Description

Yamaha YZ250 Parts Catalog – The Only Factory-Sourced Parts Breakdown You Should Trust

I’ve been turning wrenches in San Antonio for 28 years. When a customer rolls in with a YZ250 that’s been cobbled together with aftermarket bolts and mismatched pistons, the first thing I do is pull the OEM parts catalog. Not the aftermarket junk that guesses at supersessions. The real deal. This Yamaha YZ250 Parts Catalog is exactly that — factory-issued, 59 pages, covering every nut, seal, and circlip for the 5NX1 (USA/CAN), 5NX2 (Europe), 5NX3 (Japan), and 5NX4 (Australia/NZ) chassis.

You strip a cylinder head dowel? Blow a water pump seal? This catalog gives you the exact Yamaha part number — no cross-reference games. The exploded diagrams on each page show exactly where that part lives in the assembly. That matters when you’re ordering from a dealer who wants a part number, not a description. Page 4 tells you how to read the catalog: ”UR” means use that specific part, “AP” means an alternate is allowed. Learn those codes before you phone in an order.

Engine Coverage – Cylinder, Crankshaft, Transmission, and More

The Engine section starts with Cylinder Head and Governor, then runs through Crankshaft.Piston, Water Pump, Radiator.Hose, Intake, Carburetor, Exhaust, Crankcase, Crankcase Cover 1, Starter, Clutch, Transmission, Shift Cam.Fork, and Shift Shaft. Each sub-section has its own illustrated parts list. Need the correct crankshaft seal for a 2001 YZ250? Look under Crankshaft.Piston — the diagram shows the seal location and the part number is right next to it. The catalog also lists the quantity per assembly, so you don’t order one circlip when you need two. I’ve seen guys order a single clutch plate because they guessed. Waste of time. This catalog fixes that.

Chassis and Suspension – Frame, Front Fork, Rear Arm, Brake Calipers

Under Chassis you get Frame, Fender, Side Cover, Rear Arm, Rear Suspension, Steering, Front Fork, Fuel Tank, Seat, Front Wheel, Front Brake Caliper, Rear Wheel, Rear Brake Caliper, Steering Handle.Cable, Front Master Cylinder, Stand.Footrest, Rear Master Cylinder, Generator, Handle Switch.Lever, Electrical 1, and an Alternate (Chassis) section. If you’re replacing the rear brake caliper on a YZ250, you need the correct piston and seal kit — the part number is listed under Rear Brake Caliper. The exploded view shows the caliper body, bleed screw, pad spring, everything. No guesswork. That’s how you avoid a spongy lever because you used the wrong seal.

Front Fork and Steering – Factory Specs for the Suspension

The Front Fork section alone is worth the price of admission. Fork tube, spring, bushings, dust seal — all listed with Yamaha part numbers. The Steering section covers the stem, bearings, and handlebar components. When you’re rebuilding a YZ250 front end, you need the correct steering stem nut and bearing set. This catalog gives you the numbers. I’ve had guys bring me forks with aftermarket bushings that seized because the clearance was wrong. That doesn’t happen when you use factory-sourced components.

Fuel and Brake Systems – Part Numbers for Carburetors and Hydraulics

Fuel section includes the Fuel Tank assembly and graphics (with color code indicators like “MXR”). Carburetor is under Engine > Carburetor, with pilot jet, main nozzle, float bowl gasket — all OEM. Brake system is split between Front Brake Caliper, Rear Brake Caliper, Front Master Cylinder, and Rear Master Cylinder. Each caliper listing includes the piston seal, dust seal, pad set. If your YZ250’s front master cylinder is leaking, you need the rebuild kit part number — it’s right there under Front Master Cylinder. Don’t trust aftermarket rebuild kits that claim to fit five different models. The factory catalog tells you exactly what fits your 5NX1 or 5NX2.

Source Authenticity – OEM, Not Aftermarket

This is a Yamaha Motor Co., Ltd. publication — 1st Edition, July 2001. The copyright page states the catalog is for model codes 5NX1/5NX4 and 5NX2/5NX3. Any reprinting or unauthorized use is prohibited. That’s the level of authenticity you get. This isn’t a scanned third-party rehash. The PDF includes the original foreword, model label affixing locations, and a numerical index at the back to look up any part number. Compare that to cheap aftermarket catalogs that list generic part numbers and don’t tell you about ”UR” or ”AP” codes. They’ll let you order the wrong gasket kit and blame you for it.

FAQ – Yamaha YZ250 Parts Catalog

Does this parts catalog include torque specifications or service procedures?

No. This is strictly a parts catalog — exploded diagrams and part numbers. For service specs like torque values or clearances, you need the Yamaha YZ250 Service Manual. The catalog even notes on page 4: “The illustrations are for reference in finding parts numbers, not to be used for assembling. When assembling, use the applicable service manual.” Get both.

How many pages does the catalog have?

59 pages, including the foreword, model label section, and numerical index.

Which YZ250 model years and destinations are covered?

Listed models: YZ250P (5NX1) USA, Canada; YZ250 (5NX1) South Africa; YZ250 (5NX2) Europe; YZ250 (5NX3) Japan; YZ250P (5NX4) Australia, New Zealand. The catalog is first edition July 2001, so it covers those model-year variants. Check your frame and engine serial numbers against the model label codes in the catalog.

Can I use this catalog to order parts for a 2020 YZ250?

This catalog is for 2001-era models only (5NX1–5NX4). Yamaha changed part numbers over the years. For a later YZ250, you need the corresponding parts catalog. Using this one for a 2020 bike will give you wrong part numbers. Match your model code to the catalog’s coverage list.

Every time I see a torn-down YZ250 on a bench with a Ziploc bag of unlabeled bolts, I know the owner either has the factory parts catalog or is about to learn a hard lesson. The catalog lays out every component — from the cylinder head to the rear master cylinder — with OEM part numbers that match the bike’s VIN range. No guessing which shifter fork fits. No wrestling with aftermarket diagrams that omit the washer that holds your brake pad in. Access the Factory Manual and keep it next to your torque wrench. You’ll thank yourself when the order arrives and every seal fits the first time.

Related Manuals: Yamaha YZF-R1 2002 Parts Catalog – OEM Factory Part Numbers, Yamaha GTS1000AE 1993 Parts Catalog – Factory Microfiche PDF, Yamaha V125 Parts Catalog – OEM Factory Part Numbers & Diagrams. For broader context on engine systems, see Automotive Industry Overview and Internal Combustion Engine.