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
-

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