Yamaha YZ250FD / YZ250F 2013 Owner's Service Manual (P/N LIT-11626-26-28)

Yamaha's 2013 YZ250FD Owner's Service Manual, P/N LIT-11626-26-28, also covers the regional YZ250F designation for Europe and South Africa. This is the 1st Edition, April 2012, with additional cover identifier 17D-28199-13. Its seven chapters cover operation, maintenance, repair, electrical diagnosis, and competition tuning.

Searchable Service Text and PDF Navigation

Search, bookmarks, and wiring detail: The service text is searchable; the warranty page's body text is not. Embedded bookmarks provide section navigation, although the cylinder-head bookmark incorrectly opens the cover. Small wiring color codes and connector labels are clearly readable when enlarged.

One printable English PDF contains 284 pages, including 14 cover/front-matter pages, 267 numbered manual pages, one blank page, one promotional page, and one back cover.

Engine Rebuilding, Chassis Service, and Race Setup

The following selected coverage highlights summarize major workshop sections. Other topics include cold- and hot-start operation, break-in, and storage preparation.

• Engine and gearbox: Step-by-step procedures cover engine removal, crankcase separation, crankshaft installation, transmission inspection, shift-cam and shift-fork service, and kick- and shift-shaft repair.

• Top end and clutch: Camshaft timing, cylinder-head and valve-train work, piston and cylinder inspection, and clutch disassembly, measurement, and assembly.

• Carburetor service: FCR-MX39 removal and rebuilding, needle-valve inspection, float-height measurement, accelerator-pump timing, and starter-plunger checks.

• Cooling and lubrication: Radiator inspection, cooling-system pressure tests, water-pump repair, and dry-sump oil-pump, oil-tank, and balancer service.

• Chassis repair: Wheel bearings, brake discs, caliper and master-cylinder rebuilding, hydraulic bleeding, front-fork assembly, steering bearings, swingarm linkage, and rear-shock spring and bearings.

• Electrical diagnosis: Ignition and throttle-position-sensor troubleshooting, component test specifications, wiring diagrams, and cable and hose routing references.

• Competition tuning: Carburetion, final-drive gearing, tire-pressure selection, fork oil-volume effects, spring selection, rider sag, and compression and rebound damping adjustments.

The engine, chassis, and electrical sections are written for readers with basic Yamaha motorcycle service knowledge and skills; inspection and tuning material also suits competition riders with that workshop background.

Regional Settings and Competition Use

The machine is intended for sanctioned closed-course competition, rather than public-road or general recreational use. Regional tables distinguish carburetor identification marks, baseline settings, jet needles, and final-drive gearing.

These distinctions help match service and tuning information to the machine's market specification before selecting settings or replacement tuning parts.

Engine Inspection and Carburetor Detail

Internal repairs: Crankshaft and bearing checks, transmission gear dogs, shift-fork grooves, and final shifter-operation checks support bottom-end inspection and reassembly. Cylinder-head work includes valve-guide, valve-seat, and spring measurements; the valve section also specifies replacement requirements for titanium valves used during seat lapping.

Fuel-system checks: Separate procedures address the throttle valve, hot- and cold-starter plungers, pilot screw, leak jet, and accelerator-pump diaphragm. Tuning charts connect atmospheric conditions and throttle opening with main-jet, pilot-circuit, jet-needle, and accelerator-pump behavior, alongside setting-part numbers.

Loosening the TPS mounting screw outside sensor replacement can reduce engine performance, while careless connector probing can damage electrical components or compromise connector sealing. For crankcase work, Yamaha cautions against forcing unevenly separating case halves or hammering the crankshaft during removal or installation.

Fork, Brake, and Rear-Shock Work

Front-fork procedures reach the damper assembly, base valve, bushings, and oil seals. Brake coverage includes caliper piston and seal kits, master-cylinder kits, hose installation, bleeding, and leak checks; steering and swingarm sections extend to bearing races and linkage bearings.

Setup charts relate handling symptoms to spring choice, fork oil volume, rider sag, and damping adjustments, including separate low- and high-speed rear compression settings.

Rear-shock limit: Removal, inspection, spring replacement, bearing service, and installation are covered. The manual prohibits opening the nitrogen-charged shock cylinder or reservoir; it does not provide an internal shock rebuild procedure.

Ignition Tests, Diagrams, and Workshop References

The no-spark flowchart links the spark-gap test to checks of connections, the engine-stop switch, ignition coil, CDI magneto pickup and charging coils, neutral switch, and CDI unit. The separate TPS chart covers resistance response, input and output voltage, replacement, alignment, and adjustment.

Illustrations include the ignition wiring diagram, lubrication diagrams, cable and hose routing views, ignition and TPS inspection flowcharts, and exploded job-order drawings. Maintenance schedules, component torque tables, lubricant and fluid data, clearances, wear limits, and race-setting ranges accompany the procedures.

Special-tool references pair North American numbers with other-market equivalents: crankcase separator YU-1135-A / 90890-01135, flywheel puller YM-1189 / 90890-01189, fork seal driver YM-A0948 / 90890-01502, valve spring compressor YM-04019 / 90890-04019, and pocket tester YU-3112-C / 90890-03112.

A Preview of Valve and Float Specifications

Valve adjustment: Cold clearances are 0.12–0.17 mm for intake valves and 0.17–0.22 mm for exhaust valves. Pad-selection tables relate measured clearance and installed pad thickness to replacement shim selection.

Carburetor inspection: FCR-MX39 float height is specified as 6.0 mm (0.24 in), with the float arm resting on the needle valve without compressing it. The measurement section explains the reference surfaces and checks used to distinguish an adjustment issue from needle-valve or seat wear.