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

This Yamaha factory service manual, P/N 2MA-28197-80, covers the 1987 TZR250, model code 2MA. Its nine chapters cover periodic maintenance, engine overhaul, chassis service, and electrical troubleshooting.

PDF Bookmarks and Wiring Detail

Search and navigation: PDF text search is not available. Embedded bookmarks use image filenames rather than chapter titles. Small circuit labels and the color wiring diagram need zooming for detailed reading.

One printable, 333-page PDF, including 12 opening pages of cover, introductory material, and contents, plus the one-page closing safety notice. All are included in the total.

Engine Overhaul, Autolube and Electrical Fault Finding

These selected workshop topics outline the coverage rather than reproduce the full contents list. Other sections include battery inspection and headlight beam adjustment.

• Engine repair: Step-by-step engine removal, crankcase separation, cylinder and piston inspection, crankshaft measurement, and engine reassembly.

• Clutch and transmission: Clutch inspection, primary-drive service, kick-start mechanism repair, and transmission and shifter disassembly, inspection, and assembly.

• Carburetion and Autolube: Mikuni TM28SS synchronization, float and fuel-level adjustment, reed-valve inspection, pump cable and stroke adjustment, and air bleeding.

• Cooling system: Water-pump removal and seal inspection, thermostat testing, radiator-cap pressure checks, cooling-system leak testing, and coolant replacement.

• Brakes and chassis: Caliper and master-cylinder service, hydraulic bleeding, front-fork overhaul, steering-bearing adjustment, and swingarm and suspension-linkage inspection.

• Electrical diagnosis: C.D.I. ignition, charging, lighting, indicator, temperature-gauge, and Y.P.V.S. troubleshooting, supported by circuit diagrams and wire-color references.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes a basic understanding of motorcycle repair concepts and procedures.

Engine Inspection and Reassembly

The overhaul chapter distinguishes work that can be performed with the engine installed from jobs requiring engine removal. Cylinder-head, piston, clutch, power-valve, and magneto service are among the operations identified for access with the engine still mounted.

Exploded assembly views accompany inspection criteria for piston rings, clutch plates, gear dogs, shift forks, bearings, and seals. Crankcase tightening instructions distinguish fastener sizes and tightening order; a single torque value does not apply to every crankcase bolt.

Tool references include the Universal Clutch Holder 90890-04086 and Flywheel Puller 90890-01189. Before starting any major engine repair, always review the documented torque sequences and handling precautions to prevent component damage or personal injury.

Carburetor Settings and Oil Delivery

The carburetor section view identifies the main nozzle, jets, needle valve, and throttle valve. Inspection instructions distinguish worn components from blocked passages, while the adjustment sections explain the relationship between carburetor synchronization, idle speed, and throttle-cable free play.

Autolube coverage includes minimum-stroke adjustment and delivery-output checks. The bleeding instructions specifically address an empty oil tank or an oil circuit that has been disconnected.

Cooling-System Checks

The Coolant Flow Chart and Lubrication Diagram show the fluid routes alongside the service instructions. Cooling coverage extends to impeller-shaft and seal inspection, thermostat opening checks, radiator-cap testing, and pressure testing after reassembly.

Forks, Brakes and Rear Suspension

Front-fork service goes beyond oil replacement to include bushings, seals, damper components, oil-level measurement, and reassembly. The disassembly cautions explain how bottoming the inner tube can damage the oil lock piece.

Rear-suspension instructions cover shock replacement, spring-preload adjustment, and swingarm and linkage bearings. The nitrogen-charged shock cylinder must not be opened; this section does not provide an internal shock rebuild procedure.

Circuit Tests and Symptom Charts

The TZR250 Circuit Diagram and color TZR250 Wiring Diagram accompany system-specific electrical tests and cable-routing illustrations. Ignition checks include the neutral and sidestand control circuit, while charging diagnosis separates stator, wiring, and rectifier/regulator faults.

Y.P.V.S. troubleshooting distinguishes servomotor, control-unit, and C.D.I. faults. Its servomotor test carries a short-duration caution to prevent further damage.

The symptom charts connect hard starting, poor running, shifting trouble, clutch slip, and overheating with the relevant inspection sections. This helps organize fault finding across fuel, compression, electrical, and mechanical causes before selecting repair work.

Examples of Engine Clearances and Ignition Test Data

The engine tables specify a standard piston-to-cylinder clearance of 0.050–0.055 mm, with a 0.1 mm wear limit. They also list a crankshaft runout limit of 0.03 mm and a cylinder-head nut tightening torque of 22 Nm.

For ignition diagnosis, the pickup-coil specification is 94–140 ohms at 20°C, measured between the White/Green and White/Red leads. The associated test chart places this measurement within the no-spark troubleshooting sequence.