2013 Yamaha YZ250F(D) Owner's Service Manual PDF (P/N 17D-28199-33-E0)

Yamaha's 2013 YZ250F(D) Owner's Service Manual covers USA, Canadian, European, Australian, New Zealand, and South African market specifications. The repair chapters are in English: publication 17D-28199-33-E0, first edition April 2012. The multilingual outer cover carries 17D-28199-33.

Search, bookmarks and wiring detail: Service text is searchable, but some introductory notices and safety-label text are not. Subsection bookmarks link to the procedures; chapter-level entries point to the contents page. Small wiring and connector labels are clear when enlarged.

• Engine repair: Engine removal, cylinder-head and piston inspection, camshaft timing, valve clearance adjustments, crankcase separation, and crankshaft installation.

• Clutch and transmission: Wet-clutch disassembly and component replacement, kickstart and shift-shaft repair, and inspection of five-speed transmission gears, shift cam, and shift forks.

• Fuel and cooling: FCR-MX39 carburetor overhaul, accelerator-pump timing, radiator pressure testing, and water pump servicing, including shaft, bearing, and seal replacement.

• Brakes and chassis: Brake master cylinder rebuilding, caliper service, hydraulic brake bleeding, wheel-bearing replacement, steering head bearings, swingarm linkage inspection, and drive chain alignment.

• Suspension and tuning: Front fork rebuilds, rear Monocross suspension adjustment, carburetor jetting references, and symptom-based suspension setting charts.

• Electrical diagnosis: Wiring diagrams, ignition-system troubleshooting, CDI magneto inspections, and throttle position sensor testing, replacement, and output-voltage adjustment.

The engine, chassis, and electrical repair sections are intended for readers with existing Yamaha motorcycle servicing knowledge and skills; Yamaha recommends dealer maintenance for the front fork.

Engine Repair and Maintenance

This service manual details inspection and adjustment of the 250 cm³ DOHC 4-stroke engine. The maintenance schedule distinguishes break-in checks, race-based intervals, and condition-dependent work, including engine oil changes, cooling system flushes, and valve clearance checks.

Top-end work: Intake and exhaust pad-selection charts support valve adjustment. Inspection tables cover piston-to-cylinder clearance, valve-seat width, and cylinder-head warpage. Titanium intake and exhaust valves have specific lapping and replacement restrictions.

Camshaft assembly notes explain how uneven cap tightening can damage the cylinder head, camshaft caps, and camshafts.

Bottom-end work: Crankcase, crankshaft, balancer, and transmission procedures cover internal inspection and reassembly. The special-tool list identifies the crankcase separator YU-1135-A / 90890-01135, with separate US/Canadian and other-market tool numbers.

Component-specific torque tables cover engine mounting brackets, wheel axles, brake caliper bolts, and other service fasteners.

FCR-MX39 Carburetor and Market Differences

Carburetor repair covers the float valve, cold and hot starter plungers, accelerator-pump diaphragm, and throttle mechanism. Setting tables distinguish the European NFPQ jet needle from the NFPR used in the other listed markets.

The tuning chapter relates jet circuits to throttle opening and atmospheric conditions and lists jet and needle part numbers. Silencer repacking is documented separately for USA/Canada and other markets.

Fuel-system work involves highly flammable gasoline; follow the manual's handling precautions.

Cooling and Dry-Sump Lubrication

Radiator and cap pressure tests accompany cooling-system flushing and water-pump repair. Lubrication diagrams trace the oil circuit, with separate procedures for the oil tank, strainers, delivery pipes, and oil pump.

Front Forks and Rear Monocross Suspension

Front telescopic fork service covers oil-seal replacement, base-valve inspection, damper bleeding, and reassembly. The manual flags internal valve damage if the damper assembly drops into the inner tube during installation.

Rear shock coverage includes removal, spring and bearing replacement, preload, and damping adjustment. Internal rebuilding of the shock cylinder and high-pressure nitrogen reservoir is outside this scope; the manual warns against disassembling them.

Factory baseline settings for suspension damping and carburetor jetting are paired with symptom charts, helping relate handling or throttle-response complaints to the relevant setting.

CDI and Throttle Position Sensor Diagnostics

Separate ignition and TPS inspection flowcharts accompany ignition-coil, pickup-coil, and charging-coil resistance tests. CDI fault isolation also includes the TPS input-voltage check.

Detailed cable routing diagrams for the hot starter, throttle cables, and electrical harnesses aid in accurate reassembly after major service tasks.

English PDF and Included Pages

Supplied as one printable 198-page PDF: 186 chapter pages, 10 cover and introductory pages, one blank separator page, and the back cover. The 10 opening pages include the multilingual cover and reading notice; all are already included in the total.