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2005 Yamaha YZ 250/T1 owner´s service manual

Models covered in this manual:

YZ250/T1 / Yamaha Motor Co., Ltd

2005 Yamaha YZ 250/T1

File specifications

File size: 12.61 MB
File type: PDF
Language: English, French, German, Italian
Pages: 596
Printable: Yes
Estimated download time: 0.26 Minutes
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Product Information

Table of contents

General Information

  1. Description
    • Overview of the YZ250/T1 model
    • 1-1
  2. Machine Identification
    • Identification number locations
    • 1-2
  3. Important Information
    • Precautions and important notices
    • 1-3
  4. Checking of Connection
    • Inspecting electrical and mechanical connections
    • 1-6
  5. Special Tools
    • List and usage of special tools
    • 1-7
  6. Control Functions
    • Detailed description of control functions
    • 1-9
  7. Fuel and Engine Mixing Oil
    • Fuel requirements and mixing oil instructions
    • 1-12
  8. Starting and Break-In
    • Procedures for starting and breaking in a new engine
    • 1-13
  9. Torque-Check Points
    • Locations and specifications for torque checks
    • 1-16
  10. Cleaning and Storage
    • Cleaning procedures and storage guidelines
    • 1-17

Specifications

  1. General Specifications
    • Overall dimensions, weight, and capacities
    • 2-1
  2. Maintenance Specifications
    • Detailed maintenance requirements
    • 2-3
  3. General Torque Specifications
    • Torque values for various components
    • 2-13
  4. Definition of Units
    • Explanation of units used in the manual
    • 2-13
  5. Cable Routing Diagram
    • Diagrams showing proper cable routing
    • 2-14

Regular Inspection and Adjustments

  1. Maintenance Intervals
    • Schedule of regular maintenance tasks
    • 3-1
  2. Pre-Operation Inspection and Maintenance
    • Checklist for pre-operation inspection
    • 3-4
  3. Engine
    • Engine maintenance and inspection procedures
    • Air filter, spark plug, valve clearance
    • 3-5
  4. Chassis
    • Chassis inspection and adjustment procedures
    • Suspension, brakes, wheels
    • 3-17
  5. Electrical
    • Electrical system inspection and maintenance
    • Battery, lights, switches
    • 3-38

Engine

  1. Seat, Fuel Tank, and Side Covers
    • Removal and installation procedures
    • 4-1
  2. Exhaust Pipe and Silencer
    • Removal, inspection, and installation
    • 4-3
  3. Radiator
    • Inspection, maintenance, and replacement
    • 4-4
  4. Carburetor and Reed Valve
    • Disassembly, inspection, and reassembly
    • 4-7
  5. Cylinder Head, Cylinder, and Piston
    • Removal, inspection, and installation
    • 4-18
  6. Clutch and Primary Driven Gear
    • Disassembly, inspection, and reassembly
    • 4-33
  7. Kick Axle, Shift Shaft, and Primary Drive Gear
    • Inspection and maintenance
    • 4-40
  8. YPVS Governor
    • Inspection and maintenance
    • 4-49
  9. Water Pump
    • Disassembly, inspection, and reassembly
    • 4-52
  10. CDI Magneto
    • Inspection and replacement
    • 4-56
  11. Engine Removal
    • Procedures for engine removal
    • 4-60
  12. Crankcase and Crankshaft
    • Disassembly, inspection, and reassembly
    • 4-65
  13. Transmission, Shift Cam, and Shift Fork
    • Inspection and maintenance
    • 4-72

Chassis

  1. Front Wheel and Rear Wheel
    • Removal, inspection, and installation
    • 5-1
  2. Front Brake and Rear Brake
    • Inspection, maintenance, and replacement
    • 5-10
  3. Front Fork
    • Disassembly, inspection, and reassembly
    • 5-26
  4. Handlebar
    • Inspection, adjustment, and replacement
    • 5-41
  5. Steering
    • Inspection, adjustment, and replacement
    • 5-48
  6. Swingarm
    • Inspection, maintenance, and replacement
    • 5-53
  7. Rear Shock Absorber
    • Disassembly, inspection, and reassembly
    • 5-61

Electrical

  1. Electrical Components and Wiring Diagram
    • Overview and diagrams of the electrical system
    • 6-1
  2. Ignition System
    • Inspection and maintenance
    • 6-2
  3. Solenoid Valve System
    • Function and troubleshooting
    • 6-7
  4. Throttle Position Sensor (TPS) System
    • Function and troubleshooting
    • 6-9

Tuning

  1. Engine
    • Performance tuning and adjustments
    • 7-1
  2. Chassis
    • Suspension and handling adjustments
    • 7-13

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