2013–2014 Yamaha YZ250F(D) Owner's Service Manual (P/N 17D-28199-33-E0)

Yamaha’s Owner’s Service Manual for the 2013–2014 YZ250F(D), P/N 17D-28199-33-E0, covers operation, race maintenance, inspection, repair and tuning. This is the first edition, April 2012, with regional specifications for the USA, Canada, Australia, New Zealand, Europe and South Africa.

PDF Search, Bookmarks and Page Count

Finding service information: The service chapters have searchable text, although some safety notices and label graphics are not searchable. Embedded bookmarks provide access to individual service sections; the main chapter bookmarks return to the contents page. Small wire-color codes and connector labels in the wiring diagram are readable when enlarged.

One printable, English-language PDF with 198 pages, including the additional front cover, introductory pages, one unnumbered blank page and the back cover.

Engine Overhaul, Race Maintenance and Chassis Setup

The following content highlights show a selection of the work covered. Other topics include starting and break-in procedures, cleaning and storage.

• Race maintenance: Pre-operation checks, competition-based service schedules, air-filter care, oil and strainer service, valve-clearance adjustment and pad-selection tables.
• Engine repair: Step-by-step procedures for engine removal, camshaft and cylinder-head work, piston inspection, crankcase separation, crankshaft installation and balancer alignment.
• Clutch and transmission: Wet-clutch inspection and assembly, gear and bearing checks, shift-fork identification, shift-cam installation and operational checks.
• Carburetor service: Keihin FCR-MX39 disassembly, float-height inspection, accelerator-pump timing, jet selection and mixture troubleshooting.
• Cooling and lubrication: Radiator and cooling-system tests, centrifugal water-pump repair, dry-sump lubrication diagrams and oil-pump clearance checks.
• Chassis service: Front-fork disassembly and assembly, rear-shock spring and bearing service, brake overhaul and bleeding, wheel inspection and steering work.
• Electrical diagnosis: Wiring diagrams, ignition fault-isolation charts, CDI magneto tests, neutral-switch checks and throttle position sensor testing and adjustment.

The engine, chassis and electrical sections are written for readers with Yamaha servicing knowledge, including dealers and service engineers; the manual cautions inexperienced readers against undertaking this work solely by reference to its instructions.

Internal Engine Work and Assembly References

Exploded assembly views and job instruction charts accompany removal and disassembly work. The engine sections provide valve-to-guide measurements, piston-to-cylinder tolerances, crankshaft inspection limits and staged cylinder-head tightening instructions.

Pad-selection tables connect measured valve clearance with replacement adjusting-pad sizes. Camshaft timing illustrations and balancer alignment drawings support reassembly checks, while lubrication and cable-routing diagrams show oil paths and the intended positions of hoses, cables and electrical leads.

The valve section specifies that titanium valves used to lap the seats must be replaced afterward. Uneven camshaft-cap tightening can damage the cylinder head, caps and camshafts.

Carburetor Tuning and Cooling-System Checks

The tuning chapter relates jet selection to throttle opening, atmospheric conditions and running symptoms. Regional carburetor specifications distinguish European settings from those for the other listed markets, helping readers select the relevant baseline before evaluating a mixture problem.

Cooling coverage combines radiator-cap and system pressure tests with impeller-shaft, bearing and seal inspection. Total coolant capacity, including all routes, is specified as 1.00 L. Oil-service instructions distinguish routine changes from filter replacement and include the warm-up and settling conditions for checking the oil level.

Fork Service, Brakes and Suspension Limits

Front-fork procedures cover the base valve, damper assembly, seals and air bleeding. The tool references identify the cap bolt ring wrench YM-01501/90890-01501 and fork seal driver YM-A0948/90890-01502.

Brake coverage extends to caliper and master-cylinder disassembly, seal inspection, reassembly and hydraulic bleeding. Suspension-setting charts relate handling symptoms to the relevant checks and adjustments.

Rear-shock work covers removal, spring replacement, mounting bearings and setup. The manual warns against dismantling the high-pressure nitrogen cylinder or reservoir; this section should not be mistaken for an internal damper-rebuild guide.

Ignition Fault Isolation and TPS Testing

The ignition inspection chart helps trace a no-spark condition through connections, switches, coils and the CDI magneto before directing attention to the CDI unit. Component tests include lead-color references and resistance specifications.

The throttle position sensor section adds its own inspection chart, resistance tests, replacement procedure and input/output voltage checks.

Selected Valve-Clearance and Ignition Test Data

For valve-clearance inspection with the engine cold, the manual specifies 0.12–0.17 mm at the intake valves and 0.17–0.22 mm at the exhaust valves. These specifications accompany the adjustment procedures and pad-selection tables.

The CDI magneto pickup-coil resistance specification is 248–372 Ω at 20°C (68°F). The electrical section pairs this test value with lead identification and the ignition troubleshooting chart.