🏷️ Basic Information Identification Make: Yamaha Model: YZ250 Model Variant: YZ250T, YZ250T1 Year Range: 2002-2008 Codes Chassis Codes: 4SP, 4SR, 5XC, 5XJ, 1S7 👋 Introduction Market Position Segment: High-performance motocross and off-road competition motorcycle. Target Audience: Motocross racers, off-road enthusiasts, and general maintenance users seeking in-depth technical knowledge. Competitive Analysis Competitors: Honda CR250R, Kawasaki KX250, Suzuki RM250. Key Features Engine Type: Renowned for its potent 2-stroke power delivery and lightweight chassis. Chassis Design: Aluminum bilateral beam frame, contributing to agility and handling. Suspension Advancements: Industry-leading Kayaba (KYB) Speed Sensitive System (SSS) forks and a refined Monocross rear suspension system for superior damping and adjustability. 📋 Manual Details Coverage Areas Coverage: Comprehensive service, maintenance, troubleshooting, and repair information for Yamaha YZ250, YZ250T, and YZ250T1 models from 2002 to 2008. Page Count Page Count: 589 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, tuning, and troubleshooting for the 249cc liquid-cooled 2-stroke engine. Fuel System: Carburetor (Keihin PWK38S) specifications, adjustment, cleaning, and troubleshooting; fuel tank and lines. Ignition System: CDI ignition system, troubleshooting, component testing, and specifications. Cooling System: Radiator, hoses, water pump, thermostat, coolant specifications, and bleeding procedures. Transmission: 6-speed gearbox, clutch assembly (wet multi-plate), maintenance, disassembly, assembly, and lubrication. Suspension Front: Inverted telescopic fork (Kayaba), disassembly, assembly, oil change, seal replacement, compression/rebound adjustment, and spring rates. Suspension Rear: Monocross suspension, shock absorber, linkage system, bearing maintenance, and adjustment procedures. Brakes Front: Hydraulic disc brake system, caliper, master cylinder, brake fluid specifications (DOT 4), pad replacement, bleeding, and rotor inspection. Brakes Rear: Hydraulic disc brake system, caliper, master cylinder, brake fluid specifications (DOT 4), pad replacement, bleeding, and rotor inspection. Wheels And Tires: Wheel bearing inspection and replacement, spoke tension adjustment, tire pressure recommendations, and wheel alignment checks. Electrical System: Wiring diagrams, lighting system, ignition coil, stator, rectifier, and battery maintenance (if applicable for ignition). Frame And Bodywork: Frame inspection, subframe, footpegs, fuel tank, seat, fenders, and plastics removal/installation. Procedures Included Maintenance: Scheduled maintenance, routine checks, lubrication points, and cleaning procedures. Troubleshooting: Diagnostic charts for common problems, symptoms, causes, and corrective actions. Repair: Detailed step-by-step instructions for component repair and replacement. Rebuilds: Engine and transmission rebuild procedures, including torque specifications and critical measurements. Adjustments: Carburetor jetting, ignition timing, clutch play, suspension settings, and throttle cable adjustment. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and chassis overhauls. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Likely, depending on the original scanning quality. Typically, official service manuals are OCR'd. Print Quality Print Quality: Digital, allowing for high-resolution printing of individual pages or the entire manual. Binding Type Binding Type: Not applicable (digital download) Paper Type Paper Type: Not applicable (digital download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, reed valve induction, YPVS (Yamaha Power Valve System) Displacement: 249 cc Bore X Stroke: 66.4 mm x 72.0 mm Compression Ratio: 8.8:1 (typical, may vary slightly by year) Performance Horsepower: Approx. 45-50 HP (at crankshaft, manufacturer claims vary) Torque: Approx. 27-30 lb-ft (at crankshaft, manufacturer claims vary) Fuel System Carburetor: Keihin PWK38S, CDI controlled YPVS Fuel Type: Unleaded gasoline (91 octane or higher recommended) Lubrication Oil Mixture: Yamalube 2R or equivalent 2-stroke oil, pre-mix ratio 50:1 (gasoline:oil) 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed Clutch Type: Wet, multi-plate Features Gear Ratios: Refer to manual for specific year/model gear ratios. Typically includes: 1st: 2.615, 2nd: 1.933, 3rd: 1.556, 4th: 1.333, 5th: 1.182, 6th: 1.000 Final Drive: Chain drive, 520 O-ring type Transmission Oil Type: Yamalube Gear Oil 10W-30 or equivalent API SE, SF, SG type. Transmission Oil Capacity: 0.75 L (0.79 US qt) 📐 Dimensions Exterior Length: Approx. 81.7 inches (2075 mm) Width: Approx. 32.5 inches (825 mm) Height: Approx. 50.0 inches (1270 mm) Wheelbase: Approx. 57.7 inches (1465 mm) Weights Dry Weight: Approx. 217 lbs (98.5 kg) Wet Weight: Approx. 232 lbs (105 kg) (with fluids) Fuel Capacity: 2.4 US gal (9.0 L) Seat Height: Approx. 38.6 inches (980 mm) 🛡️ Safety Features Ratings Safety Standards: Not applicable for competition off-road vehicles in the same way as street-legal vehicles. Designed for off-road use only. Active Features Braking System: Powerful dual hydraulic disc brakes front and rear for effective stopping power. Passive Features Frame Strength: Rigid aluminum frame provides stability and control. Ergonomics: Optimized rider triangle for control and comfort during aggressive riding. 💡 Technology Features Infotainment Features: Not applicable to this competition-oriented off-road motorcycle. Driver Assistance Features: Not applicable. Focus is on rider control and mechanical systems. Connectivity Features: Not applicable. Powertrain Technology Ypvs: Yamaha Power Valve System enhances low-to-mid range torque and broadens the powerband. Suspension Technology Kayaba Sss Forks: Speed Sensitive System (SSS) forks offer superior...