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

• Official Yamaha Owner's Service Manual for the 2013 YZ250FD (USA, Canada, Australia, and New Zealand) and YZ250F (Europe and South Africa); P/N LIT-11626-26-28, cover code 17D-28199-13, 1st Edition, April 2012, in a 284-page PDF.
• Covers engine removal, crankcase separation, crankshaft installation, transmission/shift-cam/shift-fork service, and kick- and shift-shaft repair.
• Details FCR-MX39 carburetor disassembly, float and accelerator-pump adjustment, camshaft timing, cylinder-head and valve work, piston/cylinder inspection, and clutch repair.
• Walks through radiator and cooling-system checks plus water-pump, dry-sump lubrication, oil-pump, oil-tank, and balancer service, with the related torque tables, clearances, limits, and capacities.
• Includes wheel and bearing service, brake caliper and master-cylinder repair, hydraulic bleeding, front-fork teardown and assembly, steering and swingarm work, and rear-shock spring and bearing service.
• Provides ignition and throttle-position-sensor fault isolation, wiring and cable/hose routing diagrams, and race-tuning guidance for carburetion, gearing, tires, and front and rear suspension.

2013 Model Coverage and Workshop Level

This manual is for Yamaha's 2013 liquid-cooled, DOHC four-stroke competition motorcycle, not a street-oriented owner's booklet. Its seven chapters move from specifications and scheduled service into engine, chassis, electrical, and tuning work. The regional model designations and baseline tables matter: Yamaha separates selected carburetor settings, jet-needle specifications, and final-drive gearing for USA/Canada and other markets. The machine itself is identified for sanctioned closed-course competition rather than public-road or general recreational use.

The major engine, chassis, and electrical chapters are written for readers who already have basic knowledge and skill in Yamaha motorcycle service. That makes this manual best suited to technicians and experienced motorcycle mechanics; the inspection and tuning sections are also useful to competition riders who are already comfortable with workshop procedures.

Engine, Transmission, and FCR-MX39 Service

Engine coverage runs from fuel-tank, exhaust, and radiator removal through the carburetor, camshafts, cylinder head, valve train, piston and cylinder, clutch, water pump, balancer, oil pump, CDI magneto, and complete engine removal. The bottom-end chapters address crankcase splitting, crankshaft and bearing inspection and installation, transmission gear checks, shift-cam and shift-fork service, and final shifter-operation checks.

The carburetor section goes beyond routine jet changes. It covers the needle valve, float height, throttle valve, hot-starter plunger, accelerator pump, pilot screw, leak jet, and throttle-position sensor. The tuning chapter then relates atmospheric conditions and throttle opening to the main jet, pilot circuit, jet needle, and accelerator-pump response, with symptom-based charts and setting-part numbers.

Fork, Brake, Ignition, and TPS Procedures

Chassis procedures cover wheel bearings and brake discs, caliper piston/seal kits, master-cylinder kits, brake-hose installation and bleeding, fork damper and base-valve service, oil-seal replacement, steering bearing races, and swingarm/linkage bearings. Suspension setup material addresses fork oil-volume effects, optional spring selection, rider sag, and low- and high-speed compression and rebound damping, supported by front- and rear-suspension symptom charts.

Electrical troubleshooting follows a defined no-spark sequence from the spark-gap test and connections through the engine-stop switch, ignition coil, CDI magneto pickup and charging coils, neutral switch, and CDI unit. A separate TPS diagnostic chart covers sensor resistance, variable response, input and output voltage, replacement, alignment, and adjustment.

The rear-shock section has an important scope limit: it covers removal, spring and bearing work, inspection, and installation, but explicitly excludes disassembly of the shock cylinder or separate reservoir because it contains high-pressure nitrogen.

Diagrams, Specifications, and Special Tools

Visual references include engine lubrication diagrams, multi-view cable and hose routing diagrams, the complete ignition wiring diagram, ignition-system and TPS inspection flowcharts, and exploded job-order views for removal and disassembly work. Specification sections supply maintenance intervals, component-specific tightening torques, fluid and lubricant data, valve and chassis clearances, electrical test values, wear limits, and race-setup ranges.

The special-tool table distinguishes North American YM/YU numbers from the corresponding 90890 numbers used in other markets. Examples include the crankcase separating tool 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.

Yamaha warns that loosening the carburetor TPS screw except during sensor replacement can reduce engine performance; careless connector back-probing can also compromise sealing or damage electrical components. During crankcase repair, the case halves must separate evenly without force, and the crankshaft must be removed and installed with the specified tools rather than driven with a hammer.