Specification YAMAHA YZ250F 2007 Owner's Manual

SPEC
2 - 12 CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 300 mm (11.8 in) ----
Fork spring free length 454 mm (17.9 in) 449 mm (17.7 in)
Spring rate, STD K = 4.2 N/mm
(0.428 kg/mm, 24.0 lb/in)----
Optional spring Yes ----
Oil capacity 527 cm
3 (18.6 Imp oz, 17.8 US oz) ----
Oil grade Suspension oil “S1”----
Inner tube outer diameter 48 mm (1.89 in) ----
Front fork top end 5 mm (0.20 in) ----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 131.5 mm
(5.18 in)← ----
Spring free length Approx. 265 mm
(10.43 in)← ----
Fitting length
One I.D. mark 257 mm
(10.12 in)252 mm
(9.92 in)----
Two I.D. marks 263 mm
(10.35 in)258 mm
(10.16 in)----
Three I.D. marks 254.5 mm
(10.02 in)249.5 mm
(9.82 in)----
One I.D. mark
245.5 ~ 263.5 mm
(9.67 ~ 10.37 in)←----
Two I.D. marks
251.5 ~ 269.5 mm
(9.90 ~ 10.61 in)←----
Three I.D. marks
243.0 ~ 261.0 mm
(9.57 ~ 10.28 in)←----
Spring rate, STD K = 48.0 N/mm
(4.90 kg/mm,
274.4 lb/in)←----
Optional spring Yes← ----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)← ----
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13 Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
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 SDH/DAIDO ----
Number of links 111 links + joint ----
Chain slack 48 ~ 58 mm (1.9 ~ 2.3 in) ----
Chain length (15 links) ---- 242.9 mm
(9.563 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) 1.0 mm (0.04 in)
Master cylinder inside dia. 9.5 mm (0.374 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 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. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 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 above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 14
NOTE:
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the steer-
ing nut wrench, then loosen the steering ring nut one turn.
2. Retighten the steering ring 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 21 2.1 15
Lower bracket and outer tube M8 × 1.25 4 21 2.1 15
Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
Handlebar upper holder and handlebar lower
holderM8 × 1.25 4 28 2.8 20
Handlebar lower holder and upper bracket M10 × 1.25 2 34 3.4 25
Steering stem and steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and damper assembly M51 × 1.5 2 30 3.0 22
Front fork and adjuster M22 × 1.25 2 55 5.5 40
Damper assembly and base valve M42 × 1.5 2 29 2.9 21
Adjuster and damper assembly M12 × 1.25 2 29 2.9 21
Front fork bleed screw and base valve M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
Lower bracket and brake hose guide M6 × 1.0 1 4 0.4 2.9
Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
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 2.9
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
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 21 2.1 15
Front brake disc M6 × 1.0 6 12 1.2 8.7
Rear brake disc M6 × 1.0 6 14 1.4 10
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
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 master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15
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 10 1.0 7.2
Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 12
Engine mounting:
Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
Engine and frame (lower) M10 × 1.25 1 53 5.3 38
Upper engine bracket and frame M8 × 1.25 4 34 3.4 25
Lower engine bracket and frame M8 × 1.25 4 38 3.8 27
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 M6 × 1.0 1 10 1.0 7.2
CDI unit bracket M6 × 1.0 2 7 0.7 5.1
Cable guide and CDI unit bracket M5 × 0.8 2 4 0.4 2.9
Cable guide and frame M5 × 0.8 1 5 0.5 3.6
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 70 7.0 50
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 (upper) M8 × 1.25 1 32 3.2 23
Rear frame (lower) M8 × 1.25 2 32 3.2 23
Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting boss and frame M10 × 1.25 1 20 2.0 14
Fuel tank M6 × 1.0 2 9 0.9 6.5
Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator guard (lower) M6 × 1.0 2 7 0.7 5.1
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 16 1.6 11
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
MAINTENANCE SPECIFICATIONS

SPEC
2 - 16
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufac-
turer5XC-G0/YAMAHA ----
Charging coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F)
(Green – Brown)----
Charging coil 2 resistance (color) 44 ~ 66 Ω at 20°C (68 °F)
(Black – Pink)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5XC-90/YAMAHA (For USA)
5XC-A0/YAMAHA (Except for USA)----
----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ 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 M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9
MAINTENANCE SPECIFICATIONS

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 mkg ftlb
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

SPEC
2 - 17
CARACTERISTIQUES GENERALES DE COUPLE
Ce tableau spécifie les couples de serrage des atta-
ches standard avec filet à pas I.S.O. standard. Les
spécifications de couple pour les composants ou
ensembles spéciaux sont indiquées dans les sec-
tions appropriées de ce manuel. Pour éviter toute
déformation, serrer les ensembles à plusieurs atta-
ches en procédant en croix, par étapes progressives,
jusqu’à ce que le couple final soit atteint. Sauf indi-
cation contraire, les spécifications de couple
s’entendent pour des filets propres et secs. Les élé-
ments doivent être à température ambiante.
A: Distance entre les plats
B: Diamètre extérieur du filet
DEFINITION DES UNITES
A
(Ecrou)B
(Boulon)SPECIFICATION DE
COUPLE
Nm mkg ftlb
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
UnitéSignification Définition Mesure
mm
cmmillimètre
centimètre10
-3 mètre
10-2 mètreLongueur
Longueur
kg kilogramme 10
3 grammes Poids
N Newton 1 kg ×
m/sec
2Force
Nm
m  kgNewton-mètre
Mètre kilogrammeN ×
m
m ×
kgCouple
Couple
Pa Pascal N/m
2Pression
N/mm Newton par millimètre N/mm Raideur de ressort
L
cm
3 Litre
Centimètre cube—
—Volume ou contenance
Volume ou contenance
tr/mn Tours par minute—Régime du moteur
CARACTERISTIQUES GENERALES DE COUPLE/
DEFINITION DES UNITES

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Repair.
Radiator 1
Radiator hose joint 2
Coolant leakage → Repair or replace.
Radiator hose 3
Swelling → Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Before adjustment, expose the adjuster by
moving the boot 3 and cap 4 away.
Make minute adjustment on the lever side
using the adjuster 5.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknuts 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknuts.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)

INSP
ADJ
HINWEIS:
Den vorgeschriebenen Druck nicht
überschreiten.
Den Kühler bis zum Rand befüllen.
4. Kontrollieren:
Druck
Druck hält nicht mindestens 10
Sekunden lang an → Instand
setzen.
Kühler 1
Kühler-Schlauchkupplung 2
Undicht → Instand setzen, ggf.
erneuern.
Kühler-Schlauch 3
Aufgequollen → Erneuern.
KUPPLUNG EINSTELLEN
1. Kontrollieren:
Kupplungshebel-Spiel a
Nicht nach Vorgabe → Einstel-
len.
Kupplungshebel-Spiel a:
8–13 mm (0,31–0,51 in)
2. Einstellen:
Kupplungshebel-Spiel
HINWEIS:
Vor der Einstellung die Manschette
3 und Schutzkappe 4 von der
Einstellmutter entfernen.
Die Feineinstellung hebelseitig 5
vornehmen.
Nach der Einstellung sollte die
Funktion des Kupplungshebels
überprüft werden. Kupplungshebel-Spiel einstel-
len:
Die Muttern 1 lockern.
Die Einstellmutter 2 verdrehen,
bis das vorgeschriebene Spiel
a erreicht ist.
Die Sicherungsmuttern festzie-
hen.
T R..
Sicherungsmutter:
4 Nm
(0,4 m  kg, 2,9 ft  lb)
N.B.:
Ne pas appliquer de pression supé-
rieure à la pression spécifiée.
Le radiateur doit être entièrement rem-
pli.
4. Contrôler:
Pression
Impossible de maintenir la pres-
sion spécifiée pendant 10 secon-
des → Réparer.
Radiateur 1
Raccord de la durit de radiateur 2
Fuite de liquide de refroidisse-
ment → Réparer ou remplacer.
Durit de radiateur 3
Gonflement → Remplacer.
REGLAGE DE L’EMBRAYAGE
1. Contrôler:
Jeu du levier d’embrayage a
Hors spécifications → Régler.
Jeu du levier d’embrayage
a:
8 à 13 mm (0,31 à 0,51 in)
2. Régler:
Jeu du levier d’embrayage
N.B.:
Avant de procéder au réglage, décou-
vrir le dispositif de réglage en retirant
le bouchon 3 et le manchon 4.
Pour un réglage ponctuel, utiliser le
dispositif de réglage 5 du côté du
levier.
Après le réglage, contrôler le fonction-
nement du levier d’embrayage. Etapes du réglage du jeu du levier
d’embrayage:
Desserrer les contre-écrous 1.
Faire tourner le dispositif de
réglage 2 jusqu’à ce que le jeu a
se situe dans les limites spécifiées.
Serrer les contre-écrous.
T R..
Contre-écrou:
4 Nm
(0,4 m  kg, 2,9 ft  lb)
NOTA:
Non applicare una pressione superiore
a quella indicata.
Il radiatore deve essere completa-
mente pieno.
4. Controllare:
Pressione
Impossibile mantenere la pres-
sione indicata per 10 secondi →
Riparare.
Radiatore 1
Giunto flessibile radiatore 2
Perdita di refrigerante → Ripa-
rare o sostituire.
Flessibile radiatore 3
Rigonfiamento → Sostituire.
REGOLAZIONE FRIZIONE
1. Controllare:
Gioco leva della frizione a
Non conforme alle specifiche →
Regolare.
Gioco leva della frizione a:
8 ~ 13 mm (0,31 ~ 0,51 in)
2. Regolare:
Gioco della leva della frizione
NOTA:
Prima della regolazione, esporre il
dispositivo di regolazione allonta-
nando il parapolvere 3 e il coperchio
4.
Eseguire una regolazione minuziosa
sul lato della leva utilizzando il dispo-
sitivo di regolazione 5.
Dopo la regolazione, controllare il
corretto funzionamento della leva
della frizione. Operazioni per la regolazione del
gioco leva della frizione:
Allentare i controdadi 1.
Ruotare il dispositivo di regola-
zione 2 finché il gioco a rientri
nei limiti indicati.
Serrare i controdadi.
T R..
Controdado:
4 Nm
(0,4 m  kg, 2,9 ft  lb)
REGLAGE DE L’EMBRAYAGE
KUPPLUNG EINSTELLEN
REGOLAZIONE FRIZIONE
3 - 9

3 - 10
INSP
ADJTHROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
3. Install:
Cap 1
Boot 2
NOTE:
Place the tip a of the cap in the boot.
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
2. Adjust:
Throttle grip free play
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
Throttle grip free play adjustment steps:
Slide the adjuster cover.
Loosen the locknut 1.
Turn the adjuster 2 until the specified free
play is obtained.
Tighten the locknut.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
1 2
THROTTLE LUBRICATION
1. Remove:
Cover (throttle cable cap) 1
Cover (grip cap) 2
Throttle grip cap 3