ASSEMBLY MANUAL
LIT-11666-16-39
5UL-28107-10
EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct reassembly of this Yamaha
machine prior to delivery to the customer. Since some external parts of the machine have been
removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is
required. It should be noted that the assembled machine should be thoroughly cleaned, inspected, and
adjusted prior to delivery to the customer.
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NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its model. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the machine and/or rider.
CONCERNING CRATE DAMAGE:
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
!
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
w
Failure to follow WARNING instructions
could result in severe injury or death
to
the machine operator, a bystander, or a person inspecting or repairing the
machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
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YZ250FR
ASSEMBLY MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, August 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11666-16-39
(1)
(2)
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SYMBOLS USED IN
ASSEMBLY MANUAL
In order to simplify descriptions in this
assembly manuals, the following symbols
are used:
(1) Coat with lithium-soap-based-grease.
(2) Tighten to 10 Nm.
(10 Nm = 1.0mdkg = 7.2 ftdlb)
(3) Towards the front of the machine.
(4) Clearance required.
(5) Install so that the arrow mark faces
upward.
(6) Apply a motor oil.
(7) Made of rubber or plastics.
(8)
(3)
(4)
(5)
(6)
(7)
A: Ref No. (indicating the order of opera-
tions.)
B: Part name
C: Quantity of parts per machine.
D: Place where parts are held.
V: Stored in vinyl bag.
C: Stored in carton box.
S: Fixed inside the steel frame,
and/or contained in the styrofoam
tray (upper or lower).
*: Temporarily installed or secured.
E: Size or material of parts.
d/D: Diameter of part.
l: Length of part.
(8)
ex, D = 5 (0.2) = 5mm (0.2 in)