Yamaha TZR250 2MA Series 1987 Service Manual (P/N 2MA-28197-80)

• Covers the 1987 Yamaha TZR250 (liquid-cooled, 2-stroke, 249cc engine)
• Original OEM factory specifications (P/N 2MA-28197-80)
• 9 comprehensive chapters detailing clearances, electrical diagrams, and system layouts

Core Maintenance & Troubleshooting

• Factory workshop manual covering the entire motorcycle
• Complete engine rebuild and diagnostic instructions
• Advanced electrical system troubleshooting procedures
• Routine periodic maintenance schedules
• Technical reference data for precise chassis adjustments
• Accurate tightening torque specifications

Key Assemblies Covered

• Mikuni TM28SS carburetor tuning and synchronization
• Yamaha Power Valve System (Y.P.V.S.) checks
• Autolube pump air bleeding steps
• C.D.I. magneto ignition diagnostics
• Six-speed transmission disassembly
• Telescopic front fork oil replacement
• Thermostatic valve and water pump inspection
• Reed valve block maintenance

Document Overview and Structure

Getting a classic 2-stroke back on the road requires accurate data. This 1987 Yamaha TZR250 service manual outlines the exact factory-recommended maintenance, engine overhaul, and chassis adjustment protocols used by dealership technicians. At 333 pages, it covers the bike from the ground up. Integrating this PDF into your daily workshop routine provides a clear advantage by offering immediate access to critical pinout tests and specific fluid capacities, eliminating guesswork and accelerating complex diagnostics. The opening sections define critical vehicle identification and required special service tools. From there, the guide dives deep into periodic maintenance, engine disassembly, cooling system routing, carburetor synchronization, and troubleshooting the electrical and Y.P.V.S. setups. By following the provided step-by-step instructions for tasks like twin carburetor synchronization, front fork oil replacement, and Autolube pump stroke calibration, DIYers and mechanics can effectively avoid steep specialist repair bills.

Specifications and Technical References

Precision matters when rebuilding the 2MA-series block. Technical reference tables provide the exact numbers you need, including the 0.050–0.055 mm piston-to-cylinder clearance and 0.03 mm crankshaft runout limits. Fluid capacities are clearly mapped out, specifying 1.4 liters for the autolube tank and 1.35 liters for the cooling system. Before starting any major engine repair, always review the documented torque sequences and handling precautions to prevent component damage or personal injury.

When undertaking a repair on this parallel twin, pay special attention to specific 2-stroke pitfalls. Improper cable tensioning on the Yamaha Power Valve System during a top-end rebuild frequently leads to servo motor burnout or erratic mid-range power delivery. Furthermore, neglecting to perfectly bleed the Autolube pump after disconnecting the fluid lines is a severe mistake that causes immediate piston scoring due to oil starvation.

You will find comprehensive torque values for major assemblies, such as cylinder head nuts (22 Nm) and crankcase flange bolts (24 Nm). For electrical diagnostics, the manual lists the magneto pick-up coil resistance at 94–140 ohms (at 20°C). It also provides high-resolution wiring diagrams, exploded diagrams, coolant flow charts, lubrication diagrams, section views, TZR250 circuit diagrams, connector color codes, and cable routing illustrations to help you chase down ignition advance issues quickly.