YAMAHA YZ250R PARTS CATALOGUE 03
YZ250R
(5UP1)
USA,CANADA,S.AFRICA
YZ250
YZ250
YZ250R
(5UP2)
(5UP3)
(5UP4)
EUROPE
JAPAN
AUSTRALIA,NEW ZEALAND
1B5UP−100E1
YZ250R/YZ250
PARTS CATALOGUE
E2002 by Yamaha Motor Co., Ltd.
1st Edition, Jul. 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
A3
A4
FOREWORD
This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are
ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and
part names correctly.
YZ250R(5UP1/5UP4),YZ250(5UP2/5UP3)
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. 1 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 finding parts numbers, not to be
used for assembling. When assembling, please use the applicable service
manual.
8. The asterisk (*) before a reference number indicates modification items
after the first edition.
A5
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
ab
xxxx – xxx
c
x
(3) Model Label Affixing Location
a: Model Type Code
b: Production Code No.
c: Colouring Type
4TW1–010
A
(4) Model Code − Production Code Number of Model Listed in This Parts Catalog
Model
Code
5UP1
5UP2
5UP3 010 JAPAN
5UP4
Production
Code No.
010 USA
020 CANADA
030
010 FRANCE
020 GERMANY
030 SPAIN
040 ENGLAND
050 ITALY
010 AUSTRALIA
020
Country
(destination)
SOUTH AFRICA
NEW ZEALAND
Model
Code
Production
Code No.
(destination)
Country
(5) Coloring Information
Model
Code
5UP1
5UP2
5UP3
5UP4
A6
Colouring type
code
A 0583
Colour
code
Colour Name
DEEP PURPLISH BLUE
SOLID E
Abbrevi-
ation
DPBSE
ENGINE
CYLINDER HEAD B2...................................
GOVERNOR B4........................................
CRANKSHAFT. PISTON B5..............................
WATER PUMP B6......................................
RADIATOR. HOSE B7...................................
INTAKE B8............................................
CARBURETOR B9.....................................
EXHAUST B13..........................................
CRANKCASE B14.......................................
CRANKCASE COVER 1 B15..............................
STARTER C2..........................................
CLUTCH C3...........................................
TRANSMISSION C5....................................
SHIFT CAM. FORK C7..................................
SHIFT SHAFT C8......................................
CHASSIS
FRAME C9............................................
FENDER C11...........................................
SIDE COVER C12.......................................
REAR ARM C13.........................................
REAR SUSPENSION C15................................
STEERING D3.........................................
FRONT FORK D4......................................
FUEL TANK D7........................................
SEAT D9..............................................
FRONT WHEEL D10.....................................
FRONT BRAKE CALIPER D11............................
REAR WHEEL D12......................................
CONTENTS
REAR BRAKE CALIPER D14.............................
STEERING HANDLE. CABLE D15.........................
FRONT MASTER CYLINDER E2.........................
STAND. FOOTREST E3.................................
REAR MASTER CYLINDER E4..........................
GENERATOR E5.......................................
HANDLE SWITCH. LEVER E6...........................
ELECTRICAL 1 E7.....................................
ALTERNATE (CHASSIS) E8.............................
OPTIONAL PARTS 1 E10.................................
INDEX
NUMERICAL INDEX M1.................................
FIG. 1 CYLINDER HEAD
REF.
NO.
1 5UP−11111−00 HEAD, CYLINDER 1 1 1
2 94702−00326 PLUG, SPARK (NGK BR8EG) 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 90201−080L8 WASHER, PLATE 6 6 6 6
7 5UP−11311−00 CYLINDER 1 1 1 1 1
8 5NX−1131D−01 VALVE ASSY 1 1 1 1
9 5CU−1131U−10 HOLDER 3 1 1 1 1
10 90109−05001 BOLT 2 2 2 2
11 5CU−1132A−00 VALVE2 2222
12 5UP−11351−00 GASKET, CYLINDER 1 1 1 1
13 90116−10314 BOLT, STUD 1 1 1 1
PART NO. DESCRIPTION REMARKS
5MW−11111−01 HEAD, CYLINDER 1 1 1
94709−00326 PLUG, SPARK (NGK BR8EG) 1
5UP1
5UP2
5UP3
5UP4
B2
14 95617−10660 BOLT, STUD 1 1 1 1
15 90116−10314 BOLT, STUD 1 1 1 1
16 95617−10660 BOLT, STUD 1 1 1 1
17 99590−14016 PIN, DOWEL 2 2 2 2
18 90179−10M35 NUT 4 4 4 4
19 93210−74316 O−RING 1 1 1 1
20 93211−02703 O−RING 1 1 1 1
21 5CU−1131E−00 HOLDER 1 1 1 1 1
22 5CU−1131P−00 HOLDER 4 1 1 1 1
23 93210−15639 O−RING 2 2 2 2
24 98507−05012 SCREW 4 4 4 4
25 90201−057H5 WASHER, PLATE 2 2 2 2
FIG. 1 CYLINDER HEAD
REF.
NO.
26 5CU−11830−00 LINK ASSY 1 1 1 1
27 98907−05012 SCREW, BIND 2 2 2 2
28 93104−08040 OIL SEAL 1 1 1 1
29 5NX−11395−00 HOLDER 1 1 1 1
30 4SS−11832−00 LEVER, LINK 1 1 1 1
31 90508−155B8 SPRING, TORSION 2 2 2 2
32 5MW−1132E−00 PULLEY 1 1 1 1 1
33 5MW−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
PART NO. DESCRIPTION REMARKS
5UP1
5UP2
5UP3
5UP4
B3
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 90445−09777 HOSE (L300) 1 1 1 1
FIG. 2 GOVERNOR
REF.
NO.
1 4JY−11915−01 PLATE, THRUST 1 1 1 1 1
2 98907−05012 SCREW, BIND 1 1 1 1
3 90105−05002 BOLT, FLANGE 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 5NY−11953−00 GEAR, GOVERNOR 1 1 1 1
14 90501−256L2 SPRING, COMPRESSION 1 1 1 1
15 5CU−11952−00 PLATE 1 1 1 1
PART NO. DESCRIPTION REMARKS
5UP1
5UP2
5UP3
5UP4
B4
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
FIG. 3 CRANKSHAFT. PISTON
REF.
NO.
1 5NX−11631−00−A0 PISTON (STD) 1 1 1 1 UR
2 5CU−11603−10 PISTON RING SET (STD) 1 1 1 1
3 5UP−11633−00 PIN, PISTON 1 1 1 1
4 93450−19052 CIRCLIP 2 2 2 2
5 93310−218A6 BEARING 1 1 1 1
6 5UP−11400−00 CRANKSHAFT ASSY 1 1 1 1
7 5UP−11410−00 .CRANKSHAFT 1 1 1 1
8 5MW−11420−00 .CRANKSHAFT 1 1 1 1
9 5CU−11681−00 .PIN, CRANK 1 1 1 1 1
10 5MW−11651−00 .ROD, CONNECTING 1 1 1 1
11 93310−52406 .BEARING 1 1 1 1
12 90209−24327 .WASHER 2 2 2 2
PART NO. DESCRIPTION REMARKS
5NX−11631−00−B0 PISTON (STD) 1 1 1 1 UR
5NX−11631−00−C0 PISTON (STD) 1 1 1 1 UR
5NX−11631−00−D0 PISTON (STD) 1 1 1 1 UR
5UP1
5UP2
5UP3
5UP4
B5
13 93306−37808 BEARING 1 1 1 1
14 93102−20485 OIL SEAL 1 1 1 1
15 90280−03017 KEY, WOODRUFF 1 1 1 1
16 93306−37808 BEARING 1 1 1 1
17 93102−28004 OIL SEAL 1 1 1 1
FIG. 4 WATER PUMP
REF.
NO.
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 12−22−5HS) 1111
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 5MW−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
5UP1
5UP2
5UP3
5UP4
B6
FIG. 5 RADIATOR. HOSE
REF.
NO.
1 5NX−1240A−00 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 5NX−12461−00 RADIATOR ASSY 1 1 1 1
5 5HD−12462−00 CAP, RADIATOR 1 1 1 1
6 5CU−12481−10 PIPE 1 1 1 1 1
7 5NY−12482−00 PIPE 2 2 2 2 2
8 5CU−12484−10 PIPE 4 1 1 1 1
9 90450−28014 HOSE CLAMP ASSY 4 4 4 4
10 90450−25037 HOSE CLAMP ASSY 4 4 4 4
11 90480−15528 GROMMET 6 6 6 6
12 90387−0614M COLLAR 6 6 6 6
13 90119−06038 BOLT, WITH WASHER 6 6 6 6
14 95827−06010 BOLT, FLANGE 2 2 2 2
PART NO. DESCRIPTION REMARKS
5UP1
5UP2
5UP3
5UP4
B7
FIG. 6 INTAKE
REF.
NO.
1 5NX−13610−00 REED VALVE ASSY 1 1 1 1
2 5NX−13613−00 .REED, VALVE 2 2 2 2
3 4XL−13616−00 .STOPPER, REED VALVE 2 2 2 2
4 98507−03008 .SCREW 4 4 4 4
5 92907−03100 .WASHER, SPRING 4 4 4 4
6 4XL−13625−00 .SPACER, REED VALVE 1 1 1 1
7 5NX−13624−00 PLATE,REED VALVE 1 1 1 1
8 5NX−13622−00 GASKET, VALVE SEAT 1 1 1 1
9 5NX−13565−00 JOINT, CARBURETOR 1 1 1 1
10 91317−06025 BOLT 5 5 5 5
11 90464−06214 CLAMP 2 2 2 2
12 90450−51070 HOSE CLAMP ASSY 1 1 1 1
13 90450−70072 HOSE CLAMP ASSY 1 1 1 1
14 5NY−14401−01 AIR CLEANER CASE ASSY 1 1 1 1
15 5NX−14453−00 JOINT, AIR CLEANER 1 1 1 1 1
PART NO. DESCRIPTION REMARKS
5UP1
5UP2
5UP3
5UP4
B8
16 5NY−14459−00 HOLDER, GUIDE 1 1 1 1
17 5NY−14455−10 BAND 1 1 1 1
18 5NY−14442−00 SPACER 1 1 1 1
19 5NY−14417−00 COVER 1 1 1 1 1
20 90267−32070 RIVET, BLIND 3 3 3 3
21 90201−03313 WASHER, PLATE 6 6 6 6
22 4XM−14451−00 ELEMENT, AIR CLEANER 1 1 1 1
23 90209−06096 WASHER 1 1 1 1
24 90122−06035 BOLT, WING 1 1 1 1
25 3JD−14458−01 GUIDE 1 1 1 1
26 90183−06023 NUT, SPRING 4 4 4 4
27 90109−067F4 BOLT 4 4 4 4
FIG. 7 CARBURETOR
REF.
NO.
1 5NX−14101−00 CARBURETOR ASSY 1 1 1
2 4JT−14171−00 .PLUNGER, STARTER 1 1 1 1
3 4SR−14985−00 .FLOAT 1 1 1 1
4 4JT−14984−00 .GASKET, FLOAT CHAMBER 1 1 1 1
5 4MX−14115−00 .PLUG, SCREW 1 1 1 1
6 4MX−14561−00 .O−RING 1 1 1 1
7 4MX−14392−00 .VALVE, NEEDLE 1 1 1 1
8 4XL−14146−00 .PLATE 2 2 2 2
9 4MX−14948−07 .JET, SLOW (#50) 1 1 1 1 STD
PART NO. DESCRIPTION REMARKS
5UP−14101−10 CARBURETOR ASSY 1 1
5NX−14101−20 CARBURETOR ASSY 1 1
4MX−14948−02 .JET, SLOW (#38) 1 1 1 1 AP
4MX−14948−03 .JET, SLOW (#40) 1 1 1 1 AP
4MX−14948−04 .JET, SLOW (#42) 1 1 1 1 AP
4MX−14948−05 .JET, SLOW (#45) 1 1 1 1 AP
5UP1
5UP2
5UP3
5UP4
B9
4MX−14948−06 .JET, SLOW (#48) 1 1 1 1 AP
4MX−14948−08 .JET, SLOW (#52) 1 1 1 1 AP
4MX−14948−09 .JET, SLOW (#55) 1 1 1 1 AP
4MX−14948−10 .JET, SLOW (#58) 1 1 1 1 AP
4MX−14948−11 .JET, SLOW (#60) 1 1 1 1 AP
4MX−14948−12 .JET, SLOW (#62) 1 1 1 1 AP
10 4SR−14916−EJ .NEEDLE (N3EJ) 1 1 1 STD
4SR−14916−EW .NEEDLE (N3EW) 1 STD
4SR−14916−RW .NEEDLE (N8RW) 1 1 1 AP
4SR−14916−EW .NEEDLE (N3EW) 1 1 1 AP
4SR−14916−RJ .NEEDLE (N8RJ) 1 1 1 AP
4SR−14916−CJ .NEEDLE (N3CJ) 1 1 1 AP
FIG. 7 CARBURETOR
REF.
NO.
10 4SR−14916−EK .NEEDLE (N3EK) 1 1 1 AP
11 4MX−14919−00 .CLIP 1 1 1 1
12 5HC−14340−A7 .VALVE ASSY 1 1 1 1
13 5HC−14261−00 .HOLDER 1 1 1 1
14 5HC−14126−00 .GASKET 1 1 1 1
15 4SR−14105−00 .PILOT SCREW SET 1 1 1 1
16 5HC−14131−00 .SPRING, THROTTLE VALVE 1 1 1 1
17 663−14159−00 .CLIP 1 1 1 1
PART NO. DESCRIPTION REMARKS
4SR−14916−CK .NEEDLE (N3CK) 1 1 1 AP
4SR−14916−RH .NEEDLE (N8RH) 1 AP
4SR−14916−EH .NEEDLE (N3EH) 1 AP
4SR−14916−RW .NEEDLE (N8RW) 1 AP
4SR−14916−CJ .NEEDLE (N3CJ) 1 AP
4SR−14916−EJ .NEEDLE (N3EJ) 1 AP
4SR−14916−CW .NEEDLE (N3CW) 1 AP
5UP1
5UP2
5UP3
5UP4
B10
18 98502−04014 .SCREW, PAN HEAD 4 4 4 4
19 4XL−14197−10 .PIPE 2 2 2 2
20 4XL−14196−10 .PIPE 1 1 1 1
21 676−14548−00 .PIN, FLOAT ARM 1 1 1 1
22 3TJ−14137−40 .CLIP 5 5 5 5
23 4MX−14943−93 .JET, MAIN (#178) 1 1 1 1 STD
4MX−14943−90 .JET, MAIN (#162) 1 1 1 1 AP
4MX−14943−40 .JET, MAIN (#165) 1 1 1 1 AP
4MX−14943−91 .JET, MAIN (#168) 1 1 1 1 AP
4MX−14943−41 .JET, MAIN (#170) 1 1 1 1 AP
4MX−14943−92 .JET, MAIN (#172) 1 1 1 1 AP
4MX−14943−42 .JET, MAIN (#175) 1 1 1 1 AP
FIG. 7 CARBURETOR
REF.
NO.
23 4MX−14943−43 .JET, MAIN (#180) 1 1 1 1 AP
24 4MX−14194−00 .RING 1 1 1 1
25 98502−04012 .SCREW, PAN HEAD 2 2 2 2
26 4XL−1410E−00 .HOSE 1 1 1 1
27 4JT−1494F−07 .JET (#50) 1 1 1 STD
PART NO. DESCRIPTION REMARKS
4MX−14943−94 .JET, MAIN (#182) 1 1 1 1 AP
4MX−14943−44 .JET, MAIN (#185) 1 1 1 1 AP
4MX−14943−95 .JET, MAIN (#188) 1 1 1 1 AP
4MX−14943−45 .JET, MAIN (#190) 1 1 1 1 AP
4JT−1494F−09 .JET (#55) 1 STD
4JT−1494F−03 .JET (#40) 1 1 1 1 AP
4JT−1494F−07 .JET (#50) 1 AP
4JT−1494F−09 .JET (#55) 1 1 1 AP
4JT−1494F−11 .JET (#60) 1 1 1 1 AP
4JT−1494F−13 .JET (#65) 1 1 1 1 AP
5UP1
5UP2
5UP3
5UP4
B11
28 5HC−14146−00 .PLATE 1 1 1 1
29 98580−04006 .SCREW, PAN HEAD 1 1 1 1
30 5NX−1410H−00 .FUEL CUT SOLENOID VALVE 1 1 1 1
31 4JT−14147−00 .O−RING 1 1 1 1
32 5HC−14264−00 .COLLAR 1 1 1 1
33 5HC−14275−00 .SPRING 1 1 1 1
34 5HC−14922−00 .SCREW, THROTTLE 1 1 1 1
35 5HC−14934−00 .SPRING, THROTTLE STOP 1 1 1 1
36 5NX−14208−00 .LEVER COMP. 1 1 1 1 1
37 5HC−14216−00 .SCREW 2 2 2 2
38 5NX−85885−00 .THROTTLE SENSOR ASSY 1 1 1 1
39 5NX−14562−00 .O−RING 1 1 1 1
FIG. 7 CARBURETOR
REF.
NO.
40 5NX−14216−00 .SCREW 1 1 1 1
PART NO. DESCRIPTION REMARKS
5UP1
5UP2
5UP3
5UP4
B12
FIG. 8 EXHAUST
REF.
NO.
1 5MW−14610−10 EXHAUST PIPE ASSY 1 1 1 1
2 5MW−14642−00 SEAL, EXHAUST 2 2 2 2
3 90507−20052 SPRING, TENSION 2 2 2 2
4 5CU−14771−00 STAY, MUFFLER 1 1 1 1 1
5 90480−16561 GROMMET 1 1 1 1
6 90387−063G3 COLLAR 1 1 1 1
7 90201−06071 WASHER, PLATE 1 1 1 1
8 483−14781−02 STAY, MUFFLER 2 1 1 1 1
9 95027−06012 BOLT, FLANGE 1 1 1 1
10 90119−06192 BOLT, WITH WASHER 1 1 1 1
11 95027−06025 BOLT, FLANGE 1 1 1 1
12 95027−08012 BOLT, FLANGE 1 1 1 1
13 90201−08730 WASHER, PLATE 1 1 1 1
14 3JE−14615−01 JOINT, EXHAUST 1 1 1 1 1
PART NO. DESCRIPTION REMARKS
5UP−14610−00 EXHAUST PIPE ASSY 1 1
5UP1
5UP2
5UP3
5UP4
B13
15 5NX−14753−00 SILENCER, EXHAUST 1 1 1 1 UR
5NX−14753−10 SILENCER, EXHAUST 1 UR FOR USA
16 92017−06010 .BOLT 2 2 2 2
17 5CU−1469A−00 .FIBER 1 1 1 1 UR
5HC−1469A−10 .FIBER 1 UR FOR USA
18 90480−16561 GROMMET 1 1 1 1
19 90387−063G3 COLLAR 1 1 1 1
20 90480−16404 GROMMET 1 1 1 1
21 90387−06039 COLLAR 1 1 1 1
22 95027−06025 BOLT, FLANGE 1 1 1 1
23 90201−06071 WASHER, PLATE 1 1 1 1
Loading...