YAMAHA YZ250F 2001 Manual Online

SPEC

2 - 8
MAINTENANCE SPECIFICATIONS
Clutch:
Friction plate thickness 2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)2.7 mm
(0.106 in)
Quantity 9 ----
Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----
Quantity 8 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 40.4 mm (1.59 in) 39.4 mm
(1.55 in)
Quantity 5 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kickstarter:
Type Kick and ratchet type ----
Carburetor: USA, CDN, ZA,
AUS, NZEUROPE
Type/manufacturer FCR-MX37/
KEIHIN
¬
----
I. D. mark 5NL1 00 5NL2 10 ----
Main jet (M.J) #175
¬
----
Main air jet (M.A.J) #200
¬
----
Jet needle (J.N) OBELP-4 OBEJP-4 ----
Cutaway (C.A) 1.5
¬
----
Pilot jet (P.J) #42
¬
----
Pilot air jet (P.A.J) #100
¬
----
Pilot outlet (P.O) ø0.9
¬
----
Pilot screw (example) (P.S) 1-3/4
¬
----
Bypass (B.P) ø1.0
¬
----
Valve seat size (V.S) ø3.8
¬
----
Starter jet (G.S) #72
¬
----
Leak jet (Acc.P) #105
¬
----
Float height (F.H) 8 mm (0.31 in)
¬
----
Engine idle speed 1,700 ~
1,900 r/min
¬
----
Intake vacuum26.7 ~ 32.0 kPa
(200 ~ 240 mmHg,
7.87 ~ 9.45 inHg)
¬
---- Item Standard Limit

SPEC

2 - 9
MAINTENANCE SPECIFICATIONS
Lubrication system:
Oil filter type Wire mesh type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 107.8 mm (4.2 in) ----
Height 220 mm (8.7 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure110 kPa (1.1 kg/cm
2

, 15.6 psi)----
Radiator capacity (total) 0.56 L (0.49 lmp qt, 0.59 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

SPEC

2 - 10
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S
´
1.0 1 13 1.3 9.4
Camshaft cap M6
´
1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12
´
1.0 1 37 3.7 27
Cylinder head (stud bolt) M6
´
1.0 2 7 0.7 5.1
(stud bolt) M8
´
1.25 1 15 1.5 11
(bolt) M9
´
1.25 4 38 3.8 27
(nut) M6
´
1.0 2 10 1.0 7.2
Cylinder head cover M6
´
1.0 2 10 1.0 7.2
Cylinder M6
´
1.0 1 10 1.0 7.2
Balancer weight M6
´
1.0 2 10 1.0 7.2
Balancer shaft driven gear M14
´
1.0 1 50 5.0 36
Timing chain guide (intake side) M6
´
1.0 2 10 1.0 7.2
Decompression shaft M6
´
1.0 1 7 0.7 5.1
Decompression cable guide M6
´
1.0 1 10 1.0 7.2
Timing chain tensioner M6
´
1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6
´
1.0 1 7 0.7 5.1
Impeller M8
´
1.25 1 14 1.4 10
Radiator hose clamp M6
´
1.0 8 2 0.2 1.4
Coolant drain bolt M6
´
1.0 1 10 1.0 7.2
Water pump housing M6
´
1.0 4 10 1.0 7.2
Radiator M6
´
1.0 6 10 1.0 7.2
Radiator guard M6
´
1.0 2 10 1.0 7.2
Radiator pipe M6
´
1.0 1 10 1.0 7.2
Oil pump cover M4
´
0.7 1 3 0.3 2.2
Oil pump M6
´
1.0 3 10 1.0 7.2
Oil filter element drain bolt M6
´
1.0 1 10 1.0 7.2
Oil filter element cover M6
´
1.0 2 10 1.0 7.2
Oil strainer M6
´
1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10
´
1.25 1 20 2.0 14
(M8) M8
´
1.25 2 18 1.8 13
Oil delivery pipe 2 M6
´
1.0 1 10 1.0 7.2
Oil hose M6
´
1.0 3 10 1.0 7.2
Oil hose clamp — 2 2 0.2 1.4
Oil strainer and frame M18
´ 1.5 1 90 9.0 65
Carburetor joint clamp M4 ´ 0.7 2 3 0.3 2.2
Air filter joint clamp M6 ´ 1.0 1 3 0.3 2.2
Throttle cable cover M5 ´ 0.8 1 4 0.4 2.9
Air filter joint M5 ´ 0.8 2 5 0.5 3.6
Air filter joint and air filter case M5 ´ 0.8 5 1 0.1 0.7
Air filter element M6 ´ 1.0 1 2 0.2 1.4
Exhaust pipe (nut) M8 ´ 1.25 1 13 1.3 9.4
(bolt) M8 ´ 1.25 1 24 2.4 17
Exhaust pipe protector M6 ´ 1.0 3 10 1.0 7.2

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Silencer M8 ´ 1.25 2 35 3.5 25
Silencer clamp M8 ´ 1.25 1 20 2.0 14
Crankcase M6 ´ 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 ´ 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 ´ 1.0 4 10 1.0 7.2
Left crankcase cover M6 ´ 1.0 8 10 1.0 7.2
Right crankcase cover M6 ´ 1.0 8 10 1.0 7.2
Clutch cover M6 ´ 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 ´ 1.25 1 20 2.0 14
Drive chain sprocket cover M6 ´ 1.0 2 10 1.0 7.2
Kick shaft ratchet wheel guide M6 ´ 1.0 2 12 1.2 8.7
Kickstarter crank M8 ´ 1.25 1 33 3.3 24
Primary drive gear M18 ´ 1.0 1 75 7.5 54
Clutch spring M6 ´ 1.0 5 8 0.8 5.8
Clutch boss M16 ´ 1.0 1 60 6.0 43
Push lever shaft M6 ´ 1.0 1 10 1.0 7.2
Drive sprocket M18 ´ 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 ´ 1.0 2 10 1.0 7.2
Segument M8 ´ 1.25 1 30 3.0 22
Shift guide M6 ´ 1.0 2 10 1.0 7.2
Stopper lever M6 ´ 1.0 1 10 1.0 7.2 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

SPEC
2 - 12
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN
AUS, NZ, ZAEUROPE
Front fork travel 300 mm (11.8 in)¬----
Fork spring free length 460 mm (18.1 in)¬455 mm (17.9 in)
Spring rate, STD K = 4.31 N/mm
(0.44 kg/mm,
24.6 lb/in)K = Approx.
4.21 N/mm
(0.43 kg/mm,
24.1 lb/in)----
Optional spring/spacer Yes¬----
Oil capacity 568 cm
3
(20.0 lmp oz,
19.2 US oz) ¬----
Oil level 140 mm (5.51 in)¬----
<Min.~Max.>
(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 150 mm
(3.15 ~ 5.91 in)¬----
Oil grade Suspension oil
“01”¬----
Inner tube outer diameter 46 mm (1.81 in)¬----
Front fork top end 5 mm (0.20 in)¬----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 132 mm (5.20 in)¬----
Spring free length 260 mm
(10.24 in)275 mm
(10.83 in)----
Fitting length 248 mm
(9.76 in)262 mm
(10.31 in)----
<Min.~Max.>242 ~ 260 mm
(9.53 ~ 10.24 in)257 ~ 275 mm
(10.12 ~ 10.83 in)----
Spring rate, STD K = 47.0 N/mm
(4.80 kg/mm,
268.8 lb/in)K = Approx.
49.0 N/mm
(5.00 kg/mm,
280.0 lb/in)----
Optional spring Yes¬----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)¬----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 ´ 1.60/Aluminum ----
Rear rim size/material 19 ´ 1.85/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID520DMA2/DAIDO ----
Number of links 111 links + joint ----
Chain slack 40 ~ 50 mm (1.6 ~ 2.0 in) ----
Chain length (10 links) ----152.5 mm (6.00 in)
Front disc brake:
Disc outside dia. ´ Thickness 250 ´ 3.0 mm (9.84 ´ 0.12 in) 250 ´ 2.5 mm
(9.84 ´ 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) ´ 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. ´ Thickness 240 ´ 4.0 mm (9.45 ´ 0.16 in) 240 ´ 3.5 mm
(9.45 ´ 0.14 in)
Deflection limit ----0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) ´ 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height below footrest top)5 mm (0.20 in) ----
Clutch lever free play (at lever pivot) 2 ~ 4 mm (0.08 ~ 0.16 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 7 Nm (0.7 m • kg, 5.1 ft • lb).Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 ´ 1.25 4 23 2.3 17
Lower bracket and outer tube M8 ´ 1.25 4 20 2.0 14
Upper bracket and steering stem M24 ´ 1.0 1 145 14.5 105
Handlebar holder and upper bracket M8 ´ 1.25 4 28 2.8 20
Steering stem and steering ring nut M28 ´ 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M48 ´ 1.0 2 30 3.0 22
Front fork and base valve M30 ´ 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 ´ 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 ´ 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 ´ 1.0 6 10 1.0 7.2
Front fork and brake hose guide M5 ´ 0.8 1 4 0.4 2.2
Front fork and brake hose holder M6 ´ 1.0 2 10 1.0 7.2
Front fork and brake hose cover (M8) M8 ´ 1.25 1 16 1.6 11
(M6) M6 ´ 1.0 1 7 0.7 5.1
Throttle grip cap M5 ´ 0.8 2 4 0.4 2.2
Front brake master cylinder M6 ´ 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 ´ 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 ´ 1.0 1 6 0.6 4.3
Brake lever position locknut M6 ´ 1.0 1 5 0.5 3.6
Clutch lever holder M5 ´ 0.8 2 4 0.4 2.2
Clutch lever mounting bolt M6 ´ 1.0 1 2 0.2 1.4
Decompression lever holder M5 ´ 0.8 2 4 0.4 2.2
Front brake master cylinder cap M4 ´ 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 ´ 1.25 2 30 3.0 22
Front brake caliper M8 ´ 1.25 2 23 2.3 17
Pad pin plug M10 ´ 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 ´ 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 ´ 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 ´ 1.5 1 105 10.5 75
Front wheel axle holder M8 ´ 1.25 4 23 2.3 17
Front brake disc M6 ´ 1.0 6 12 1.2 8.7
Rear brake disc M6 ´ 1.0 6 14 1.4 10
Brake pedal M8 ´ 1.25 1 26 2.6 19
Rear brake master cylinder M6 ´ 1.0 2 10 1.0 7.2
Rear brake reservoir tank M6 ´ 1.0 1 10 1.0 7.2
Rear brake reservoir tank cap M4 ´ 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 ´ 1.25 2 30 3.0 2.2
Rear wheel axle and axle nut M20 ´ 1.5 1 125 12.5 90

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke) — 72 3 0.3 2.2
Rear wheel sprocket M8 ´ 1.25 6 42 4.2 30
Rear brake disc cover M6 ´ 1.0 2 7 0.7 5.1
Rear brake caliper protector M6 ´ 1.0 2 7 0.7 5.1
Engine mounting:
Engine and engine bracket (front) M10 ´ 1.25 1 69 6.9 50
Engine and frame (lower) M10 ´ 1.25 1 69 6.9 50
Engine bracket and frame M8 ´ 1.25 6 34 3.4 24
Engine and engine bracket (upper) M10 ´ 1.25 1 55 5.5 40
Lower engine guard M6 ´ 1.0 3 10 1.0 7.2
Right engine guard M8 ´ 1.25 2 10 1.0 7.2
Pivot shaft and nut M16 ´ 1.5 1 85 8.5 61
Relay arm and swingarm M14 ´ 1.5 1 80 8.0 58
Relay arm and connecting rod M14 ´ 1.5 1 80 8.0 58
Connecting rod and frame M14 ´ 1.5 1 80 8.0 58
Rear shock absorber and frame M10 ´ 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 ´ 1.25 1 53 5.3 38
Rear frame M8 ´ 1.25 3 29 2.9 21
Swingarm and brake hose holder M5 ´ — 4 4 0.4 2.9
Drive chain tensioner M8 ´ 1.25 2 19 1.9 13
Drive chain case M6 ´ 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 ´ 0.8 4 6 0.6 4.3
Fuel tank M6 ´ 1.0 2 10 1.0 7.2
Fuel cock M6 ´ 1.0 2 7 0.7 5.1
Seat set bracket and fuel tank M6 ´ 1.0 1 7 0.7 5.1
Hooking screw (fitting band) and fuel tank M6 ´ 1.0 1 7 0.7 5.1
Radiator cover M6 ´ 1.0 6 4 0.4 2.9
Front fender M6 ´ 1.0 4 7 0.7 5.1
Rear fender M6 ´ 1.0 4 7 0.7 5.1
Side cover M6 ´ 1.0 2 7 0.7 5.1
Seat M8 ´ 1.25 2 23 2.3 17
Number plate M6 ´ 1.0 1 7 0.7 5.1

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model/manufacturer F5JG 11/YAMAHA----
Charging coil 1 resistance (color) 720 ~ 1,080 W at 20 ˚C (68 ˚F)
(Green – Brown)----
Charging coil 2 resistance (color) 44 ~ 66 W at 20 ˚C (68 ˚F)
(Black – Pink)----
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5NL-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4SR-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.20 ~ 0.30 W at 20 ˚C (68 ˚F) ----
Secondary coil resistance 9.5 ~ 14.3 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 ´ 1.0 3 10 1.0 7.2
Rotor M10 ´ 1.25 1 48 4.8 35
Neutral switch M5 ´ 0.8 2 4 0.4 2.9
Ignition coil M6 ´ 1.0 2 7 0.7 5.1

SPEC
2 - 17
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg ´ m/sec
2 Force
Nm
m • kgNewton meter
Meter kilogramN ´ m
m ´ kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute — Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS