Yamaha 2002 YZ250FR User manual

YZ250FR
5UL-28107-10
ASSEMBLY MANUAL
LIT-11666-16-39

YZ250FR
ASSEMBLY MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, August 2002
All rights reserved.
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.
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1
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EAA00070
PARTS LOCATION
1. Front wheel
2. Front fender
3. Carton Box 1
4. Carton Box 2
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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)]
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3
-

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

1 Handlebar 1 C
2 Collar 1 V
3 Handlebar upper holder 2 V
4 Flange bolt 4 V d=8 (0.31), l=35 (1.38)
-
5
-
EAA00200
1. HANDLEBAR
A: Clean the right handlebar
end. Apply light coat grease.
B: Before inserting the handle-
bar into the throttle grip, make
sure the collar is installed.
NOTE:
The upper handlebar holder
should be installed with the
punched mark (a) forward.
C:
CAUTION:
Proper cable and lead routing
is essential to assure safe
machine operation. REFER TO
"CABLE ROUTING".
EAA00018
2. THROTTLE GRIP
A: Slip the throttle grip over the
right handlebar completely
and then slide it back about 2
mm (0.08 in).
B: Tighten the screws to specifi-
cation.
Screw:
4 Nm (0.4 mdkg, 2.9 ftdlb)
C: Check the throttle grip for
smooth action.
W
DThe throttle cables should
not be twisted, and make
sure that the throttle grip
rotates on the handlebar
freely, without binding.
DProper cable routing is
essential to assure safe
motorcycle operation.
Refer to "CABLE ROUTING".
D: First tighten the bolts 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 using a rag dampened
with a solvent. Foreign materi-
al on the braking surface may
cause impaired braking action.
E: Lift the front wheel and install
the front wheel axle.
NOTE:
Do not depress the brake lever
when the caliper is off the brake
disc.
F: Tighten the wheel axle to
specification.
Wheel axle:
105 Nm (10.5 mdkg, 75 ftdlb)
CAUTION:
Before tightening the pinch
bolts, stroke the front fork sev-
eral times to make sure of
proper fork operation.
G: Tighten the axle pinch bolts to
specification.
Axle pinch bolt:
23 Nm (2.3 mdkg, 17 ftdlb)
1 Throttle grip 1 *
2 Panhead screw 2 *d=5 (0.2), l=20 (0.78)
3 Grip cap cover 1 *
1 Front wheel 1 S
2 Front wheel axle 1 *
3 Collar1 1 V d=20 (0.79)
4 Collar2 1 V d=20 (0.79)
5 Axle nut 1 *d=16 (0.63)
6 Axle pinch bolt 4 *d=8 (0.31), l=40 (1.57)

-
6
-
EAA00030
4. FRONT BRAKE HOSE
HOLDER
A: Remove the front fork cover
bolts to slide the front fork
cover upwards.
B:
NOTE:
DAlign the top (d) of the brake
hose neck with the brake
hose holder bottom (c).
DPass the brake hose in front
of the axle boss (a), then fit it
into the brake hose groove (b).
DMake sure that brake hose
does not contact the front
axle nut.
C: Tighten the brake 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 ftdlb)
1 Brake hose cover 1 V
2 Collar 1 V d=8 (0.31)
3 Collar 1 V d=6 (0.24)
4 Flange bolt 1 V d=8 (0.31), l=20 (0.79)
5 Plain Washer 1 V d=8 (0.31)
6 Flange bolt 1 V d=6 (0.24), l=12 (0.47)

-
7
-
EAA00109
6. FRONT FENDER
A: Install the collars.
B: Tighten the bolts to specifica-
tion.
Bolt:
7 Nm (0.7 mdkg, 5.1 ftdlb)
CAUTION:
Be careful not to scratch the
front fender with the front fork
outer tubes.
W
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to "CABLE ROUTING".
EAA00033
7. FRONT BRAKE MAS-
TER CYLINDER
A: Lubricate the pivoting part of
the brake lever.
Recommended lubricants:
Lithium-soap-based
grease
B: Make sure that the "UP" mark
on the bracket is pointed
upwards.
NOTE:
DFirst tighten the bolt on the
upper side of the master cylinder
bracket, and then tighten the bolt
on the lower side.
DTighten the bolts to specification.
Bolt:
9 Nm (0.9 mdkg, 6.5 ftdlb)
C: Check the brake lever for
smooth action.
W
Proper hose routing is essen-
tial to assure safe machine
operation. Refer to "CABLE
ROUTING".
1 Front fender 1 S
2Hexagon 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 *
2Front 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 oil
C: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjusting nut on
the lever holder until tight.
Next, align the slit in the
adjusting nut and cable sock-
et with the slit in the lever
holder.
b. Insert the cable end into the
lever hole. Next, while pulling
the outer cable in the direc-
tion opposite to the lever, seat
the outer cable into the cable
socket.
NOTE:
Check the clutch 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".
1 Clutch cable 1 *
2 Boot 1 V
3 Lever cover 1 V

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8
-
EAA00198
9. HOT STARTER (CHOKE)
CABLE
A: Install the boot to the hot
starter (choke) lever.
B: Lubricate the pivoting part of
the hot starter (choke) lever.
Recommended lubricants:
Yamaha cable lube or
motor oil
C: Insert the cable end into the
lever hole, then squeeze the
lever.
While pulling the outer cable
in the direction opposite to the
lever, release the lever quick-
ly.
While releasing the lever, seat
the outer cable into the lever
holder.
NOTE:
Check the hot starter (choke)
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 *
2Panhead screw with
spring washer 1 V d=3 (0.12), l=14 (0.55)
3Engine stop button
holder (Upper and lower) 2V
EAA00128
11. CABLE CLAMP
A: Secure the engine stop switch
lead with a cable clamp.
NOTE:
DThe cable tie should be
installed according to the
dimensions shown.
DRefer to “CABLE ROUTING”.
1 Handlebar clamp 2 V

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9
-
EAA01070
12. NUMBER PLATE
A: Tighten the bolt to specifica-
tion.
Bolt:
7 Nm (0.7 mdkg, 5.1 ftdlb)
EAA00071
13. FUEL TANK BREATHER
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

CAUTION:
Proper cable and lead routing are essential to insure safe
machine operation.
(1) Fuel tank breather hose
(2) Clutch cable
(3) Hot starter (choke) cable
(4) Cable guide
(5) Hose guide
(6) Brake hose
(7) “ENGINE STOP” button lead
(A)Pass the fuel tank breather hose 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)Fit the brake hose into the guides on the protector.

(1) Hot starter (choke) cable
(2) Throttle cable (return)
(3) Throttle cable (pull)
(4) Cable guide
(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.
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11
-

(1) Throttle Cable
(2) Fuel tank breather hose
(3) Clamp
(4) Clutch cable
(5) Hot starter (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.
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12
-

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

-
14
-
EAA01005
A. DRAINING THE FUEL
1. Put a rag under the carburetor drain
hose so fuel does not contact the
crankcase.
2. Loosen the drain screw (1) and drain the
standing fuel.
W
FUEL IS HIGHLY FLAMMABLE:
DAlways turn off the engine when
draining fuel.
DTake care not to spill any fuel on the
engine or exhaust pipe(s)/muffler(s)
when draining fuel.
DDNever drain fuel while smoking or in
the vicinity of an open flame.
EAA01009
B. MEASURING THE TIRE PRESSURE
1. Measure:
Dtire pressure
Out of specification>Adjust.
NOTE:
DCheck the tire while it is cold.
DLoose bead stoppers allow the tire to slip
off its position on the rim when the tire
pressure is low.
DA tilted tire valve stem indicates that the
tire slips off its position on the rim.
DIf the tire valve stem is found tilted, the
tire is considered to be slipping off its
position.
Basic weight:
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:
DPlace the machine on a suitable stand.
DMake 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 level (1)
Coolant level should be up to the bottom
of the hole.
Coolant level is too low>Add the recom-
mended coolant to the proper level.
CAUTION:
DDAdding water instead of coolant low-
ers the antifreeze content of the
coolant. If water is used instead of
coolant, check and correct the
antifreeze concentration of the
coolant.
DDUse only distilled water. Soft water
may be used if distilled water is not
available.
4. Start the engine, warm it up for several
minutes, and then turn it off.
5. Check:
Dcoolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
6. Install:
Dradiator cap
3. Tighten the drain screw securely.