YAMAHA YZ250F 2008 Service Manual

2-19
CABLE ROUTING DIAGRAM
F. Pass the clutch cable in front of the radiator mounting boss.
G. Pass the fuel hose between the hot starter cable and throttle po-
sition sensor lead.
H. Pass the carburetor breater hos- es so that they are not pinched
between the upper engine
bracket and carburetor.
I. Pass the carburetor breather
hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.

2-20
CABLE ROUTING DIAGRAM
1. Hot starter cable
2. Radiator hose 2
3. Clamp
4. Ignition coil lead
5. Throttle position sensor lead
6. Hump (frame)
7. Oil hose
8. Hose guide
9. Neutral switch lead
10. CDI magneto lead
11. Clutch cable12. Radiator breather hose
13. Engine stop switch lead
14. Sub-wire harness
15. CDI unit bracket
16. CDI unit
17. Throttle cable
18. Cylinder head breather hose
A. Fasten the hot starter cable,
throttle cables, throttle position
sensor lead and ignition coil
lead. B. Fasten the throttle position sen-
sor lead behind the hump of the
frame.
C. Fasten the neutral switch lead on the oil hose.
D. Pass the neutral switch lead on the inside of the oil hose.
E. Fasten the neutral switch lead,
CDI magneto lead and radiator
breather hose.

2-21
CABLE ROUTING DIAGRAM
F. Fasten the neutral switch lead, CDI magneto lead, radiator
breather hose and clutch cable
over the radiator mounting boss.
G. Pass the radiator breather hose in front of the radiator, on the left
of the chassis, and then be-
tween the frame and radiator
hose 4.
H. Fasten the sub-wire harness
and engine stop switch lead to
the CDI unit bracket at the white-
taped portion of the subwire har-
ness and with the clamp ends
facing downward.
I. Locate the clamp ends in the ar-
rowed range.
J. Fasten the neutral switch lead and CDI magneto lead over the
hump of the frame.
K. Fasten the hot starter cable and throttle cable onto the frame. Lo-
cate the clamp ends under the
hot starter cable.

2-22
CABLE ROUTING DIAGRAM
1. Throttle cable (pull)
2. Throttle cable (return)
3. Radiator hose 2
4. Ignition coil
5. Cylinder head breather hose
6. Clamp
7. Rear arm bracket
A. Pass the throttle cables over the radiator hose 2. B. Pass the cylinder head breather
hose so that it does not contact
the ignition coil.
C. Fasten the throttle cables with the clamp so that the cables are
not bent, and pass them under
the rear arm bracket.

2-23
CABLE ROUTING DIAGRAM
1. Brake master cylinder
2. Brake hose holder
3. Brake hose
A. Install the brake hose so that its pipe portion directs as shown
and lightly touches the projec-
tion on the brake caliper.
B. Pass the brake hose into the
brake hose holders. C. If the brake hose contacts the
spring (rear shock absorber),
correct its twist.
D. Install the brake hose so that its pipe portion directs as shown
and lightly touches the projec-
tion on the brake master cylin-
der.

2-24
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Hot starter cable
4. Clutch cable
5. Engine stop switch lead
6. Cable guide
7. Brake hose
8. Hose guide
A. Fasten the engine stop switch lead to the handlebar. B. Pass the clutch cable and hot
starter cable through the cable
guide.
C. Pass the brake hose in front of the number plate.
D. Pass the throttle cables through the cable guide.
E. Pass the clutch cable and hot
starter cable through the cable
guide on the number plate.

3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
Item After
break- in Every
race
Every
third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks
ENGINE OIL Replace
●●
Inspect●●
OIL FILTER ELEMENT, OIL
STRAINERClean
●
VALVESCheck the valve clearances
●●The engine must be cold.
Inspect
●Check the valve seats and valve
stems for wear.
Replace
●
VALVE SPRINGS Inspect
●Check the free length and the tilt.
Replace
●
VALVE LIFTERS Inspect
●Check for scratches and wear.
Replace
●
CAMSHAFTS Inspect the camshaft surface.
Inspect
●Inspect the decompression system.
Replace
●
TIMING CHAIN SPROCKETS,
TIMING CHAIN Inspect
●Check for wear on the teeth and for
damage.
Replace
●
PISTON Inspect
●●Inspect crack.
Clean
●Inspect carbon deposits and eliminate
them.
Replace
●
PISTON RING Inspect
●Check ring end gap.
Replace
●●
PISTON PIN Inspect
●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean
●Change gasket.
3

3-2
MAINTENANCE INTERVALS
CYLINDERInspect and clean
●Inspect score marks.
Replace
●Inspect wear.
CLUTCH Inspect and adjust
●●Inspect housing, friction plate, clutch
plate and spring.
Replace
●
TRANSMISSION Inspect
●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BARInspect
●Inspect wear.
ROTOR NUT Retighten
●●
EXHAUST PIPE, SILENCER,
PROTECTORInspect and retighten
●●
Clean●
Replace●* Whichever comes first
CRANK Inspect and clean
●●
CARBURETORInspect, adjust and clean
●●
SPARK PLUGInspect and clean
●●
Replace●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment
●●Chain slack: 48–58 mm (1.9–2.3 in)
Replace
●
COOLING SYSTEM Check coolant level and leakage
●●
Check radiator cap operation●
Replace coolant●Every two years
Inspect hoses
●
OUTSIDE NUTS AND BOLTS Retighten
●●Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER Clean and lubricate
●●Use foam air-filter oil or equivalent oil.
Replace
●
OIL FILTER Replace
●●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-3
MAINTENANCE INTERVALS
OIL STRAINERClean
●
FRAMEClean and inspect
●●
FUEL TANK, COCKClean and inspect
●●
BRAKESAdjust lever position and pedal
height
●●
Lubricate pivot point●●
Check brake disc surface●●
Check fluid level and leakage●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts●●
Replace pads●
Replace brake fluid●Every one year
FRONT FORKS Inspect and adjust
●●
Replace oil●●Suspension oil "S1"
Replace oil seal
●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube
●●Lithium base grease
PROTECTOR GUIDE Replace
●
REAR SHOCK ABSORBERInspect and adjust
●●
Lube●
(After rain
ride)
●Molybdenum disulfide grease
Replace spring seat
●Every one year
Retighten
●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect
●●
SWINGARMInspect, lube and retighten
●●Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten
●●Molybdenum disulfide grease
STEERING HEAD Inspect free play and retighten
●●
Clean and lube●Lithium base grease
Replace bearing
●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-4
MAINTENANCE INTERVALS
TIRE, WHEELSInspect air pressure, wheel run-
out, tire wear and spoke loose-
ness
●●
Retighten sprocket bolt●●
Inspect bearings●
Replace bearings●
Lubricate●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection
●●
Lubricate●●Yamaha cable lube or SAE 10W-30
motor oil
Inspect and clean (throttle ca-
ble)
●●Inspect dirt and wear on the throttle
cable on the carburetor side.
HOT STARTER, CLUTCH LEVER Inspect free play
●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks