YAMAHA YZ250F 2008 Manual Online

4-12
CARBURETOR
9. Install:• Push rod "1"
While holding down the lever 1 "2", in-
sert the push rod farthest into the car-
buretor.
10. Install:• Starter jet "1"
• Pilot jet "2"
• Spacer "3"
• Needle jet "4"
•Main jet "5"
11. Install: • Needle valve "1"
•Float "2"
• Float pin "3"
• After installing the needle valve to
the float, install them to the carbure-
tor.
• Check the float for smooth move- ment.
12. Install:
• Pilot screw "1"
• Spring "2"
•Washer "3"
• O-ring "4"
Note the following installation
points:
a. Turn in the pilot screw until it is lightly seated.
b. Turn out the pilot screw by the
number of turns recorded before
removing.
13. Install:• O-ring
•Leak jet "1"
• Float chamber "2"
• Bolt (float chamber) "3"
• Cable holder (throttle stop screw cable) "4"
• Hose holder (carburetor breather hose) "5"
14. Install: • Diaphragm (accelerator pump) "1"
• Spring "2"
• O-ring "3"
• Accelerator pump cover "4"
• Hose holder (drain hose) "5"
• Screw (accelerator pump cover)
"6"
Install the diaphragm (accelerator
pump) with its mark "a" facing the
spring.
15. Install:•Jet needle "1"
•Collar "2"
• Spring "3"
• Needle holder "4"
• Throttle valve plate "5"
To throttle valve "6".
16. Install: • Throttle valve assembly "1"
• Screw (throttle shaft) "2"
Install the valve lever rollers "3" into
the slits "a" of the throttle valve.
17. Install:• O-ring "1"
• Valve lever housing cover "2"
• Bolt (valve lever housing cover) "3"
Pilot screw (example): 2-3/8 turns out

4-13
CARBURETOR
18. Install:• Carburetor breather hose "1"
Install the carburetor breather hoses
to the carburetor so that the hoses do
not bend near where they are in-
stalled.
ADJUSTING THE ACCELERATOR
PUMP TIMING
Adjustment steps:
In order for the throttle valve height
"a" to achieve the specified value,
tuck under the throttle valve plate "1"
the rod "2" etc. with the same outer di-
ameter as the specified value.
a. Fully turn in the accelerator pump adjusting screw "3".
b. Check that the link lever "4" has free play "b" by pushing lightly on
it.
c. Gradually turn out the adjusting screw while moving the link lever
until it has no more free play.
INSTALLING THE CARBURETOR
1. Install:
• Carburetor joint "1" 2. Install:
• Carburetor "1"
Install the projection "a" between the
carburetor joint slots.
3. Install:• Hot starter plunger "1"
4. Tighten: • Bolt (carburetor joint) "1"
• Bolt (air filter joint) "2"
5. Install: • Throttle cable (pull) "1" • Throttle cable (return) "2"
6. Adjust: • Throttle grip free playRefer to "ADJUSTING THE
THROTTLE CABLE FREE PLAY"
section in the CHAPTER 3.
7. Install: • Throttle cable cover "1"
• Bolt (throttle cable cover) "2"
8. Install: • Throttle position sensor lead cou-
pler "1"
•Clamp "2" Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
Throttle valve height:
0.8 mm (0.031 in)
Carburetor joint: 10 Nm (1.0 m•kg, 7.2
ft•lb)
Hot starter plunger:2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (carburetor joint): 3 Nm (0.3 m•kg, 2.2
ft•lb)
Bolt (air filter joint): 3 Nm (0.3 m•kg, 2.2
ft•lb)
Throttle cable (pull): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Throttle cable (return):11 Nm (1.1 m•kg, 8.0
ft•lb)
Bolt (throttle cable cov-
er): 4 Nm (0.4 m•kg, 2.9
ft•lb)

4-14
CAMSHAFTS
CAMSHAFTS
REMOVING THE CYLINDER HEAD COVEROrder Part name Q'ty Remarks Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
1 Spark plug 1
2 Cylinder head breather hose 1
3 Bolt (cylinder head cover) 2
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1

4-15
CAMSHAFTS
REMOVING THE CAMSHAFTSOrder Part name Q'ty Remarks1 Timing mark accessing screw 1 Refer to removal section.
2 Crankshaft end accessing screw 1 Refer to removal section.
3 Timing chain tensioner cap bolt 1 Refer to removal section.
4 Timing chain tensioner 1 Refer to removal section.
5 Camshaft cap 2 Refer to removal section.
6 Clip 2 Refer to removal section.
7 Exhaust camshaft 1 Refer to removal section.
8 Intake camshaft 1 Refer to removal section.

4-16
CAMSHAFTS
REMOVING THE CAMSHAFT
1. Remove:• Timing mark accessing screw "1"
• Crankshaft end accessing screw "2"
2. Align: • T.D.C. mark
With align mark.
Checking steps:
a. Turn the crankshaft counterclock- wise with a wrench.
b. Align the T.D.C. mark "a" on the rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
In order to be sure that the piston is at
Top Dead Center, the punch mark "c"
on the exhaust camshaft and the
punch mark "d" on the intake cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion.
3. Remove:• Timing chain tensioner cap bolt
"1"
• Timing chain tensioner "2"
•Gasket 4. Remove:
• Bolt (camshaft cap) "1"
• Camshaft cap "2"
•Clip
Remove the bolts (camshaft cap) in a
crisscross pattern, working from the
outside in.
The bolts (camshaft cap) must be
removed evenly to prevent dam-
age to the cylinder head, cam-
shafts or camshaft caps.
5. Remove:• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to
prevent it from falling into the crank-
case.
CHECKING THE CAMSHAFT
1. Inspect:• Cam lobe
Pitting/scratches/blue discolora-
tion
→Replace.
2. Measure:
• Cam lobe length "a" and "b" Out of specification
→Replace.
3. Measure: • Runout (camshaft)Out of specification
→Replace.
Cam lobes length: Intake "a":30.246–30.346 mm
(1.1908–1.1947 in)
: 30.146 mm (1.1869 in)
Intake "b":
22.45–22.55 mm
(0.8839–0.8878 in)
:
22.35 mm (0.8799 in)
Exhaust "a": 30.399–30.499 mm
(1.1968–1.2007 in)
: 30.299 mm (1.1929 in)
Exhaust "b": 22.45–22.55 mm
(0.8839–0.8878 in)
: 22.35 mm (0.8799 in)
Runout (camshaft): Less than 0.03 mm
(0.0012 in)

4-17
CAMSHAFTS
4. Measure:• Camshaft-to-cap clearanceOut of specification
→Measure
camshaft outside diameter.
Measurement steps:
a. Install the camshaft onto the cylin-
der head.
b. Position a strip of Plastigauge
®
"1" onto the camshaft.
c. Install the clip, dowel pins and camshaft caps.
• Tighten the bolts (camshaft cap) in a crisscross pattern from innermost
to outer caps.
• Do not turn the camshaft when measuring clearance with the Plas-
tigauge
®.
d. Remove the camshaft caps and measure the width of the Plasti-
gauge
® "1".
5. Measure:• Camshaft outside diameter "a"Out of specification
→Replace
the camshaft.
Within specification
→Replace
camshaft case and camshaft
caps as a set. CHECKING THE CAMSHAFT
SPROCKET
1. Inspect:
• Camshaft sprocket "1"
Wear/damage
→Replace the
camshaft assembly and timing
chain as a set.
CHECKING THE
DECOMPRESSION SYSTEM
1. Check: • Decompression system
Checking steps:
a. Check that the decompression mechanism cam "1" moves
smoothly.
b. Check that the decompression
mechanism cam lever pin "2"
projects from the camshaft.
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:• While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver "1" and wind the ten-
sioner rod up fully clockwise.
• When releasing the screwdriver by pressing lightly with fingers,
make sure that the tensioner rod
will come out smoothly.
• If not, replace the tensioner as- sembly. INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock- wise with a wrench.
• Apply the molybdenum disulfide oil
on the camshafts.
• Apply the engine oil on the decom- pression system.
• Squeezing the decompression le- ver allows the crankshaft to be
turned easily.
b. Align the T.D.C. mark "a" on the rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
:0.08 mm (0.003
in)
Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Camshaft outside diame-
ter: 21.959–21.972 mm
(0.8645–0.8650 in)

4-18
CAMSHAFTS
c. Fit the timing chain "3" onto both camshaft sprockets and install the
camshafts on the cylinder head.
The camshafts should be installed
onto the cylinder head so that the
punch mark "c" on the exhaust cam-
shaft and the punch mark "d" on the
intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
Do not turn the crankshaft during
the camshaft installation. Damage
or improper valve timing will re-
sult.
d. Install the clips, camshaft caps "4" and bolts (camshaft cap) "5".
• Before removing the clips, cover the cylinder head with a clean rag to
prevent the clips from into the cylin-
der head cavity.
• Apply the molybdenum disulfide oil
on the thread of the bolts (camshaft
cap).
• Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
The bolts (camshaft cap) must be
tightened evenly, or damage to the
cylinder head, camshaft caps, and
camshaft will result.
2. Install:• Timing chain tensioner
Installation steps:
a. While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver and wind the tension-
er rod up fully clockwise.
b. With the rod fully wound and the chain tensioner UP mark "a" fac-
ing upward, install the gasket "1"
and the timing chain tensioner "2",
and tighten the bolt "3" to the
specified torque.
c. Release the screwdriver, check the tensioner rod to come out and
tighten the gasket "4" and the cap
bolt "5" to the specified torque.
3. Turn:
• CrankshaftCounterclockwise several turns.
4. Check: • Rotor T.D.C. markAlign with the crankcase align
mark.
• Camshaft match marks Align with the cylinder head sur-
face.
Out of alignment
→Adjust. 5. Install:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw "2"
6. Install: • Timing chain guide (top side) "1"
• Cylinder head cover gasket "2"
• Cylinder head cover "3"
• Bolt (cylinder head cover) "4"
Apply the sealant on the cylinder
head cover gasket.
7. Install:• Cylinder head breather hose
• Spark plug
Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain ten-
sioner):10 Nm (1.0 m•kg, 7.2
ft•lb)
Tensioner cap bolt: 7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (cylinder head cov-
er):
10 Nm (1.0 m•kg, 7.2
ft•lb)
YAMAHA Bond No. 1215
(ThreeBond
® No. 1215):
90890-85505
Spark plug: 13 Nm (1.3 m•kg, 9.4
ft•lb)

4-19
CYLINDER HEAD
CYLINDER HEAD
REMOVING THE CYLINDER HEADOrder Part name Q'ty Remarks Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER"
section.
Radiator hose 1 Disconnect at cylinder head side.
Carburetor Refer to "CARBURETOR" section.
Camshaft Refer to "CAMSHAFTS" section.
Upper engine bracket Refer to "ENGINE REMOVAL" section.
1 Radiator pipe 1
2 Oil delivery pipe 1
3Nut 2
4 Bolt [L = 135 mm (5.31 in)] 2
5 Bolt [L = 145 mm (5.71 in)] 2
6 Cylinder head 1
7 Timing chain guard (exhaust side) 1

4-20
CYLINDER HEAD
CHECKING THE CYLINDER HEAD
1. Eliminate:• Carbon deposits (from the com-bustion chambers)
Use a rounded scraper.
Do not use a sharp instrument to
avoid damaging or scratching:
• Spark plug threads
•Valve seats
2. Inspect:
• Cylinder headScratches/damage
→Replace.
3. Measure: • Cylinder head warpageOut of specification
→Resurface.
Warpage measurement and resur-
facing steps:
a. Place a straightedge and a feeler
gauge across the cylinder head.
b. Use a feeler gauge to measure
the warpage.
c. If the warpage is out of specifica- tion, resurface the cylinder head.
d. Place a 400–600 grit wet sandpa- per on the surface plate, and re-
surface the head using a figure-
eight sanding pattern.
To ensure an even surface rotate the
cylinder head several times.
INSTALLING THE CYLINDER
HEAD
1. Install:• Dowel pin "1"
• Cylinder head gasket "2"
• Timing chain guide (exhaust side) "3"
• Cylinder head "4"
While pulling up the timing chain, in-
stall the timing chain guide (exhaust
side) and cylinder head.
2. Install: •Washer "1"
• Cable guide "2"
• Bolts [L = 145 mm (5.71 in)] "3"
• Bolts [L = 135 mm (5.31 in)] "4"
•Nuts "5"
• Apply the molybdenum disulfide grease on the thread and contact
surface of the bolts.
• Follow the numerical order shown in the illustration. Tighten the bolts
and nuts in two stages.
3. Install:• Copper washer "1"
• Oil delivery pipe "2"
• Union bolt (M8) "3"
• Union bolt (M10) "4"
4. Install: • Radiator pipe "1"
• Bolt (radiator pipe) "2"
Cylinder head warpage:
Less than 0.05 mm
(0.002 in)
Bolts [L = 145 mm (5.71
in)]:38 Nm (3.8 m•kg, 27
ft•lb)
Bolts [L = 135 mm (5.31
in)]: 38 Nm (3.8 m•kg, 27
ft•lb)
Nuts: 10 Nm (1.0 m•kg, 7.2
ft•lb)
Union bolt (M8):
18 Nm (1.8 m•kg, 13
ft•lb)
Union bolt (M10): 20 Nm (2.0 m•kg, 14
ft•lb)
Bolt (radiator pipe): 10 Nm (1.0 m•kg, 7.2
ft•lb)

4-21
VALVES AND VALVE SPRINGS
VALVES AND VALVE SPRINGS
REMOVING THE VALVES AND VALVE SPRINGSOrder Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section.
1 Valve lifter 5 Refer to removal section.
2 Adjusting pad 5 Refer to removal section.
3 Valve cotter 10 Refer to removal section.
4 Valve spring retainer 5
5 Valve spring 5
6 Valve stem seal 5
7 Valve spring seat 5
8 Exhaust valve 2
9 Intake valve 3