YAMAHA YZ250S, YZ250 PARTS CATALOGUE 04

YZ250S (5XF1) U.S.A.,CANADA,S.AFRICA YZ250 (5XF2) EUROPE YZ250 (5XF3) JAPAN YZ250S (5XF4) AUSTRALIA,NEW ZEALAND

1C5XF-100E1

2C5XF-100E1

()

YZ250S/YZ250

PARTS CATALOGUE

1st edition, June 2003

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) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the 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” Locally Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.) “O/S” Over Size

3. The number of components for assembly

• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below.

• The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

6. The asterisk (*) before a reference number indicates modified items after the first edition.

4. Applicable colours 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

5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.

A5

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583

FOREWORD

A6

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–reference the “model code – production code No.” in the catalogue with the “model code – production code No.” indicated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

5XF1

5XF2

5XF3

5XF4

Colouring

Type Code

A 0583

Colour

Code

Colour Name

DEEP PURPLISH BLUE SOLID E DPBSE

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

5XF1

5XF2

5XF3 010 JAPAN

5XF4 010

Production

Code No.

010 U.S.A.

020 CANADA

030 SOUTH AFRICA

010 FRANCE

020 GERMANY

030 SPAIN

040

050 ITALY

Country

(destination)

UNITED KINGDOM

AUSTRALIA

NEW ZEALAND

Model

Code

Production

Code No.

Country

(destination)

A7

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 .....................................................................................D8

FRONT WHEEL .................................................................... D9

FRONT BRAKE CALIPER ....................................................D10

REAR WHEEL .......................................................................D11

REAR BRAKE CALIPER .......................................................D13

STEERING HANDLE & CABLE ............................................D14

FRONT MASTER CYLINDER ...............................................D15

STAND & FOOTREST ..........................................................E2

REAR MASTER CYLINDER .................................................E3

GENERATOR ........................................................................E4

HANDLE SWITCH & LEVER ................................................E5

ELECTRICAL 1 .....................................................................E6

ALTERNATE FOR CHASSIS ................................................E7

OPTIONAL PARTS 1 ............................................................E9

CONTENTS

INDEX

NUMERICAL INDEX ............................................................. M1

FIG. 1 CYLINDER HEAD

REF. NO.

1

PART NO. DESCRIPTION

5UP–11111–00

HEAD, CYLINDER 1 1 1

5XF1

5XF2

5XF3

5XF4

REMARKS

5MW–11111–01

2

94702–00326

94709–00326

3

90116–08394

4

93604–08071

5

90176–08026

6

90201–080L8

7

5UP–11311–00

8

5XF–1131D–00

9

5CU–1131U–10

10

90109–05001

11

5CU–1132A–00

12

5UP–11351–00

13

90116–10314

14

95617–10660

15

90116–10314

16

95617–10660

HEAD, CYLINDER 1 1 1

PLUG, SPARK (NGK BR8EG) 1 1 1

PLUG, SPARK (NGK BR8EG) 1

BOLT, STUD 6 6 6 6

PIN, DOWEL 2 2 2 2

NUT, CROWN 6 6 6 6

WASHER, PLATE 6 6 6 6

CYLINDER 1 1 1 1 1

VALVE ASSY 1111

HOLDER 3 1 1 1 1

BOLT 2222

VALV E 2 2 2 2 2

GASKET, CYLINDER 1 1 1 1

BOLT, STUD 1 1 1 1

B

2

17

99590–14016

18

90179–10M35

19

93210–74316

20

93211–02703

21

5CU–1131E–00

22

5CU–1131P–00

23

93210–15639

24

98507–05012

25

90201–057H5

PIN, DOWEL 2 2 2 2

NUT 4444

O-RING 1 1 1 1

HOLDER 1 1 1 1 1

HOLDER 4 1 1 1 1

O-RING 2 2 2 2

SCREW, PAN HEAD 4 4 4 4

WASHER, PLATE 2 2 2 2

FIG. 1 CYLINDER HEAD

REF. NO.

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

PART NO. DESCRIPTION

5CU–11830–00

98907–05012

93104–08040

5NX–11395–00

4SS–11832–00

90508–155B8

5MW–1132E–00

5MW–1132F–00

90201–081G0

90501–046L6

5CU–1131V–00

91317–04008

5CU–11991–00

5CU–11993–00

97007–05020

LINK ASSY 1 1 1 1

SCREW, BIND 2 2 2 2

OIL SEAL 1 1 1 1

HOLDER 1111

LEVER, LINK 1111

SPRING, TORSION 2 2 2 2

PULLEY 1 1 1 1 1

PULLEY 2 1 1 1 1

WASHER, PLATE 2 2 2 2

SPRING, COMPRESSION 2 2 2 2

SHAFT 1 1 1 1 1

BOLT 3333

HOUSING 1 1 1 1 1

.GASKET 1 1 1 1

BOLT 4444

5XF1

5XF2

5XF3

5XF4

REMARKS

B

3

41

92907–05600

42

5CU–11995–00

43

5CU–1131M–00

44

353–13115–01

45

5CU–11354–00

46

98907–05016

47

90445–09777

WASHER, PLATE 4 4 4 4

SEAL, HOUSING 1 1 1 1

COVER 1 1 1 1

CONNECTOR, SUCTION PIPE 1 1 1 1

GASKET 1 1 1 1

SCREW, BIND 4 4 4 4

HOSE (L300) 1 1 1 1

FIG. 2 GOVERNOR

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

4JY–11915–01

98907–05012

90105–05002

90201–057H5

90387–085E1

93104–08040

5CU–11990–00

3JE–11922–01

91317–04006

93300–60801

5X4–11921–02

5NY–11953–00

90501–256L2

5CU–11952–00

PLATE, THRUST 1 1 1 1 1

SCREW, BIND 1 1 1 1

BOLT, FLANGE 1 1 1 1

WASHER, PLATE 1 1 1 1

COLLAR 1111

OIL SEAL 1 1 1 1

PUSH ROD ASSY 1 1 1 1

FORK, GOVERNOR 1 1 1 1

BOLT 2222

BEARING (B0060) 1 1 1 1 KOYO

SHAFT, GOVERNOR 1 1 1 1

GEAR, GOVERNOR 1 1 1 1

SPRING, COMPRESSION 1 1 1 1

PLATE 1 1 1 1

5XF1

5XF2

5XF3

5XF4

REMARKS

B

4

16

90201–150U6

17

90387–152F2

18

93340–21505

19

5CU–11912–00

20

5CU–11911–00

21

93507–16020

22

93603–14240

23

93604–29184

WASHER, PLATE 4 4 4 4

COLLAR 1111

BEARING 2 2 2 2

RETAINER, WEIGHT 1 1 1 1

RETAINER 1111

BALL 4444

PIN, DOWEL 1 1 1 1

PIN, DOWEL 1 1 1 1 AP

FIG. 3 CRANKSHAFT & PISTON

REF. NO.

1

PART NO. DESCRIPTION

5NX–11631–00–A0

PISTON (STD) 1 1 1 1 UR RED

5XF1

5XF2

5XF3

5XF4

REMARKS

5NX–11631–00–B0

5NX–11631–00–C0

5NX–11631–00–D0

2

5CU–11603–10

3

5UP–11633–00

4

93450–19052

5

93310–218A6

6

5UP–11400–00

7

5UP–11410–00

8

5MW–11420–00

9

5CU–11681–00

10

5MW–11651–00

11

93310–52406

12

90209–24327

13

93306–37808

14

93102–20485

15

90280–03017

PISTON (STD) 1 1 1 1 UR ORANGE

PISTON (STD) 1 1 1 1 UR GREEN

PISTON (STD) 1 1 1 1 UR PURPLE

PISTON RING SET (STD) 1 1 1 1

PIN, PISTON 1 1 1 1

CIRCLIP 2 2 2 2

BEARING 1 1 1 1

CRANKSHAFT ASSY 1 1 1 1

.CRANKSHAFT 1 1 1 1

.PIN, CRANK 1 1 1 1 1

.ROD, CONNECTING 1 1 1 1

.BEARING 1111

.WASHER 2 2 2 2

BEARING 1 1 1 1

OIL SEAL 1 1 1 1

KEY, WOODRUFF 1111

B

5

16

93306–37808

17

93102–28004

BEARING 1 1 1 1

OIL SEAL 1 1 1 1

FIG. 4 WATER PUMP

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

PART NO. DESCRIPTION

5CU–12459–00

5DJ–12451–00

90201–08512

93109–11073

93102–12106

93306–00105

90201–08784

99001–06600

5MW–12422–00

5XF–12428–00

93604–10011

90430–06014

95027–06025

95027–06065

GEAR, IMPELLER SHAFT 1 1 1 1

IMPELLER, WATER PUMP 1 1 1 1

WASHER, PLATE 1 1 1 1

OIL SEAL 1 1 1 1

OIL SEAL (SD 12-22-5 HS) 1 1 1 1

BEARING (B6001) 1 1 1 1

WASHER, PLATE 1 1 1 1

CIRCLIP 1 1 1 1

COVER, HOUSING 1 1 1 1

GASKET, HOUSING COVER 2 1 1 1 1

PIN, DOWEL 2 2 2 2

GASKET 1 1 1 1

BOLT, FLANGE 2 2 2 2

5XF1

5XF2

5XF3

5XF4

REMARKS

B

6

FIG. 5 RADIATOR & HOSE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5NX–1240A–00

91A20–05065

90467–09006

5NX–12461–00

5HD–12462–00

5CU–12481–10

5NY–12482–00

5XF–12484–00

90450–28014

90450–25037

90480–15528

90387–06065

95027–06025

90201–06571

95827–06010

RADIATOR ASSY 1 1 1 1

TUBE, FLEXIBLE VINYL 1 1 1 1

CLIP 1111

RADIATOR ASSY 1 1 1 1

CAP, RADIATOR 1 1 1 1

PIPE 1 1 1 1 1

PIPE 2 2 2 2 2

PIPE 4 1 1 1 1

HOSE CLAMP ASSY 4 4 4 4

GROMMET 6 6 6 6

COLLAR 6666

BOLT, FLANGE 6 6 6 6

WASHER, PLATE 6 6 6 6

BOLT, FLANGE 2 2 2 2

5XF1

5XF2

5XF3

5XF4

REMARKS

B

7

FIG. 6 INTAKE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5NX–13610–00

5NX–13613–00

4XL–13616–00

98507–03008

92907–03100

4XL–13625–00

5NX–13624–00

5XF–13622–00

5NX–13565–00

91317–06025

90464–06214

90450–51070

90450–70072

5NY–14401–01

5NX–14453–00

REED VALVE ASSY 1 1 1 1

.REED, VALVE 2 2 2 2

.STOPPER, REED VALVE 2 2 2 2

.SCREW, PAN HEAD 4 4 4 4

.WASHER, SPRING 4 4 4 4

.SPACER, REED VALVE 1 1 1 1

PLATE,REED VALVE 1 1 1 1

GASKET, VALVE SEAT 1 1 1 1

JOINT, CARBURETOR 1 1 1 1

BOLT 5555

CLAMP 2 2 2 2

HOSE CLAMP ASSY 1 1 1 1

AIR CLEANER CASE ASSY 1 1 1 1

JOINT, AIR CLEANER 1 1 1 1 1

5XF1

5XF2

5XF3

5XF4

REMARKS

B

8

16

5NY–14459–00

17

5NY–14455–10

18

5NY–14442–00

19

5NY–14417–00

20

90267–32070

21

90201–03313

22

4XM–14451–00

23

90209–06096

24

90122–06035

25

3JD–14458–01

26

90183–06023

27

90109–067F4

HOLDER, GUIDE 1 1 1 1

BAND 1111

SPACER 1111

COVER 1 1 1 1 1

RIVET, BLIND 3 3 3 3

WASHER, PLATE 6 6 6 6

ELEMENT, AIR CLEANER 1 1 1 1

WASHER 1 1 1 1

BOLT, WING 1111

GUIDE 1 1 1 1

NUT, SPRING 4 4 4 4

BOLT 4444

FIG. 7 CARBURETOR

REF. NO.

1

PART NO. DESCRIPTION

5NX–14101–00

CARBURETOR ASSY 1 1 1

5XF1

5XF2

5XF3

5XF4

REMARKS

5UP–14101–10

5NX–14101–20

2

4JT–14171–00

3

4SR–14985–00

4

4JT–14984–00

5

4MX–14115–00

6

4MX–14561–00

7

4MX–14392–00

8

4XL–14146–00

9

4MX–14948–07

4MX–14948–08

4MX–14948–02

4MX–14948–03

4MX–14948–04

4MX–14948–05

4MX–14948–06

4MX–14948–07

CARBURETOR ASSY 1 1

.PLUNGER, STARTER 1 1 1 1

.FLOAT 1111

.GASKET, FLOAT CHAMBER 1 1 1 1

.PLUG, SCREW 1 1 1 1

.O-RING 1 1 1 1

.VALVE, NEEDLE 1 1 1 1

.PLATE 2222

.JET, SLOW (#50) 1 1 1 STD

.JET, SLOW (#52) 1 STD

.JET, SLOW (#38) 1 1 1 1 AP

.JET, SLOW (#40) 1 1 1 1 AP

.JET, SLOW (#42) 1 1 1 1 AP

.JET, SLOW (#45) 1 1 1 1 AP

.JET, SLOW (#48) 1 1 1 1 AP

.JET, SLOW (#50) 1 AP

B

9

4MX–14948–08

4MX–14948–09

4MX–14948–10

4MX–14948–11

4MX–14948–12

10

4SR–14916–EJ

4SR–14916–EW

4SR–14916–CK

4SR–14916–EW

.JET, SLOW (#52) 1 1 1 AP

.JET, SLOW (#55) 1 1 1 1 AP

.JET, SLOW (#58) 1 1 1 1 AP

.JET, SLOW (#60) 1 1 1 1 AP

.JET, SLOW (#62) 1 1 1 1 AP

.NEEDLE (N3EJ) 1 1 STD

.NEEDLE (N3EW) 1 1 STD

.NEEDLE (N3CK) 1 1 AP

.NEEDLE (N3EW) 1 1 AP

FIG. 7 CARBURETOR

REF. NO.

10

PART NO. DESCRIPTION

4SR–14916–EK

.NEEDLE (N3EK) 1 1 AP

5XF1

5XF2

5XF3

5XF4

REMARKS

4SR–14916–RJ

4SR–14916–CJ

4SR–14916–RW

4SR–14916–CW

4SR–14916–RH

4SR–14916–EH

4SR–14916–EJ

11

4MX–14919–00

12

5HC–14340–A7

13

5HC–14261–00

14

5HC–14126–00

15

4SR–14105–00

16

5HC–14131–00

17

663–14159–00

18

98502–04014

19

4XL–14197–10

20

4XL–14196–10

.NEEDLE (N8RJ) 1 1 AP

.NEEDLE (N3CJ) 1 1 1 1 AP

.NEEDLE (N8RW) 1 1 1 1 AP

.NEEDLE (N3CW) 1 1 AP

.NEEDLE (N8RH) 1 1 AP

.NEEDLE (N3EH) 1 1 AP

.NEEDLE (N3EJ) 1 1 AP

.CLIP 1 1 1 1

.VALVE ASSY 1 1 1 1

.HOLDER 1 1 1 1

.GASKET 1 1 1 1

.PILOT SCREW SET 1 1 1 1

.SPRING, THROTTLE VALVE 1 1 1 1

.CLIP 1 1 1 1

.SCREW, PAN HEAD 4 4 4 4

.PIPE 2 2 2 2

.PIPE 1 1 1 1

B

10

21

676–14548–00

22

3TJ–14137–40

23

4MX–14943–93

4MX–14943–43

4MX–14943–90

4MX–14943–40

4MX–14943–91

4MX–14943–41

4MX–14943–92

.PIN, FLOAT ARM 1 1 1 1

.CLIP 5 5 5 5

.JET, MAIN (#178) 1 1 1 STD

.JET, MAIN (#180) 1 STD

.JET, MAIN (#162) 1 1 1 1 AP

.JET, MAIN (#165) 1 1 1 1 AP

.JET, MAIN (#168) 1 1 1 1 AP

.JET, MAIN (#170) 1 1 1 1 AP

.JET, MAIN (#172) 1 1 1 1 AP

FIG. 7 CARBURETOR

REF. NO.

23

PART NO. DESCRIPTION

4MX–14943–42

.JET, MAIN (#175) 1 1 1 1 AP

5XF1

5XF2

5XF3

5XF4

REMARKS

4MX–14943–93

4MX–14943–43

4MX–14943–94

4MX–14943–44

4MX–14943–95

4MX–14943–45

24

4MX–14194–00

25

98502–04012

26

4XL–1410E–00

27

4JT–1494F–07

4JT–1494F–03

4JT–1494F–09

4JT–1494F–11

4JT–1494F–13

4JT–1494F–15

28

5HC–14146–00

29

98580–04006

.JET, MAIN (#178) 1 AP

.JET, MAIN (#180) 1 1 1 AP

.JET, MAIN (#182) 1 1 1 1 AP

.JET, MAIN (#185) 1 1 1 1 AP

.JET, MAIN (#188) 1 1 1 1 AP

.JET, MAIN (#190) 1 1 1 1 AP

.RING 1 1 1 1

.SCREW, PAN HEAD 2 2 2 2

.HOSE 1 1 1 1

.JET (#50) 1111 STD

.JET (#40) 1111 AP

.JET (#55) 1111 AP

.JET (#60) 1111 AP

.JET (#65) 1111 AP

.JET (#70) 1111 AP

.PLATE 1111

.SCREW, PAN HEAD 1 1 1 1

B

11

30

5NX–1410H–00

31

4JT–14147–00

32

5HC–14264–00

33

5HC–14275–00

34

5HC–14922–00

35

5HC–14934–00

36

5NX–14208–00

37

5HC–14216–00

38

5NX–85885–00

.FUEL CUT SOLENOID VALVE 1 1 1 1

.O-RING 1 1 1 1

.COLLAR 1 1 1 1

.SPRING 1 1 1 1

.SCREW, THROTTLE 1 1 1 1

.SPRING, THROTTLE STOP 1 1 1 1

.LEVER COMP. 1 1 1 1 1

.SCREW 2 2 2 2

.THROTTLE SENSOR ASSY 1 1 1 1

FIG. 7 CARBURETOR

REF. NO.

39

40

PART NO. DESCRIPTION

5NX–14562–00

5NX–14216–00

.O-RING 1 1 1 1

.SCREW 1 1 1 1

5XF1

5XF2

5XF3

5XF4

REMARKS

B

12

YAMAHA YZ250S, YZ250 PARTS CATALOGUE 04

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

MODEL LABEL

ENGINE

CHASSIS