Yamaha YZ250 Instruction Manual

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YZ250M(5HC1) CANADA,U.S.A.,SOUTH AFRICA
YZ250 (5HC2) EUROPE
YZ250 (5HC3) JAPAN
YZ250M(5HC4) OCEANIA
205HC–100E1

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FOREWORD
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This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are
orderingreplacementparts,pleaserefertothisParts Catalogueandquotebothpartnumbersand
part names correctly.
YZ250M(5HC1/5HC4),YZ250(5HC2/5HC3)
1. Modifications or additions which have been made after issue of the Parts
Catalogue will be announced in the Yamaha Parts News.
It is advisable that you make necessary corrections to the Parts Catalogue
according to the Yamaha Parts News.
2. Abbreviations
The Following abbreviations are used in this Parts Catalogue.
“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Local Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in
front of the part name as shown below.
EXAMPLE
CARBURETOR ASSY
.JET, PILOT
.NOZZLE, MAIN
4. Number of component for assembly
The numeral appearing to the right of each component part indicates the
quantity of parts for each assembly unit.
EXAMPLE
PART NO. DESCRIPTION Q’TY REMARKS
2F5–83310–60 FRONT FLASHER LIGHT ASSY 2
115–83311–60 .BULB (6V–18W) 1
1M1–83309–60 .REFLECTOR 1
5. Applicable colors of graphics are represented in the “REMARKS” as shown
below.
PART NO. DESCRIPTION Q’TY REMARKS
2N4–24110–00–X5 .FUEL TANK COMP. 2 MXR
3J1–24240–10 .GRAPHIC, FUEL TANK 1 for MXR
6. Applicable Serial No.
Engine Serial No. Frame Serial No.
7. Note that the illustrations for reference in funding parts numbers, not to be
used for assembling. When assembling, pleas use the applicable service
manual.
8. The asterisk (*) before a reference number indicates modification items
after the first edition.

MODEL LABEL
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(1) A label called “Model Label” is affixed in the location as indicated in (3) below.
When using this parts catalogue, please be sure to cross–refer the “model code –
production code No.” in the catalogue to the “model code – production code No.
“indicated on the Model Label affixed onto the product concemed.
(2) “Model Label”Indication
a: Model Type Code
b: Production Code No.
c: Colouring Type
xxxx – xxx
x
ab
c4TW1–010
A
(3) Model Label Affixing Location
(4) Model Code – Production Code Number of Model Listed in This Parts Catalog
Model
Code Production Code No. Country (destination) Model Code Production Code No. Country (destination)
010 U.S.A.
5HC1 020 CANADA
030 SOUTH AFRICA
010 FRANCE
020 GERMANY
5HC2 030 ESPAÑA
040 ENGLAND
050 ITALY
5HC3 010 JAPAN
010 AUSTRALIA
5HC4 020 NEW ZEALAND
(5) Colouning Information
Model
Code Colouring type code Colour code Colour Name Abbrevi- ation
5HC1
5HC2 DEEP PURPLISH BLUE
5HC3 A0583 DEEP PURPLISH BLUE
SOLID E DPBSE
5HC4

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FIG. 1 CYLINDER HEAD
1 5CU–11111–00 HEAD, CYLINDER 1 1 1 1 1
2 94702–00326 PLUG, SPARK (NGK BR8EG) 1 1 1 1
3 90116–08394 BOLT, STUD 6 6 6 6
4 93604–08071 PIN, DOWEL 2 2 2 2
5 90176–08026 NUT, CROWN 6 6 6 6
6 90201–08087 WASHER, PLATE 6 6 6 6
7 5CU–11311–00 CYLINDER 1 1 1 1 1
8 5CU–1131D–00 VALVE ASSY 1 1 1 1
9 5CU–1131U–00 HOLDER 3 1 1 1 1
10 98907–05012 SCREW, BIND 2 2 2 2
11 90201–057H5 WASHER, PLATE 2 2 2 2
12 5CU–1132A–00 VALVE 2 2 2 2 2
13 5CU–11351–10 GASKET, CYLINDER 1 1 1 1
14 90116–10314 BOLT, STUD 1 1 1 1
15 95617–10660 BOLT, STUD 1 1 1 1
16 90116–10314 BOLT, STUD 1 1 1 1
17 95617–10660 BOLT, STUD 1 1 1 1
18 99530–14016 PIN, DOWEL 2 2 2 2
19 95707–10500 NUT, FLANGE 4 4 4 4
20 93210–74316 O–RING 1 1 1 1
21 93211–02703 O–RING 1 1 1 1
22 5CU–1131E–00 HOLDER 1 1 1 1 1
23 5CU–1131P–00 HOLDER 4 1 1 1 1
24 93210–15639 O–RING 2 2 2 2
25 98507–05012 SCREW, PAN HEAD 4 4 4 4
26 90201–057H5 WASHER, PLATE 2 2 2 2
27 5CU–11830–00 LINK ASSY 1 1 1 1
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4

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FIG. 1 CYLINDER HEAD
28 98907–05012 SCREW, BIND 2 2 2 2
29 93104–08040 OIL SEAL 1 1 1 1
30 4SS–11832–00 LEVER, LINK 1 1 1 1
31 90508–155B8 SPRING, TORSION 2 2 2 2
32 5CU–1132E–00 PULLEY 1 1 1 1 1
33 5CU–1132F–00 PULLEY 2 1 1 1 1
34 90201–081G0 WASHER, PLATE 2 2 2 2
35 90501–046L6 SPRING, COMPRESSION 2 2 2 2
36 5CU–1131V–00 SHAFT 1 1 1 1 1
37 91317–04008 BOLT 3 3 3 3
38 5CU–11991–00 HOUSING 1 1 1 1 1
39 5CU–11993–00 .GASKET 1 1 1 1
40 97007–05020 BOLT 4 4 4 4
41 92907–05600 WASHER, PLATE 4 4 4 4
42 5CU–11995–00 SEAL, HOUSING 1 1 1 1
43 5CU–1131M–00 COVER 1 1 1 1
44 353–13115–01 CONNECTOR, SUCTION PIPE 1 1 1 1
45 5CU–11354–00 GASKET 1 1 1 1
46 98907–05016 SCREW, BIND 4 4 4 4
47 90445–09226 HOSE 1 1 1 1
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4

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FIG. 2 GOVERNOR
1 4JY–11915–01 PLATE, THRUST 1 1 1 1 1
2 98907–05012 SCREW, BIND 1 1 1 1
3 90105–05002 BOLT, WASHER BASED 1 1 1 1
4 90201–057H5 WASHER, PLATE 1 1 1 1
5 90387–085E1 COLLAR 1 1 1 1
6 93104–08040 OIL SEAL 1 1 1 1
7 5CU–11990–00 PUSH ROD ASSY 1 1 1 1
8 3JE–11922–01 FORK, GOVERNOR 1 1 1 1
9 91317–04006 BOLT 2 2 2 2
10 93300–60801 BEARING (B0060) 1 1 1 1 KOYO
11 93300–60801 BEARING (B0060) 1 1 1 1 KOYO
12 5X4–11921–02 SHAFT, GOVERNOR 1 1 1 1
13 24X–11953–01 GEAR, GOVERNOR 1 1 1 1
14 90501–256L2 SPRING, COMPRESSION 1 1 1 1
15 5CU–11952–00 PLATE 1 1 1 1
16 90201–150U6 WASHER, PLATE 4 4 4 4
17 90387–152F2 COLLAR 1 1 1 1
18 93340–21505 BEARING 2 2 2 2
19 5CU–11912–00 RETAINER, WEIGHT 1 1 1 1
20 5CU–11911–00 RETAINER 1 1 1 1
21 93507–16020 BALL 4 4 4 4
22 93603–14240 PIN, DOWEL 1 1 1 1
23 93604–29184 PIN, DOWEL 1 1 1 1 AP FOR PUSH ROD
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4

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FIG. 3 CRANKSHAFT. PISTON
1 5CU–11631–00–A0 PISTON (STD) 1 1 1 1 UR
5CU–11631–00–B0 PISTON (STD) 1 1 1 1 UR
5CU–11631–00–C0 PISTON (STD) 1 1 1 1 UR
5CU–11631–00–D0 PISTON (STD) 1 1 1 1 UR
2 5CU–11603–00 PISTON RING SET (STD) 1 1 1 1
3 5CU–11633–10 PIN, PISTON 1 1 1 1
4 93450–19052 CIRCLIP 2 2 2 2
5 93310–218A6 BEARING 1 1 1 1
6 5CU–11400–00 CRANKSHAFT ASSY 1 1 1 1
7 5CU–11410–00 .CRANKSHAFT 1 1 1 1
8 5CU–11420–00 .CRANKSHAFT 1 1 1 1
9 5CU–11681–00 .PIN, CRANK 1 1 1 1 1
10 5CU–11651–00 .ROD, CONNECTING 1 1 1 1
11 93310–5240J .BEARING 1 1 1 1
12 90209–24327 .WASHER 2 2 2 2
13 93306–37808 BEARING 1 1 1 1
14 93102–20485 OIL SEAL 1 1 1 1
15 90280–03045 KEY, WOODRUFF 1 1 1 1
16 93306–37808 BEARING 1 1 1 1
17 93103–36182 OIL SEAL 1 1 1 1
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4

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FIG. 4 WATER PUMP
1 5CU–12459–00 GEAR, IMPELLER SHAFT 1 1 1 1
2 5DJ–12451–00 IMPELLER, WATER PUMP 1 1 1 1
3 90201–08512 WASHER, PLATE 1 1 1 1
4 93109–11073 OIL SEAL 1 1 1 1
5 93102–12106 OIL SEAL (SD 12–22–5 HS) 1 1 1 1
6 93306–00105 BEARING (B6001) 1 1 1 1
7 90201–08784 WASHER, PLATE 1 1 1 1
8 99001–06600 CIRCLIP 1 1 1 1
9 5CU–12422–00 COVER, HOUSING 1 1 1 1
10 5CU–12428–00 GASKET, HOUSING COVER 2 1 1 1 1
11 93604–10011 PIN, DOWEL 2 2 2 2
12 90430–06014 GASKET 1 1 1 1
13 95027–06025 BOLT, FLANGE 2 2 2 2
14 95027–06065 BOLT, FLANGE 2 2 2 2
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4

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FIG. 5 RADIATOR. HOSE
1 4SR–1240A–10 RADIATOR ASSY 1 1 1 1
2 91A20–05065 TUBE, FLEXIBLE VINYL 1 1 1 1
3 90467–09006 CLIP 1 1 1 1
4 4SR–12461–10 RADIATOR ASSY 1 1 1 1
5 5HD–12462–00 CAP, RADIATOR 1 1 1 1
6 5CU–12481–00 PIPE 1 1 1 1 1
7 4SS–12482–00 PIPE 2 2 2 2 2
8 5CU–12484–00 PIPE 4 1 1 1 1
9 90450–28014 HOSE CLAMP ASSY 4 4 4 4
10 90450–25037 HOSE CLAMP ASSY 2 2 2 2
11 90467–21068 CLIP 2 2 2 2
12 90480–15528 GROMMET 6 6 6 6
13 90387–0614M COLLAR 6 6 6 6
14 90119–06214 BOLT, WITH WASHER 6 6 6 6
PART NO. DESCRIPTION REMARKS
REF.
NO.
5HC1 5HC2 5HC3 5HC4