Yamaha TZ250M1 Application guide

5KE-28199-10LIT-11626-13-41

OWNER’S SERVICE MANUAL

TZ250M1/(M)

OWNER’S SERVICE MANUAL

1st Edition, September 1999

unauthorized use without the written

permission of Yamaha Motor Corporation

U.S.A. is expressly prohibited.

Printed in Japan

P/N. LIT-11626-13-41

EC010000

EC020000 INTRODUCTION

Congratulations on your purchase of a Yamaha

TZ series. This model is the culmination of

Yamaha’s vast experience in the production of

pacesetting racing machines. It represents the

highest grade of craftsmanship and reliability

that have made Yamaha a leader.

This manual explains operation, inspection,

basic maintenance and tuning of your

machine. If you have any questions about this

manual or your machine, please contact your

Yamaha dealer.

NOTE:

As improvements are made on this model,

some data in this manual may become outdat-

ed. If you have any questions, please consult

your Yamaha dealer.

PLEASE READ THIS MANUAL CAREFULLY

AND COMPLETELY BEFORE OPERATING

THIS MACHINE. DO NOT ATTEMPT TO

OPERATE THIS MACHINE UNTIL YOU

HAVE ATTAINED A SATISFACTORY

KNOWLEDGE OF ITS CONTROLS AND

OPERATING FEATURES AND UNTIL YOU

HAVE BEEN TRAINED IN SAFE AND PROP-

ER RIDING TECHNIQUES. REGULAR

INSPECTIONS AND CAREFUL MAINTE-

NANCE, ALONG WITH GOOD RIDING

SKILLS, WILL ENSURE THAT YOU SAFELY

ENJOY THE CAPABILITIES AND THE

RELIABILITY OF THIS MACHINE.

EC030010 WARRANTY INFORMATION

This model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD-

LESS OF THE INTENDED USE.

THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPON-

SIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.

EC040001 IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY

FOR COMPETITION USE, ONLY ON A

CLOSED COURSE. It is illegal for this

machine to be operated on any public street,

road, or highway. Off-road use on public lands

may also be illegal. Please check local regula-

tions before riding.

1. THIS MACHINE IS TO BE OPERATED

BY AN EXPERIENCED RIDER ONLY.

Do not attempt to operate this

machine at maximum power until you

are totally familiar with its character-

istics.

2. THIS MACHINE IS DESIGNED TO BE

RIDDEN BY THE OPERATOR ONLY.

Do not carry passengers on this

machine.

3. ALWAYS WEAR PROTECTIVE APPAR-

EL.

When operating this machine, always

wear an approved helmet with gog-

gles or a face shield. Also wear heavy

boots, gloves, and protective cloth-

ing. Always wear proper fitting cloth-

ing that will not be caught in any of

the moving parts or controls of the

machine.

4. ALWAYS MAINTAIN YOUR MACHINE

IN PROPER WORKING ORDER.

For safety and reliability, the machine

must be properly maintained. Always

perform the pre-operation checks

indicated in this manual. Correcting a

mechanical problem before you ride

may prevent an accident.

5. GASOLINE IS HIGHLY FLAMMABLE.

Always turn off the engine while refu-

eling. Take care to not spill any gaso-

line on the engine or exhaust system.

Never refuel in the vicinity of an open

flame, or while smoking.

&SAFETY INFORMATION

6. GASOLINE CAN CAUSE INJURY.

If you should swallow some gasoline,

inhale excess gasoline vapors, or

allow any gasoline to get into your

eyes, contact a doctor immediately. If

any gasoline spills onto your skin or

clothing, immediately wash skin

areas with soap and water, and

change your clothes.

7. ONLY OPERATE THE MACHINE IN AN

AREA WITH ADEQUATE VENTILA-

TION.

Never start the engine or let it run for

any length of time in an enclosed

area. Exhaust fumes are poisonous.

These fumes contain carbon monox-

ide, which by itself is odorless and

colorless. Carbon monoxide is a dan-

gerous gas which can cause uncon-

sciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY;

TURN OFF THE ENGINE.

Always turn off the engine if you are

going to leave the machine. Do not

park the machine on a slope or soft

ground as it may fall over.

9. PROPERLY SECURE THE MACHINE

BEFORE TRANSPORTING IT.

When transporting the machine in

another vehicle, always be sure it is

properly secured and in an upright

position and that the fuel cock is in

the “OFF” position. Otherwise, fuel

may leak out of the carburetor or fuel

tank.

EC050000 TO THE NEW OWNER

This manual will provide you with a good basic

understanding of features, operation, and

basic maintenance and inspection items of this

machine. Please read this manual carefully

and completely before operating your new

machine. If you have any questions regarding

the operation or maintenance of your machine,

please consult your Yamaha dealer.

NOTE:

This manual should be considered a perma-

nent part of this machine and should remain

with it even if the machine is subsequently

sold.

EC060000 NOTICE

Some data in this manual may become outdat-

ed due to improvements made to this model in

the future. If there is any question you have

regarding this manual or your machine, please

consult your Yamaha dealer.

Weights of machines without fuel

The minimum weights for road race

machines are:

for the class 125 cc . . . . . . . . . . .minimum

70 kg (154 lb)

for the class 250 cc . . . . . . . . . . .minimum

95 kg (209 lb)

for the class 500 cc . . . . . . . . . . .minimum

131 kg (289 lb)

In modifying your machine (e.g., for weight

reduction), take note of the above limits of

weight.

EC070011

F.I.M. MACHINE WEIGHTS:

EC080000 HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFOR-

MATION

The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS

INVOLVED!

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.

CCCAUTION:

A CAUTION indicates special precautions that

must be taken to avoid damage to the

machine.

NOTE:

A NOTE provides key information to make pro-

cedures easier or clearer.

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

“General Information”, “Specifications”,

“Regular inspection and adjustments”,

“Engine”, “Chassis”, “Electrical” and

“Tuning”.

2. The table of contents is at the beginning of

the manual. Look over the general layout of

the book before finding then required chap-

ter and item.

Bend the book at its edge, as shown, to find

the required fore edge symbol mark and go

to a page for required item and description.

EC083000

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The infor-

mation has been complied to provide the mechanic with an easy to read, handy reference that con-

tains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.,

•Bearings

Pitting/Damage ≥Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 1is provided for removal and disassembly jobs.

2. Numbers 2are given in the order of the jobs in the exploded diagram.Anumber that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

3. The meanings of the symbol marks are given on the next page.

4. Ajob instruction chart 4accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. Extent of removal 5is provided in the job instruction chart to save the trouble of an unneces-

sary removal job.

6. For jobs requiring more information, the step-by-step format supplements 6are given in addi-

tion to the exploded diagram and job instruction chart.

CLUTCH

4-25

ENG

EC4A8100

CLUTCH HOUSING AND PUSH LEVER AXLE

Extend of removal: 1Clutch housing removal 2Push lever axle removal

Extend of removal Order Part name Q’ty Remarks

CLUTCH HOUSING AND

PUSH LEVER AXLE

REMOVAL

1 Nut (clutch boss) 1

2 Lock washer 1 Use special tool.

3 Clutch boss 1 Refer to “REMOVAL POINTS”.

4 Spacer 2 1

5 O-ring (small) 1

6 Clutch housing 1

7 O-ring (large) 1

8 Bearing 1

9 Spacer 1 1

10 Ball 1

11 Push rod 1

12 Bolt (seat plate) 1

13 Seat plate 1

14 Push lever axle 1

50 Nm (5.0 mdkg, 36 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

CLUTCH

4-26

EC4A3000

REMOVAL POINTS

EC483211

Clutch boss

1. Remove:

•Nut 1

•Lock washer 2

•Clutch boss 3

NOTE:

Straighten the lock washer tab and use the

clutch holding tool 4, 5to hold the clutch

boss.

Clutch holding tool:

YM-91042 . . . . . . . . . . . . . . . .44

90890-04086 . . . . . . . . . . . . .55

AFor USA and CDN

BExcept for USA and CDN

EC4A4000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

•Clutch housing 1

Cracks/Wear/Damage ≥Replace.

•Clutch boss 2

Scoring/Wear/Damage ≥Replace.

EC4A4100

Clutch housing

1. Check:

•Circumferential play

Free play exists ≥Replace.

•Gear teeth a

Wear/Damage ≥Replace.

•O-ring 1

Damage ≥Replace.

EC484400

Clutch spring

1. Measure:

•Clutch spring free length a

Out of specification ≥Replace springs as

a set.

Clutch spring free length:

Standard <Limit>

36.0 mm (1.417 in) 35.0 mm (1.378 in)

{

ENG

EC085002

ILLUSTRATED SYMBOLS

(Refer to the illustration)

Illustrated symbols 1to 7are designed as

thumb tabs to indicate the chapter’s number

and content.

1General information

2Specifications

3Regular inspection and adjustments

4Engine

5Chassis

6Electrical

7Tuning

Illustrated symbols 8to ¢are used to identi-

fy the specifications appearing in the text.

8With engine mounted

9Special tool

0Filling fluid

¡Lubricant

™Tightening

£Specified value, Service limit

¢Resistance ( Ω), Voltage ( V ), Electric cur-

rent ( A )

Illustrated symbols ∞to ªin the exploded dia-

grams indicate grade of lubricant and location

of lubrication point.

∞Apply transmission oil

§Apply engine mixing oil

¶Apply molybdenum disulfide oil

•Apply lightweight lithium-soap base grease

ªApply molybdenum disulfide grease

Illustrated symbols ºto !in the exploded dia-

grams indicate where to apply a locking agent

and where to install new parts.

ºApply locking agent (LOCTITE®)

!Use new one

GEN

INFO

INSP

ADJ

CHAS

TUN

ELEC

ENG

SPEC

∞

º!

•ª

¶§

™

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