Yamaha YZ250 Instruction Manual

YZ250M(5HC1) CANADA,U.S.A.,SOUTH AFRICA

YZ250 (5HC2) EUROPE

YZ250 (5HC3) JAPAN

YZ250M(5HC4) OCEANIA

205HC–100E1

FOREWORD

This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are

orderingreplacementparts,pleaserefertothisParts Catalogueandquotebothpartnumbersand

part names correctly.

YZ250M(5HC1/5HC4),YZ250(5HC2/5HC3)

1. Modifications or additions which have been made after issue of the Parts

Catalogue will be announced in the Yamaha Parts News.

It is advisable that you make necessary corrections to the Parts Catalogue

according to the Yamaha Parts News.

2. Abbreviations

The Following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number.

“UN” Use as many as needed.

“AP” Alternate Parts

“LM” Local Made (Parts need to be ordered locally)

“F#” Frame No. (Applicable machine No.)

3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in

front of the part name as shown below.

EXAMPLE

CARBURETOR ASSY

.JET, PILOT

.NOZZLE, MAIN

4. Number of component for assembly

The numeral appearing to the right of each component part indicates the

quantity of parts for each assembly unit.

EXAMPLE

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

1M1–83309–60 .REFLECTOR 1

5. Applicable colors of graphics are represented in the “REMARKS” as shown

below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 .FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 for MXR

6. Applicable Serial No.

Engine Serial No. Frame Serial No.

7. Note that the illustrations for reference in funding parts numbers, not to be

used for assembling. When assembling, pleas use the applicable service

manual.

8. The asterisk (*) before a reference number indicates modification items

after the first edition.

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross–refer the “model code –

production code No.” in the catalogue to the “model code – production code No.

“indicated on the Model Label affixed onto the product concemed.

(2) “Model Label”Indication

a: Model Type Code

b: Production Code No.

c: Colouring Type

xxxx – xxx

c4TW1–010

(3) Model Label Affixing Location

(4) Model Code – Production Code Number of Model Listed in This Parts Catalog

Model

Code Production

Code No. Country

(destination) Model

Code Production

Code No. Country

(destination)

010 U.S.A.

5HC1 020 CANADA

030 SOUTH AFRICA

010 FRANCE

020 GERMANY

5HC2 030 ESPAÑA

040 ENGLAND

050 ITALY

5HC3 010 JAPAN

010 AUSTRALIA

5HC4 020 NEW ZEALAND

(5) Colouning Information

Model

Code Colouring type

code Colour

code Colour Name Abbrevi-

ation

5HC1

5HC2 DEEP PURPLISH BLUE

5HC3 A0583 DEEP PURPLISH BLUE

SOLID E DPBSE

5HC4

FIG. 1 CYLINDER HEAD

1 5CU–11111–00 HEAD, CYLINDER 1 1 1 1 1

2 94702–00326 PLUG, SPARK (NGK BR8EG) 1 1 1 1

3 90116–08394 BOLT, STUD 6 6 6 6

4 93604–08071 PIN, DOWEL 2 2 2 2

5 90176–08026 NUT, CROWN 6 6 6 6

6 90201–08087 WASHER, PLATE 6 6 6 6

7 5CU–11311–00 CYLINDER 1 1 1 1 1

8 5CU–1131D–00 VALVE ASSY 1 1 1 1

9 5CU–1131U–00 HOLDER 3 1 1 1 1

10 98907–05012 SCREW, BIND 2 2 2 2

11 90201–057H5 WASHER, PLATE 2 2 2 2

12 5CU–1132A–00 VALVE 2 2 2 2 2

13 5CU–11351–10 GASKET, CYLINDER 1 1 1 1

14 90116–10314 BOLT, STUD 1 1 1 1

15 95617–10660 BOLT, STUD 1 1 1 1

16 90116–10314 BOLT, STUD 1 1 1 1

17 95617–10660 BOLT, STUD 1 1 1 1

18 99530–14016 PIN, DOWEL 2 2 2 2

19 95707–10500 NUT, FLANGE 4 4 4 4

20 93210–74316 O–RING 1 1 1 1

21 93211–02703 O–RING 1 1 1 1

22 5CU–1131E–00 HOLDER 1 1 1 1 1

23 5CU–1131P–00 HOLDER 4 1 1 1 1

24 93210–15639 O–RING 2 2 2 2

25 98507–05012 SCREW, PAN HEAD 4 4 4 4

26 90201–057H5 WASHER, PLATE 2 2 2 2

27 5CU–11830–00 LINK ASSY 1 1 1 1

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

FIG. 1 CYLINDER HEAD

28 98907–05012 SCREW, BIND 2 2 2 2

29 93104–08040 OIL SEAL 1 1 1 1

30 4SS–11832–00 LEVER, LINK 1 1 1 1

31 90508–155B8 SPRING, TORSION 2 2 2 2

32 5CU–1132E–00 PULLEY 1 1 1 1 1

33 5CU–1132F–00 PULLEY 2 1 1 1 1

34 90201–081G0 WASHER, PLATE 2 2 2 2

35 90501–046L6 SPRING, COMPRESSION 2 2 2 2

36 5CU–1131V–00 SHAFT 1 1 1 1 1

37 91317–04008 BOLT 3 3 3 3

38 5CU–11991–00 HOUSING 1 1 1 1 1

39 5CU–11993–00 .GASKET 1 1 1 1

40 97007–05020 BOLT 4 4 4 4

41 92907–05600 WASHER, PLATE 4 4 4 4

42 5CU–11995–00 SEAL, HOUSING 1 1 1 1

43 5CU–1131M–00 COVER 1 1 1 1

44 353–13115–01 CONNECTOR, SUCTION PIPE 1 1 1 1

45 5CU–11354–00 GASKET 1 1 1 1

46 98907–05016 SCREW, BIND 4 4 4 4

47 90445–09226 HOSE 1 1 1 1

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

FIG. 2 GOVERNOR

1 4JY–11915–01 PLATE, THRUST 1 1 1 1 1

2 98907–05012 SCREW, BIND 1 1 1 1

3 90105–05002 BOLT, WASHER BASED 1 1 1 1

4 90201–057H5 WASHER, PLATE 1 1 1 1

5 90387–085E1 COLLAR 1 1 1 1

6 93104–08040 OIL SEAL 1 1 1 1

7 5CU–11990–00 PUSH ROD ASSY 1 1 1 1

8 3JE–11922–01 FORK, GOVERNOR 1 1 1 1

9 91317–04006 BOLT 2 2 2 2

10 93300–60801 BEARING (B0060) 1 1 1 1 KOYO

11 93300–60801 BEARING (B0060) 1 1 1 1 KOYO

12 5X4–11921–02 SHAFT, GOVERNOR 1 1 1 1

13 24X–11953–01 GEAR, GOVERNOR 1 1 1 1

14 90501–256L2 SPRING, COMPRESSION 1 1 1 1

15 5CU–11952–00 PLATE 1 1 1 1

16 90201–150U6 WASHER, PLATE 4 4 4 4

17 90387–152F2 COLLAR 1 1 1 1

18 93340–21505 BEARING 2 2 2 2

19 5CU–11912–00 RETAINER, WEIGHT 1 1 1 1

20 5CU–11911–00 RETAINER 1 1 1 1

21 93507–16020 BALL 4 4 4 4

22 93603–14240 PIN, DOWEL 1 1 1 1

23 93604–29184 PIN, DOWEL 1 1 1 1 AP FOR PUSH ROD

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

FIG. 3 CRANKSHAFT. PISTON

1 5CU–11631–00–A0 PISTON (STD) 1 1 1 1 UR

5CU–11631–00–B0 PISTON (STD) 1 1 1 1 UR

5CU–11631–00–C0 PISTON (STD) 1 1 1 1 UR

5CU–11631–00–D0 PISTON (STD) 1 1 1 1 UR

2 5CU–11603–00 PISTON RING SET (STD) 1 1 1 1

3 5CU–11633–10 PIN, PISTON 1 1 1 1

4 93450–19052 CIRCLIP 2 2 2 2

5 93310–218A6 BEARING 1 1 1 1

6 5CU–11400–00 CRANKSHAFT ASSY 1 1 1 1

7 5CU–11410–00 .CRANKSHAFT 1 1 1 1

8 5CU–11420–00 .CRANKSHAFT 1 1 1 1

9 5CU–11681–00 .PIN, CRANK 1 1 1 1 1

10 5CU–11651–00 .ROD, CONNECTING 1 1 1 1

11 93310–5240J .BEARING 1 1 1 1

12 90209–24327 .WASHER 2 2 2 2

13 93306–37808 BEARING 1 1 1 1

14 93102–20485 OIL SEAL 1 1 1 1

15 90280–03045 KEY, WOODRUFF 1 1 1 1

16 93306–37808 BEARING 1 1 1 1

17 93103–36182 OIL SEAL 1 1 1 1

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

FIG. 4 WATER PUMP

1 5CU–12459–00 GEAR, IMPELLER SHAFT 1 1 1 1

2 5DJ–12451–00 IMPELLER, WATER PUMP 1 1 1 1

3 90201–08512 WASHER, PLATE 1 1 1 1

4 93109–11073 OIL SEAL 1 1 1 1

5 93102–12106 OIL SEAL (SD 12–22–5 HS) 1 1 1 1

6 93306–00105 BEARING (B6001) 1 1 1 1

7 90201–08784 WASHER, PLATE 1 1 1 1

8 99001–06600 CIRCLIP 1 1 1 1

9 5CU–12422–00 COVER, HOUSING 1 1 1 1

10 5CU–12428–00 GASKET, HOUSING COVER 2 1 1 1 1

11 93604–10011 PIN, DOWEL 2 2 2 2

12 90430–06014 GASKET 1 1 1 1

13 95027–06025 BOLT, FLANGE 2 2 2 2

14 95027–06065 BOLT, FLANGE 2 2 2 2

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

FIG. 5 RADIATOR. HOSE

1 4SR–1240A–10 RADIATOR ASSY 1 1 1 1

2 91A20–05065 TUBE, FLEXIBLE VINYL 1 1 1 1

3 90467–09006 CLIP 1 1 1 1

4 4SR–12461–10 RADIATOR ASSY 1 1 1 1

5 5HD–12462–00 CAP, RADIATOR 1 1 1 1

6 5CU–12481–00 PIPE 1 1 1 1 1

7 4SS–12482–00 PIPE 2 2 2 2 2

8 5CU–12484–00 PIPE 4 1 1 1 1

9 90450–28014 HOSE CLAMP ASSY 4 4 4 4

10 90450–25037 HOSE CLAMP ASSY 2 2 2 2

11 90467–21068 CLIP 2 2 2 2

12 90480–15528 GROMMET 6 6 6 6

13 90387–0614M COLLAR 6 6 6 6

14 90119–06214 BOLT, WITH WASHER 6 6 6 6

PART NO. DESCRIPTION REMARKS

REF.

NO.

5HC1

5HC2

5HC3

5HC4

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