2007 Yamaha YZ250FW / YZ250F Owner's Service Manual

This Yamaha Owner's Service Manual covers the 2007 YZ250FW for the USA, Canada, Australia and New Zealand, and the YZ250F for Europe and South Africa. Specifications also identify France-specific chassis and tire configurations.

Search, bookmarks and wiring detail: The manual text is searchable; the cover is not. Embedded bookmarks lead to chapters and service sections. Small wiring and connector labels are readable when enlarged.

• Engine repair: Engine removal, crankcase separation, crankshaft inspection, cylinder and piston service, camshaft timing, and valve and valve spring inspection.

• Clutch and transmission: Wet multiple-disc clutch inspection, constant-mesh transmission repair, and shift cam, shift fork and kickstarter service.

• Fuel and cooling: Keihin FCR-MX37 disassembly, float inspection, accelerator pump timing adjustment, radiator pressure testing and water pump service.

• Chassis and suspension: Telescopic front fork overhaul, swingarm linkage service, steering bearing work, and rear shock spring and bearing replacement.

• Brake repair: Front and rear caliper and master cylinder disassembly, seal inspection, pad replacement and hydraulic system bleeding.

• Electrical diagnosis: Wiring diagrams, ignition troubleshooting and throttle position sensor tests, with connector views, resistance specifications and voltage checks.

The repair sections are written for mechanics using workshop measuring equipment and special tools; owners also get operating instructions and routine maintenance guidance.

Engine Repair and Valve Adjustment

Engine coverage extends through crankshaft runout and connecting rod clearance checks, balancer gear alignment, and five-speed transmission inspection. Gearbox assembly notes identify shift fork positions and the adjacent gears involved when a fork malfunctions.

The intake and exhaust Pad Selection Tables help match measured valve clearance and installed pad size to a replacement shim. The camshaft chapter warns that uneven cap tightening can damage the cylinder head, camshafts and caps.

Dry sump lubrication coverage includes oil pressure inspection, the oil tank and trochoid oil pump. Lubrication Diagrams trace oil delivery through the engine and transmission.

Keihin Carburetor and Cooling System

Carburetor specifications distinguish 5XCG G0 and 5XCH H0 identification marks, with different USA/Canada and other-market pilot screw baselines and leak jets. Carburetor setting charts connect mixture symptoms with the relevant throttle range and fuel circuit.

Cooling procedures cover radiator cap tests, system leak checks, hose routing and inspection of the water pump impeller, shaft, bearing and seals.

Ignition and TPS Troubleshooting

The Ignition System and Throttle Position Sensor System inspection charts work with the wiring diagram and terminal illustrations to distinguish connection, switch, coil and sensor faults. Procedures cover spark testing, ignition timing checks and TPS replacement with output-voltage adjustment.

Specifications identify 5XC-90 USA CDI units and 5XC-A0 units for other markets. The seven-page Cable Routing Diagram section shows electrical lead, control cable and hose placement.

Fork, Shock and Chassis Service

Front fork procedures cover damper bleeding, base valve inspection, seal installation and oil setting. Yamaha recommends dealer maintenance for the fork; assembly notes explain how a dropped damper assembly can damage its internal valve.

Rear shock coverage includes removal, spring and bearing work, preload and damping adjustment. It does not include internal rebuilding of the nitrogen-filled cylinder or reservoir; Yamaha warns against opening these pressurized components.

Suspension setting charts connect handling symptoms with checks and adjustments. Regional baseline settings, chassis geometry data, and titanium and steel rear spring identification tables help match the information to the installed configuration.

Workshop Specifications and Tools

Torque tables cover chassis and powertrain fasteners, including the primary drive gear. Reference data also covers cylinder head warpage, valve clearances, fluid capacities, wear limits and spark plug specifications.

Special-tool references include crankcase separator YU-1135-A/90890-01135 and fork seal driver YM-A0948/90890-01502. Exploded assembly views accompany sequential job instruction charts showing the required extent of disassembly.

English PDF and Included Pages

One printable 305-page PDF contains 293 chapter pages plus 12 front-matter pages: the cover and 11 pages of introductory information, safety notices, manual-use guidance, index and contents. All front matter is included in the total.