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Yamaha · Two-stroke single, premix, chain drive

YZ 250

Library entry covers 2002-2025

66 factory 52 guideline

Published source

Yamaha YZ250J2/YZ250XJ Owner's Service Manual (1st edition, April 2017), Maintenance Intervals pp.3-1 to 3-4 (ManualsLib 2755462 pages 58-61)

Factory owner's handbook. Covers YZ250J2/YZ250XJ (2018 model) Owner's Service Manual, 1st edition April 2017, LIT-11626-31-12; chart columns are races, with the hours printed in the column headers.

118 items for a 2020 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2020 Yamaha YZ 250

On the road: every 200 km

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 km or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 5,000 km or 12 months

11 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 6,500 km or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 9,500 km or 12 months

8 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 19,500 km or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 2.5 h

34 items

Cooling system - check coolant level and leakage

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Cooling system - inspect hoses

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every race (about 2.5 hours).
Cylinder - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Inspect score marks.
Cylinder head - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Inspect carbon deposits and eliminate them. Check gasket.
Cylinder head - retighten

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Muffler - inspect

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Muffler - retighten

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Outside nuts and bolts - retighten

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Refer to "STARTING AND BREAK-IN" section in CHAPTER 1.
Piston - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Inspect crack.
Piston pin, small end bearing - inspect

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every race (about 2.5 hours).
Piston ring - inspect

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Check ring end gap.
Relay arm, connecting rod - inspect, lube and retighten

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Molybdenum disulfide grease.
YPVS - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Inspect carbon deposits and eliminate them.
Air filter - clean and lubricate

Fuel and air

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Use the Yamaha foam air filter oil or other quality foam air filter oil.
Carburetor - inspect, adjust and clean

Fuel and air

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Clutch - inspect and adjust

Primary and gearbox

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Inspect housing, friction plate, clutch plate and spring.
Drive chain - lubricate, slack, alignment

Final drive

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Use chain lube. Chain slack: 48.0-58.0 mm (1.89-2.28 in).
Drive chain guide and rollers - inspect

Final drive

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Front fork oil seal and dust seal - clean and lube

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Lithium base grease.
Front forks - inspect and adjust

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Steering head - inspect free play and retighten

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Frame - clean and inspect

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Rear shock absorber - inspect and adjust

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Rear shock absorber - retighten

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Swingarm - inspect, lube and retighten

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Molybdenum disulfide grease.
Brakes - adjust lever position and pedal height

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Brakes - check brake disc surface

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Brakes - check fluid level and leakage

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Brakes - lubricate pivot point

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Brakes - retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Tire, wheels - inspect air pressure, wheel run-out, tire wear and spoke looseness

Wheels and tires

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Tire, wheels - retighten sprocket bolt

Wheels and tires

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Throttle, control cable - check routing and connection

Controls and cables

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours).
Throttle, control cable - lubricate

Controls and cables

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every race (about 2.5 hours). Remarks: Yamaha cable lube or SAE 10W-40 motor oil.

Every 7.5 h

6 items

Piston ring - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every third race (about 7.5 hours); as required.
Spark plug - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every third race (about 7.5 hours).
Fuel tank, cock - clean and inspect

Fuel and air

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every third race (about 7.5 hours).
Rear shock absorber - lube

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every third race (about 7.5 hours); as required. Remarks: Molybdenum disulfide grease. The as-required mark is printed with "(After rain ride)".
Tire, wheels - inspect bearings

Wheels and tires

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every third race (about 7.5 hours).
Tire, wheels - lubricate

Wheels and tires

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every third race (about 7.5 hours). Remarks: Lithium base grease.

Every 12.5 h

7 items

Crank - inspect and clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every fifth race (about 12.5 hours); as required.
Muffler - clean

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every fifth race (about 12.5 hours).
Piston - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every fifth race (about 12.5 hours); as required. Remarks: Inspect carbon deposits and eliminate them.
Rotor nut - retighten

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every fifth race (about 12.5 hours).
Transmission - replace oil

Primary and gearbox

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every fifth race (about 12.5 hours). Remarks: Recommended brand: YAMALUBE; SAE 10W-40; API service SG type or higher; JASO standard MA.
Front forks - replace oil

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked after break-in; every fifth race (about 12.5 hours). Remarks: Yamaha Suspension Oil S1.
Steering head - clean and lube

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked every fifth race (about 12.5 hours). Remarks: Lithium base grease.

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Brakes - replace brake fluid

Brakes

Factory

Factory: Maintenance Intervals p.3-3: marked as required; Remarks: Every one year.

Every 2 years

5 items

Cooling system - replace coolant

Engine

Factory

Factory: Maintenance Intervals p.3-2: marked as required; Remarks: Every two years.
Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

17 items

Cooling system - check radiator cap operation

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Cylinder - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required. Remarks: Inspect wear.
Muffler - replace fiber

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required. Remarks: When the exhaust sound becomes louder or when a performance drop is felt.
Piston pin, small end bearing - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Protector guide - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Spark plug - replace

Engine

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Air filter - replace

Fuel and air

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Clutch - replace

Primary and gearbox

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Transmission - inspect

Primary and gearbox

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Transmission - replace bearing

Primary and gearbox

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Drive chain - replace

Final drive

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Front forks - replace oil seal

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Shift fork, shift cam, guide bar - inspect

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required. Remarks: Inspect wear.
Steering head - replace bearing

Front end

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Sidestand (YZ250X) - lubricate

Rear suspension and frame

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required. Remarks: Lithium base grease.
Brakes - replace pads

Brakes

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.
Tire, wheels - replace bearings

Wheels and tires

Factory

Factory: Maintenance Intervals pp.3-1 to 3-4: marked as required.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.