YAMAHA YZ250F 2009 Owners Manual

6-2
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM
ELECTRICAL COMPONENTS
1. Engine stop switch
2. Throttle position sensor
3. Neutral switch4. CDI magneto
5. Ignition coil
6. Spark plug7. CDI unit
WIRING DIAGRAM
1. Engine stop switch
2. Throttle position sensor
3. Neutral switch
4. CDI magneto
5. Ignition coil
6. Spark plug
7. CDI unitCOLOR CODE
BBlack
Br Brown
GGreen
LBlue
OOrange
PPink
RRed
Sb Sky blue
WWhite
Y YellowB/L Black/Blue
B/W Black/White
B/Y Black/Yellow
G/B Green/Black
L/W Blue/White
R/W Red/White
B/WB/W
B/L
B/Y
SbSb
G/B
LYLY
P
B
B
B
B
G
O
WR
P
GW
R P
B Br W
W
B/Y GBr
G RR
OB Sb Sb Y
Y
WY
W
GG
B
PP
Br BrR R
OL
B SbY LL
B/L B/W B/WG/B
B B
B/L L Sb
B/L
G/B
G/BB/Y
B/Y
B/W
O B/W
BrBrP6

6-3
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*marked: Only when the ignition checker is used.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
Spark gap test Spark→*Clean or replace spark plug.
No spark↓
Check entire ignition system for connection.
(couplers, leads and ignition coil)No good→
Repair or replace.
OK↓
Check engine stop switch. No good→Replace.
OK↓
Check ignition coil. (primary coil and secondary
coil)No good→
Replace.
OK↓
Check CDI magneto. (pickup coil and charging
coil)No good→
Replace.
OK↓
Check neutral switch. No good→Repair or replace.
OK↓
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112

6-4
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the ignition coil from
spark plug.
2. Remove the ignition coil cap.
3. Connect the dynamic spark tester
"1" (ignition checker "2") as
shown.
• Ignition coil "3"
• Spark plug "4"
A. For USA and CDN
B. Except for USA and CDN
4. Kick the kickstarter crank.
5. Check the ignition spark gap.
6. Start engine, and increase spark
gap until misfire occurs. (for USA
and CDN only)
CHECKING THE COUPLERS,
LEADS AND IGNITION COIL
CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
• Ignition coil and spark plug as
they are fitted
Push in the ignition coil until it
closely contacts the spark plug
hole in the cylinder head cover.
CHECKING THE ENGINE STOP
SWITCH
1. Inspect:
• Engine stop switch conductionNot conductive while it is pushed→
Replace.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE IGNITION COIL
1. Remove the ignition coil cap.
2. Inspect:
• Primary coil resistance
Out of specification→Replace.
3. Inspect:
• Secondary coil resistance
Out of specification→Replace.4. Inspect:
• Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"
Wear →Replace.
CHECKING THE CDI MAGNETO
1. Inspect:
• Pickup coil resistance
Out of specification→Replace.
2. Inspect:
• Charging coil 1 resistance
Out of specification→Replace. Minimum spark gap:
6.0 mm (0.24 in)
Tester (+) lead→Black/White lead
"1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
engine stop switch is
pushed)
Tester (+) lead→Orange lead "1"
Tester (-) lead→Black lead "2"
Primary
coil resis-
tanceTester se-
lector posi-
tion
0.08–0.10
Ω at 20 °C
(68 °F) Ω × 1
Tester (+) lead→Orange lead "1"
Tester (-) lead→Spark plug termi-
nal "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
4.6–6.8
kΩat 20 °C
(68 °F) kΩ × 1
Tester (+) lead→Red lead "1"
Tester (-) lead→White lead "2"
Pickup coil
resistanceTester se-
lector posi-
tion
248-372 Ω
at 20 °C (68
°F)Ω ×100
Tester (+) lead→Brown lead "1"
Tester (-) lead→Green lead "2"
Charging
coil 1 resis-
tanceTester se-
lector posi-
tion
720-1,080
Ω at 20 °C
(68 °F)Ω ×100

6-5
IGNITION SYSTEM
3. Inspect:
• Charging coil 2 resistance
Out of specification→Replace.
CHECKING THE NEUTRAL
SWITCH
1. Inspect:
• Neutral switch conduction
Not conductive while it is in neutral→
Replace.
Conductive while it is engaged→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE CDI UNIT
Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again.Tester (+) lead→Pink lead "1"
Tester (-) lead→Black lead "2"
Charging
coil 2 resis-
tanceTester se-
lector posi-
tion
44-66 Ω at
20 °C (68
°F)Ω ×10
Tester (+) lead→Sky blue lead "1"
Tester (-) lead→Ground "2"
Result
Conductive (while gear
is in neutral)

6-6
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM
INSPECTION STEPS
If the throttle position sensor will not operate, use the following inspection steps.
*marked: Refer to "IGNITION SYSTEM" section.
Use the following special tools in this inspection.
Check entire ignition system for connection. No good→Repair or replace.
OK↓
Check throttle position sensor. (Throttle position
sensor coil)No good→
Replace.
OK↓
*Check CDI magneto. (Charging coil) No good→Replace.
OK↓
Check CDI unit. (Throttle position sensor input
voltage)No good→
Replace.
Pocket tester:
YU-3112-C/90890-03112

6-7
THROTTLE POSITION SENSOR SYSTEM
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE THROTTLE
POSITION SENSOR COIL
1. Inspect:
• Throttle position sensor coil resis-
tance
Out of specification→Replace.
2. Loosen:
• Throttle stop screw "1"
Turn out the throttle stop screw until
the throttle shaft is in the full close po-
sition.
3. Inspect:
• Throttle position sensor coil vari-
able resistance
Check that the resistance in in-
creased as the throttle grip is
moved from the full close position
to the full open position.
Out of specification→Replace.
CHANGING AND ADJUSTING THE
THROTTLE POSITION SENSOR
1. Remove:
• Throttle position sensor coupler
•Carburetor
2. Remove:
• Screw (throttle position sensor)
"1"
• Throttle position sensor "2"
Loosen the screw (throttle position
sensor) using the T25 bit.
3. Replace:
• Throttle position sensor
4. Install:
• Throttle position sensor "1"
• Screw (throttle position sensor)
"2"
• Align the slot "a" in the throttle posi-
tion sensor with the projection "b"
on the carburetor.
• Temporarily tighten the screw
(throttle position sensor).
5. Install:
•Carburetor
• Throttle position sensor coupler
6. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section in
the CHAPTER 3.
7. Insert the thin electric conductors
"2" (lead) into the throttle position
sensor coupler "1", as shown, and
connect the tester to them.
• Do not insert the electric conduc-
tors more than required because
it may reduce the waterproof
function of the coupler.
• Make sure that a short-circuit
does not develop between the
terminals because it may cause
damage to electrical compo-
nents.
8. Start the engine.
9. Adjust:
• Throttle position sensor output
voltage
Adjustment steps:
a. Adjust the installation angle of the
throttle position sensor "1" to ob-
tain the specified output voltage. Tester (+) lead→Blue lead "1"
Tester (-) lead→Black lead "2"
Throttle po-
sition sen-
sor coil
resistanceTester se-
lector posi-
tion
4–6 kΩ at
20°C (68 °F) kΩ×1
Tester (+) lead→Yellow lead "1"
Tester (-) lead→Black lead "2"
Throttle position
sensor coil vari-
able resistanceTester
selec-
tor po-
sition
Full
closedFull
opened
kΩ×1 Zero –3
kΩat
20°C
(68 °F)4–6
kΩat
20 °C
(68 °F)
Tester (+) lead→Yellow lead "3"
Tester (-) lead→Black lead "4"

6-8
THROTTLE POSITION SENSOR SYSTEM
Measure the output voltage accurate-
ly with a digital electronic voltmeter
that gives an easy reading of a small
voltage.
10. Put the aligning marks "a" on the
throttle position sensor and car-
buretor.
11. Stop the engine.
12. Remove the carburetor.
13. Tighten:
• Screw (throttle position sensor)
"1"
Tighten the screw (throttle position
sensor) using the T25 bit.
14. Install the carburetor.
CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Start the engine.3. Inspect:
• Throttle position sensor input volt-
age
Out of specification→Replace the
CDI unit.
Throttle po-
sition sen-
sor output
voltageTester se-
lector posi-
tion
0.58–0.78 V DCV
Tester (+) lead→Blue lead "1"
Tester (-) lead→Black/Blue lead
"2"
Throttle po-
sition sen-
sor input
voltage Tester se-
lector posi-
tion
4–6 V DCV-20

7-1
ENGINE
TUNING
ENGINE
CARBURETOR SETTING
• The air/fuel mixture will vary de-
pending on atmospheric conditions.
Therefore, it is necessary to take
into consideration the air pressure,
ambient temperature, humidity,
etc., when adjusting the carburetor.
• Perform a test run to check for prop-
er engine performance (e.g., throt-
tle response) and spark plug(-s)
discoloration or fouling. Use these
readings to determine the best pos-
sible carburetor setting.
It is recommended to keep a record of
all carburetor settings and external
conditions (e.g., atmospheric condi-
tions, track/surface conditions, lap
times) to make future carburetor set-
ting easier.
• The carburetor is a part of the
fuel line. Therefore, be sure to in-
stall it in a wellventilated area,
away from flammable objects
and any sources of fire.
• Never look into the carburetor in-
take. Flames may shoot out from
the pipe if the engine backfires
while it is being started. Gasoline
may be discharged from the ac-
celerator pump nozzle when the
carburetor has been removed.
• The carburetor is extremely sen-
sitive to foreign matter (dirt,
sand, water, etc.). During instal-
lation, do not allow foreign mat-
ter to get into the carburetor.
• Always handle the carburetor
and its components carefully.
Even slight scratches, bends or
damage to carburetor parts may
prevent the carburetor from
functioning correctly. Carefully
perform all servicing with the ap-
propriate tools and without ap-
plying excessive force.
• When the engine is stopped or
when riding at no load, do not
open and close the throttle un-
necessarily. Otherwise, too
much fuel may be discharged,
starting may become difficult or
the engine may not run well.• After installing the carburetor,
check that the throttle operates
correctly and opens and closes
smoothly.
ATMOSPHERIC CONDITIONS AND
CARBURETOR SETTINGS
The air density (i.e., concentration of
oxygen in the air) determines the rich-
ness or leanness of the air/fuel mix-
ture.
• Higher temperature expands the air
with its resultant reduced density.
• Higher humidity reduces the
amount of oxygen in the air by so
much of the water vapor in the
same air.
• Lower atmospheric pressure (at a
high altitude) reduces the density of
the air.
EFFECT OF SETTING PARTS IN
RELATION TO THROTTLE VALVE
OPENING
A. Closed
B. Fully open
1. Pilot screw/pilot jet
2. Throttle valve cutaway
3. Jet needle
4. Main jetCONSTRUCTION OF
CARBURETOR AND SETTING
PARTS
The FLATCR carburetor has a prima-
ry main jet. This type of main jet is
perfect for racing machines since it
supplies an even flow of fuel, even at
full load. Use the main jet and the jet
needle to set the carburetor.
The FLATCR carburetor is manufac-
tured with a pilot screw. The pilot
screw adjustment ranges from fully
closed throttle to 1/4 open throttle.
1. Jet needle
2. Pilot air jet
3. Needle jet
4. Main jet
5. Pilot jet
6. Pilot screw
ADJUSTING THE MAIN JET
The richness of the air-fuel mixture at
full throttle can be set by changing the
main jet "1".
If the air-fuel mixture is too rich or too
lean, the engine power will drop, re-
sulting in poor acceleration.
Effects of changing the main jet
(reference)
A. Idle
B. Fully open
1. #180
2. #175
3. #178 Air
tem
p.Hu-
midi-
tyAir
pres-
sure
(alti-
tude)Mix-
tureSet-
ting
High HighLow
(high)Rich-
erLean-
er
Low LowHigh
(low)Lean-
erRich-
er
Standard main jet #178

7-2
ENGINE
ADJUSTING THE PILOT SCREW
The richness of the air-fuel mixture
with the throttle fully closed to 1/4
open can be set by turning the pilot
screw "1". Turning in the pilot screw
will make the mixture lean at low
speeds, and turning it out will enrich
it.
• If the engine idling speed fluctuates,
turn the pilot screw only 1/2 of a turn
in either direction.
• To optimize the fuel flow at a small-
er throttle opening, each machine's
pilot screw has been individually set
at the factory. Before adjusting the
pilot screw, turn it in fully and count
the number of turns. Record this
number as the factory-set number
of turns out.
Effects of adjusting the pilot screw
(reference)
A. Idle
B. Fully open
1. 2-1/2 turns out
2. 1-1/2 turns out
3. 2 turns out
ADJUSTING THE PILOT JET
The richness of the air-fuel mixture
with the throttle open 1/4 or less can
be set by adjusting the pilot jet "1".Effects of adjusting the pilot jet
(reference)
A. Idle
B. Fully open
1. #45
2. #40
3. #42
ADJUSTING THE JET NEEDLE
GROOVE POSITION
Adjusting the jet needle "1" position
affects the acceleration when the
throttle is 1/8 to 3/4 open.
1. Too rich at intermediate speeds
• Rough engine operation is felt
and the engine will not pick up
speed smoothly.
Step up the jet needle clip by one
groove and move down the nee-
dle to lean out the mixture.
2. Too lean at intermediate speeds
• The engine breathes hard and will
not pick up speed quickly.
Step down the jet needle clip by
one groove and move up the nee-
dle to enrich the mixture.
Effects of changing the jet needle
groove position (reference)
A. Idle
B. Fully open
1. No.5 groove
2. No.3 groove
3. No.4 groove
ADJUSTING THE JET NEEDLE
The jet needle is adjusted by chang-
ing it.The jet needle setting parts, having
the same taper angle, are available in
different straight portion diameters
and in different taper starting posi-
tions.
a. Diameter of the straight por-
tion
b. Reference needle
c. 0.5 leaner
Changing from NHKR-4 to NFPR-5
has the same effect as a lowering of
0.5 clip position.
Effects of changing the jet needle
(reference)
(Diameter of the straight portion)
Changing the diameter of the straight
portion adjusts the air-fuel mixture
when the throttle is 1/8 to 1/4 open.
A. Idle
B. Fully open
RELATIONSHIP WITH THROTTLE
OPENING
The flow of the fuel through the car-
buretor main system is controlled by
the main jet and then, it is further reg-
ulated by the area between the main
nozzle and the jet needle.
The fuel flow relates to the diameter
of the straight portion of the jet needle
with the throttle 1/8 to 1/4 open and
relates to the clip position with the
throttle 1/8 to 3/4 open.
Therefore, the fuel flow is balanced at
each stage of throttle opening by the
combination of the jet needle straight
portion diameter and clip position. Standard pilot screw
position (example)2
Standard pilot jet #42
* #45
* Except for USA and CDN
Standard clip posi-
tionNo.4
groove
* No.5
groove
* Except for USA and CDN
Standard jet needle NHKR
* NFLR
* Except for USA and CDN
7

7-3
ENGINE
ADJUSTING THE LEAK JET
(ADJUSTING THE ACCELERATOR
PUMP)
The leak jet "1" is a setting part that
adjusts the flow of fuel discharged by
the accelerator pump. Since the ac-
celerator pump operates only when
throttle is open, the leak jet is used to
adjust a fuel mixture ratio for quick
throttle opening and is therefore dif-
ferent from other setting parts that ad-
just a fuel mixture for each throttle
opening (each engine speed).
1. When the engine breathes hard in
quick throttle opening, select a
leak jet having lower calibrating
No. than standard to enrich the
mixture. #70→#60
2. When rough engine operation is
felt in quick throttle opening, se-
lect a leak jet having higher cali-
brating No. than standard to lean
out the mixture. #70
→#80CARBURETOR SETTING PARTS
Standard leak jet #70
Main jet Size Part number
Rich #188 4MX-14943-95
#185 4MX-14943-44
#182 4MX-14943-94
#180 4MX-14943-43
(STD) #178 4MX-14943-93
#175 4MX-14943-42
#172 4MX-14943-92
#170 4MX-14943-41
Lean #168 4MX-14943-91
Pilot jet Size Part number
Rich #48 4MX-14948-06
* (STD) #45 4MX-14948-05
(STD) #42 4MX-14948-04
#40 4MX-14948-03
Lean #38 4MX-14948-02
Jet nee-
dleSize Part number
Rich NFPN 5TA-14916-PN
NFPP 5TA-14916-PP
NFPQ 5TA-14916-P1
NFPR 5TA-14916-PR
(STD) NHKR 5TA-14916-KR
NFPS 5TA-14916-PS
NFPT 5TA-14916-PT
Lean NFPU 5TA-14916-PU
Rich NFLN 5TA-14916-LN
NFLP 5TA-14916-LP
NFLQ 5TA-14916-L1
* (STD) NFLR 5TA-14916-LR
NFLS 5TA-14916-LS
NFLT 5TA-14916-LT
Lean NFLU 5TA-14916-LU
Leak jet Size Part number
Rich #40 4JT-1494F-03
#50 4JT-1494F-07
#60 4JT-1494F-11
(STD) #70 4JT-1494F-15
#80 4JT-1494F-19
#90 4JT-1494F-23
Lean #100 4JT-1494F-27
* Except for USA and CDN