x1 25 29 2 9 21 Swingarm and brake hose holder M 5x0 8 1 0 1 0 7 Swingarm and patch M 4x0 7 2 0 2 1 4 Drive chain tensioner mounting upper M 8x1 25 19 1 9 13 Drive chain tensioner mounting lower M 8x1 25 20 2 0 14 Chain support and swingarm M 6x1 0 7 0...

Page 31: ...PRINTED IN U S A ...

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