Yamaha YZ250 1994-1998, WR250 1994-1997 Repair & Service Manual

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Item # M498  ISBN: 0892877472




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This repair & service manual covers Yamaha YZ250 1994-1998, and WR250Z 1994-1997 motocross and off-road bikes.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE—GENERAL INFORMATION
Manual organization | Cleaning parts | Handling gasoline safely | Service hints | Serial numbers | Warning labels | Torque specifications | Fasteners | Lubricants | Sealant, cements and cleaners | Threadlocking compound | Basic hand tools | Precision measuring tools | Test equipment | Special tools | Mechanic's tips | Bearing replacement | Seals

CHAPTER TWO—TROUBLESHOOTING
Operating requirements | Starting the engine | Starting difficulties | Engine performance | Engine noises | Two-stroke leak down test | Fuel system | Electrical troubleshooting | Test equipment | Ignition system | Clutch | External shift mechanism and transmission | Kickstarter | Drive train noise | Front suspension and steering | Rear suspension | Frame noise | Brakes

CHAPTER THREE—LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals | Tune-up | Pre-ride inspection | Engine lubrication | Transmission oil | Air filter | Engine compression check | Ignition timing | Spark plug | Carburetor | Exhaust system | Cooling system | Control cable lubrication | Clutch | Throttle cable adjustment | Engine top end inspection | Kickstarter pedal and shift pedal | Brakes | Drive chain and sprockets | Tires and wheels | Wheel bearings | Steering | Front fork | Rear swing arm and linkage | General lubrication | Nuts, bolts and other fasteners | Storage

CHAPTER FOUR—ENGINE TOP END
Engine operating principals | Cleanliness | Exhaust system | Cylinder head | Cylinder block | Exhaust valve | Exhaust valve service | Piston, piston pin, and piston rings | Reed valve assembly | Engine break-in

CHAPTER FIVE—ENGINE BOTTOM END
Servicing engine in frame | Engine | Countershaft seal replacement | Left-side main bearing seal replacement | Crankcase and crankshaft

CHAPTER SIX—CLUTCH, KICKSTARTER, IDLE GEAR AND EXTERNAL SHIFT MECHANISM
Clutch cover | Clutch release lever | Right crankcase cover | Exhaust valve governor | Clutch | Clutch service | Primary drive gear | Kickstarter and idle gear | External shift mechanism | Clutch cable replacement

CHAPTER SEVEN—TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation | Transmission troubleshooting | Transmission | Transmission overhaul | Transmission inspection | Internal shift mechanism

CHAPTER EIGHT—FUEL SYSTEM
Carburetor | Carburetor (1994 YZ250) | Carburetor (1995 YZ250) | Carburetor (1996-1998 YZ250) | Carburetor (1994-1997 WR250Z) | Carburetor cleaning and inspection (all models and years) | Float level adjustment | Carburetor rejetting | Fuel tank | Fuel valve | Throttle cable replacement

CHAPTER NINE—IGNITION SYSTEM
Component testing | Capacitor discharge ignition | Flywheel | Stator coils | CDI unit | Ignition coil | Engine stop switch | Ignition timing

CHAPTER TEN—LIQUID COOLING SYSTEM
Safety precautions | Hoses and hose clamps | Cooling system inspection | Radiators | Water pump (1994-1997 YZ250,1994-on WR250Z) | Water pump (1998 YZ250)

CHAPTER ELEVEN—WHEELS, TIRES AND DRIVE CHAIN
Front wheel | Rear wheel | Front and rear hubs | Rim and spoke service | Tire changing | Drive chain | Sprocket replacement

CHAPTER TWELVE—FRONT SUSPENSION AND STEERING<
Handlebar | Steering head | Front fork oil change and oil level adjustment | Front fork | Fork tools (all models) | Front fork service (1994-1997) | Front fork (1998) | Inspection (all models) | Fork oil refilling (1998 models) | Front fork adjustment (1994-1997) | Front fork adjustment (1998)

CHAPTER THIRTEEN—REAR SUSPENSION
Rear suspension system | Shock absorber (all models) | Shock linkage (1994-1995 YZ250, 1994-on WR250Z) | Rear swing arm (1994-1995 YZ250, 1994-on WR250Z) | Shock linkage (1996-on YZ250) | Rear swing arm (1996-on YZ250) | Rear swing arm service (all models) | Connecting rod and relay arm (all models) | Rear suspension adjustment

CHAPTER FOURTEEN—BRAKES
Brake fluid selection | Disc brake | Front brake pads | Brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake hose replacement | Brake disc | Draining brake fluid | Brake bleeding | Rear brake pedal

CHAPTER FIFTEEN—BODY
Seat | Side covers | Radiator covers | Front fender | Rear fender | Subframe

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Yamaha YZ250 1994-1998, WR250 1994-1997 Repair & Service Manual