YAMAHA YZ250F 2008 Repair Manual

3-15
CHASSIS
CHECKING AND REPLACING THE
FRONT BRAKE PADS
1. Inspect:• Brake pad thickness "a"Out of specification
→Replace as
a set.
2. Replace: •Brake pad
Brake pad replacement steps:
a. Remove the pad pin plug "1".
b. Loosen the pad pin "2".
c. Remove the brake caliper "3" from the front fork.
d. Remove the pad pin and brake pads "4". e. Connect the transparent hose "5"
to the bleed screw "6" and place
the suitable container under its
end.
f. Loosen the bleed screw and push the brake caliper piston in.
Do not reuse the drained brake flu-
id.
g. Tighten the bleed screw.
h. Install the brake pads "7" and pad
pin.
ŒInstall the brake pads with their pro-
jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at this point.
i. Install the brake caliper "8" and
tighten the pad pin "9". j. Install the pad pin plug "10".
3. Inspect:
• Brake fluid levelRefer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check: • Brake lever operationA softy or spongy feeling
→Bleed
brake system.
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion.
CHECKING AND REPLACING THE
REAR BRAKE PADS
1. Inspect: • Brake pad thickness "a"
Out of specification
→Replace as
a set.
2. Replace: • Brake pad
Brake pad replacement steps:
a. Remove the protector "1" and pad pin plug "2".
Brake pad thickness:
4.4 mm (0.17 in)
: 1.0 mm (0.04
in)
Bleed screw:6 Nm (0.6 m•kg, 4.3
ft•lb)
Bolt (brake caliper): 28 Nm (2.8 m•kg, 20
ft•lb)
Pad pin: 18 Nm (1.8 m•kg, 13
ft•lb)
Pad pin plug:3 Nm (0.3 m•kg, 2.2
ft•lb)
Brake pad thickness: 6.4 mm (0.25 in)
: 1.0 mm (0.04
in)

3-16
CHASSIS
b. Loosen the pad pin "3".
c. Remove the rear wheel "4" and brake caliper "5".
Refer to "FRONT WHEEL AND
REAR WHEEL" section in the
CHAPTER 5.
d. Remove the pad pin "6" and brake pads "7".
e. Connect the transparent hose "8" to the bleed screw "9" and place
the suitable container under its
end.
f. Loosen the bleed screw and push the brake caliper piston in.
Do not reuse the drained brake flu-
id.
g. Tighten the bleed screw.
h. Install the brake pad "10" and pad pin "11".
• Install the brake pads with their pro-jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at this point.
i. Install the brake caliper "12" and
rear wheel "13".
Refer to "FRONT WHEEL AND
REAR WHEEL" section in the
CHAPTER 5.
j. Tighten the pad pin "14".
k. Install the pad pin plug "15" and
protector "16".
3. Inspect:• Brake fluid levelRefer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check: • Brake pedal operationA softy or spongy feeling
→Bleed
brake system.
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion.
CHECKING THE REAR BRAKE
PAD INSULATOR
1. Remove: •Brake pad
Refer to "CHECKING AND RE-
PLACING THE REAR BRAKE PADS" section.
2. Inspect: • Rear brake pad insulator "1"Damage
→Replace.
CHECKING THE BRAKE FLUID
LEVEL
1. Place the brake master cylinder so that its top is in a horizontal po-
sition.
2. Inspect:
• Brake fluid levelFluid at lower level
→Fill up.
• Use only designated quality brake fluid to avoid poor brake
performance.
• Refill with same type and brand of brake fluid; mixing fluids
could result in poor brake perfor-
mance.
• Be sure that water or other con- taminants do not enter master
cylinder when refilling.
• Clean up spilled fluid immediate- ly to avoid erosion of painted
surfaces or plastic parts.
a. Lower level
A. Front
B. Rear
CHECKING THE SPROCKET
1. Inspect: • Sprocket teeth "a"Excessive wear
→Replace.
Replace the drive sprocket, rear
wheel sprocket and drive chain as a
set.
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
Pad pin:18 Nm (1.8 m•kg, 13
ft•lb)
Pad pin plug: 3 Nm (0.3 m•kg, 2.2
ft•lb)
Bolt (protector): 7 Nm (0.7 m•kg, 5.1
ft•lb)
Recommended brake flu-
id:DOT #4

3-17
CHASSIS
CHECKING THE DRIVE CHAIN
1. Measure:• Drive chain length (15 links) "a"Out of specification
→Replace.
• While measuring the drive chain
length, push down on the drive
chain to increase its tension.
• Measure the length between drive
chain roller "1" and "16" as shown.
• Perform this measurement at two or three different places.
2. Remove:
• Master link clip
•Joint "1"
• Drive chain "2"
3. Clean: • Drive chain
Place it in kerosene, and brush off
as much dirt as possible. Then re-
move the drive chain from the ker-
osene and dry the drive chain.
4. Check: • Drive chain stiffness "a"
Clean and oil the drive chain and hold as illustrated.
Stiff
→Replace the drive chain.
5. Install: • Drive chain "1"
• Joint "2"
• Master link clip "3"
Be sure to install the master link
clip to the direction as shown.
a. Turning direction
6. Lubricate: • Drive chain
ADJUSTING THE DRIVE CHAIN
SLACK
1. Elevate the rear wheel by placing the suitable stand under the en-
gine.
2. Check:
• Drive chain slack "a"Above the seal guard installation
bolt.
Out of specification
→Adjust.
Before checking and/or adjusting, ro-
tate the rear wheel through several
revolutions and check the slack sev-
eral times to find the tightest point.
Check and/or adjust the drive chain
slack with the rear wheel in this "tight chain" position.
3. Adjust:
• Drive chain slack
Drive chain slack adjustment
steps:
a. Loosen the axle nut "1" and lock- nuts "2".
b. Adjust the drive chain slack by
turning the adjusters "3".
c. Turn each adjuster exactly the same amount to maintain correct
axle alignment. (There are marks
"a" on each side of the drive chain
puller alignment.)
Turn the adjuster so that the drive
chain is in line with the sprocket, as
viewed from the rear.
Too small drive chain slack will
overload the engine and other vital
parts; keep the slack within the
specified limits.
d. Tighten the axle nut while pushing down the drive chain.
e. Tighten the locknuts.
Drive chain length (15
links): : 242.9 mm
(9.563 in)
Drive chain lubricant:SAE 10W-30 motor oil
or suitable chain lubri-
cants
Drive chain slack: 48–58 mm (1.9–2.3 in)
To tighten→Turn the adjuster "3"
counterclockwise.
To loosen
→Turn the adjuster "3"
clockwise and push wheel for-
ward.
Axle nut:125 Nm (12.5 m•kg, 90
ft•lb)
Locknut: 19 Nm (1.9 m•kg, 13
ft•lb)

3-18
CHASSIS
CHECKING THE FRONT FORK
1. Inspect:• Front fork smooth actionOperate the front brake and
stroke the front fork.
Unsmooth action/oil leakage
→
Repair or replace.
CLEANING THE FRONT FORK OIL
SEAL AND DUST SEAL
1. Remove: •Protector
• Dust seal "1"
Use a thin screw driver, and be care-
ful not to damage the inner fork tube
and dust seal.
2. Clean:• Dust seal "a"
•Oil seal "b"
•Clean the dust seal and oil seal af-
ter every run.
• Apply the lithium soap base grease
on the inner tube.
RELIEVING THE FRONT FORK
INTERNAL PRESSURE
If the front fork initial movement feels
stiff during a run, relieve the front fork
internal pressure.
1. Elevate the front wheel by placing a suitable stand under the engine.
2. Remove the air bleed screw "1" and release the internal pressure
from the front fork.
3. Install: • Air bleed screw
ADJUSTING THE FRONT FORK
REBOUND DAMPING FORCE
1. Adjust: • Rebound damping force
By turning the adjuster "1".
• STANDARD POSITION: This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
ADJUSTING THE FRONT FORK
COMPRESSION DAMPING FORCE
1. Adjust:• Compression damping force
By turning the adjuster "1".
• STANDARD POSITION: This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:• Swingarm smooth action
Abnormal noise/unsmooth action
→Grease the pivoting points or
repair the pivoting points.
Damage/oil leakage
→Replace.
Air bleed screw:
1 Nm (0.1 m•kg, 0.7
ft•lb)
Stiffer "a"
→Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b"
→Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)
Standard position: 11 clicks out
* 10 clicks out
* For EUROPE
Stiffer "a" →Increase the com-
pression damping force. (Turn
the adjuster "1" in.)
Softer "b"
→Decrease the com-
pression damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)
Standard position: 9 clicks out
* 10 clicks out
* For EUROPE

3-19
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER SPRING PRELOAD
1. Elevate the rear wheel by placing the suitable stand under the en-
gine.
2. Remove: • Rear frame
3. Loosen: • Locknut "1"
4. Adjust:
• Spring preloadBy turning the adjuster "2".
•Be sure to remove all dirt and mud
from around the locknut and adjust-
er before adjustment.
• The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.
• The I.D. mark "b" is marked at the end of the spring.
• The standard length and extent of
adjustment vary according to the
quantity of I.D. marks.
Never attempt to turn the adjuster
beyond the maximum or minimum
setting.
5. Tighten:• Locknut
6. Install: • Rear frame (upper)
• Rear frame (lower)
ADJUSTING THE REAR SHOCK
ABSORBER REBOUND DAMPING
FORCE
1. Adjust: • Rebound damping forceBy turning the adjuster "1". • STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the bracket.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
ADJUSTING THE REAR SHOCK
ABSORBER LOW COMPRESSION
DAMPING FORCE
1. Adjust:• Low compression damping forceBy turning the adjuster "1".
Stiffer
→Increase the spring pre-
load. (Turn the adjuster "2" in.)
Softer
→Decrease the spring pre-
load. (Turn the adjuster "2"
out.)
Spring length (installed)
"a":
Standard length Extent of ad-
justment
One I.D. mark 268 mm
(10.55 in)
*262 mm
(10.31 in)
Two I.D. marks 274 mm
(10.79 in)
*268 mm
(10.55 in)
Three I.D.
marks 265.5 mm
(10.45 in)
*259.5 mm
(10.22 in) 255.5–273.5
mm (10.06–
10.77 in)
261.5–279.5
mm (10.30–
11.00 in)
253.0–271.0
mm (9.96–10.67
in)
* For EUROPE
Rear frame (upper): 38 Nm (3.8 m•kg, 27
ft•lb)
Rear frame (lower): 32 Nm (3.2 m•kg, 23
ft•lb)
Stiffer "a"
→Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b"
→Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)
Standard position: About 8 clicks out
Stiffer "a"
→Increase the low
compression damping force.
(Turn the adjuster "1" in.)
Softer "b"
→Decrease the low
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 20 clicks out
(from maximum
position)

3-20
CHASSIS
• STANDARD POSITION:This is the position which is back
by the specific number of clicks
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the high compression
damping adjuster.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
ADJUSTING THE REAR SHOCK
ABSORBER HIGH COMPRESSION
DAMPING FORCE
1. Adjust:• High compression damping force
By turning the adjuster "1".
• STANDARD POSITION: This is the position which is back
by the specific number of turns
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the adjuster body.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
CHECKING THE TIRE PRESSURE
1. Measure:
• Tire pressureOut of specification
→Adjust.
•Check the tire while it is cold.
• Loose bead stoppers allow the tire
to slip off its position on the rim
when the tire pressure is low.
• A tilted tire valve stem indicates that
the tire slips off its position on the
rim.
• If the tire valve stem is found tilted,
the tire is considered to be slipping
off its position. Correct the tire posi-
tion.
CHECKING AND TIGHTENING THE
SPOKES
1. Inspect:• Spokes "1"Bend/damage
→Replace.
Loose spoke
→Retighten.
2. Tighten: •Spokes
Be sure to retighten these spokes be-
fore and after break-in. After a prac-
tice or a race check spokes for
looseness.
CHECKING THE WHEELS
1. Inspect:
• Wheel runoutElevate the wheel and turn it.
Abnormal runout
→ Replace.
2. Inspect: • Bearing free play
Exist play
→Replace.
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Elevate the front wheel by placing a suitable stand under the engine.
2. Check:
• Steering stemGrasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play
→Adjust steering head.
Standard position:
About 8 clicks out
Stiffer "a"
→Increase the high
compression damping force.
(Turn the adjuster "1" in.)
Softer "b"
→Decrease the high
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position 2 turns out
(from maximum
position)
Standard position:
About 1-1/2 turns out
Standard tire pressure: 100 kPa (1.0 kgf/cm
2,
15 psi)
Spokes: 3 Nm (0.3 m•kg, 2.2
ft•lb)

3-21
CHASSIS
3. Check:• Steering smooth actionTurn the handlebar lock to lock.
Unsmooth action
→Adjust steer-
ing ring nut.
4. Adjust: • Steering ring nut
Steering ring nut adjustment
steps:
a. Remove the number plate.
b. Remove the handlebar and upper
bracket.
c. Loosen the steering ring nut "1"
using the steering nut wrench "2".
d. Tighten the steering ring nut "3" using steering nut wrench "4".
• Apply the lithium soap base grease
on the thread of the steering stem.
• Set the torque wrench to the steer- ing nut wrench so that they form a
right angle.
e. Loosen the steering ring nut one
turn.
f. Retighten the steering ring nut us- ing the steering nut wrench.
Avoid over-tightening.
g. Check the steering stem by turn-ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
h. Install the washer "5", upper bracket "6", washer "7", steering
stem nut "8", handlebar "9", han-
dlebar upper holder "10" and
number plate "11".
• The handlebar upper holder should be installed with the punched mark
"a" forward.
• Install the handlebar so that the marks "b" are in place on both
sides.
• Install the handlebar so that the pro- jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• Insert the end of the fuel breather
hose "12" into the hole in the steer-
ing stem.
First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
Steering nut wrench: YU-33975/90890-01403
Steering nut wrench: YU-33975/90890-01403
Steering ring nut (initial
tightening): 38 Nm (3.8 m•kg, 27
ft•lb)
Steering ring nut (final
tightening):7 Nm (0.7 m•kg, 5.1
ft•lb)
Steering stem nut: 145 Nm (14.5 m•kg, 105
ft•lb)
Handlebar upper holder: 28 Nm (2.8 m•kg, 20
ft•lb)
Pinch bolt (upper brack-
et): 21 Nm (2.1 m•kg, 15
ft•lb)
Number plate:
7 Nm (0.7 m•kg, 5.1
ft•lb)

3-22
CHASSIS
LUBRICATION
To ensure smooth operation of all
components, lubricate your machine
during setup, after break-in, and after
every race.
1. All control cable
2. Clutch lever pivot
3. Shift pedal pivot
4. Footrest pivot
5. Throttle-to-handlebar contact
6. Drive chain7. Tube guide cable winding por-
tion
8. Throttle cable end
9. Clutch cable end
10. Hot starter cable end
A. Use Yamaha cable lube or
equivalent on these areas.
B. Use SAE 10W-30 motor oil or suitable chain lubricants. C. Lubricate the following areas
with high quality, lightweight lith-
ium-soap base grease.
Wipe off any excess grease, and
avoid getting grease on the brake
discs.

3-23
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:• Spark plug
2. Inspect:
• Electrode "1"Wear/damage
→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color
→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure: • Plug gap "a"Use a wire gauge or thickness
gauge.
Out of specification
→Regap.
4. Clean the plug with a spark plug cleaner if necessary.
5. Tighten: • Spark plug
• Before installing a spark plug, clean the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:• Timing mark accessing screw "1" 2. Attach:
• Timing light
• Inductive tachometerTo the ignition coil lead (orange
lead"1").
3. Adjust: • Engine idling speedRefer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check: • Ignition timing
Visually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range
→Check ro-
tor and pickup assembly.
5. Install: • Timing mark accessing screw
Spark plug gap:
0.7–0.8 mm (0.028–
0.031 in)
Spark plug: 13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:YM-33277-A/90890-
03141

4-1
SEAT, FUEL TANK AND SIDE COVERS
ENGINE
SEAT, FUEL TANK AND SIDE COVERS
REMOVING THE SEAT, FUEL TANK AND SIDE COVERSOrder Part name Q'ty Remarks Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Refer to removal section.
6 Right side cover 1 Refer to removal section.
7 Number plate 1 Refer to removal section.