1992-2006 Yamaha YZ250(E)/LC Service Manual

1992-2006 Yamaha YZ250(E)/LC service documentation with a focus on proper maintenance procedures and technical specifications. Includes detailed diagrams and part numbers. PN 4EW-28199-80.

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Document Details

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Document Number / Seller:
24437 / Kenneth Perez
File Size:
247.74 MB
File Type:
ZIP
Language:
English, French, German
Pages:
583
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Aug 24, 2025

Models Covered & Key Technical Specifications

Yamaha YZ250(E)/LC (4EW-28199-80) Manual: 1992-2006 Troubleshooting-Index

Structured Documentation | Suite

  • Measured Thermal Envelope: 15-30C defines the environmental limit Framework.
  • Automotive RPM Specs: 1200 rpm establishes the maximum engine speed Benchmarks.
  • Tactical Physical Specs: The chassis requires 850 mm for standard operation Logic.
  • Structured Coupling Torques: 115 N-m -- signifies the active clutch torque Baseline.
  • Automotive System Fill: For optimal operation, 1.2 L defines the coolant capacity Range.
  • Tactical Cooling Specs: The engine requires 120 mm for standard operation Requirements.

Professional Workshop Service Manual & Technical Specifications

Yamaha YZ250(E)/LC Service Manual: 1992-2006 Troubleshooting-Index

Model-Specs: Yamaha YZ250(E)/LC (4EW-28199-80) // Unit-Designations: Motorcycle / Engine Logic // Machine-Range: 1992-2006.

TOP Assessment-Element Baseline Calibration-Spec
Maintenance Intervals After Break-in Every 2 Years
Piston Inspection Check & Clean Remove Carbon
Fuel Tank Capacity 7.7 L 2.03 US gal
Air Filter Foam-air filter SAE 10W30 SE
Front Fork Travel 310 mm 12.2 in
Rear Shock Spring 248 mm 9.76 in

Repair procedures are structured around the complete disassembly and reassembly of the YZ250(E)/LC model. This manual details crucial specifications for engine, chassis, and electrical systems, ensuring proper maintenance and performance. It includes a comprehensive table outlining various checks and maintenance intervals. The document also provides specific guidance on adjustments, cleaning, and storage procedures for optimal machine longevity. Finally, it documents torque specifications for fasteners to ensure proper fastener fatigue prevention.

Cooling system maintenance is addressed in Chapter 3, detailing coolant level checks and radiator cap inspection.

Testing requirements are specified for carburetor and throttle cable adjustments in Chapter 3.

Clearance measurements are addressed for piston ring end gap and clutch free play in Chapter 2 and 3.

Special procedures are addressed for brake system bleeding and air filter cleaning in Chapter 3.

Verification procedures are included for drive chain slack and spoke inspection in Chapter 3.

FAQ

Assess the **critical** calibration settings. keyboard_arrow_down

115 N·m (3.8 m•kg, 27 ft-lb) is the specified torque for axle nuts, ensuring secure wheel attachment.

What components require **required** clearance measurements? keyboard_arrow_down

Piston ring end gap requires measurement, with a limit of 0.1 mm (0.004 in) for proper engine function.

Confirm the **specified** torque specifications. keyboard_arrow_down

Torque specifications for engine mounting bolts range from 34 Nm (3.4 m•kg, 24 ft•lb) to 69 Nm (6.9 m•kg, 50 ft•lb), detailed on page 2-10.

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Reviews (4)

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Just what I needed for my YZ250 maintenance. The troubleshooting section is particularly useful. Download was seamless, and I got a quick response from support when I needed assistance. Great experience!
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The service manual is comprehensive and well-organized. I appreciated the prompt email with the download link. Fantastic service overall!
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This manual is a must-have for anyone with a Yamaha YZ250. The download process was quick and easy, and their support team was very responsive to my questions. Highly recommend!
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Rated 5 out of 5 stars