radiator YAMAHA YZ250F 2009 Owners Manual

CONTENTS
CHAPTER 1
GENERAL
INFORMATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION .................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
STARTING AND
BREAK-IN ........................ 1-8
TORQUE-CHECK
POINTS........................... 1-11
CLEANING AND
STORAGE ...................... 1-12
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-10
LUBRICATION
DIAGRAMS .................... 2-16
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR
INSPECTION AND
ADJUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-24
CHAPTER 4
ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-5
CARBURETOR................. 4-7
CAMSHAFTS.................. 4-14
CYLINDER HEAD........... 4-19
VALVES AND VALVE
SPRINGS ........................ 4-21
CYLINDER AND
PISTON ........................... 4-25
CLUTCH ......................... 4-29
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-33
BALANCER .................... 4-37
OIL PUMP ....................... 4-39
KICK SHAFT AND
SHIFT SHAFT ................. 4-42
CDI MAGNETO............... 4-47
ENGINE REMOVAL ....... 4-49
CRANKCASE AND
CRANKSHAFT ............... 4-53
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK................... 4-59
CHAPTER 5
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................5-1
FRONT BRAKE AND
REAR BRAKE ..................5-6
FRONT FORK ................. 5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-31
REAR SHOCK
ABSORBER ....................5-36
CHAPTER 6
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........6-2
IGNITION SYSTEM...........6-3
THROTTLE POSITION
SENSOR SYSTEM ...........6-6
CHAPTER 7
TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6

1-1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1. Clutch lever
2. Hot starter lever
3. Front brake lever
4. Throttle grip
5. Radiator cap
6. Fuel tank cap
7. Engine stop switch
8. Kickstarter crank
9. Fuel tank
10. Radiator
11. Coolant drain bolt
12. Rear brake pedal
13. Valve joint14. Fuel cock
15. Cold starter knob
16. Drive chain
17. Air filter
18. Oil level check window
19. Shift pedal
20. Front fork
1

1-5
SPECIAL TOOLS
Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352These tools are used for checking
the cooling system.
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.
Cap bolt wrench
YM-01500, 90890-01500This tool is used to loosen or tighten
the base valve.
Cap bolt ring wrench
YM-01501, 90890-01501This tool is used to loosen or tighten
the damper assembly.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Spoke nipple wrench
YM-01521, 90890-01521 This tool is used to tighten the
spoke.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age. Tool name/Part number How to use Illustration

2-8
MAINTENANCE SPECIFICATIONS
CHASSISIntake vacuum 29.3–34.7 kPa
(220–260 mmHg,
8.66–9.45 inHg)←----
Hot starter lever free play 3–6 mm (0.12–0.24
in)←----
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008
in)
Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009
in)
Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 120.2 mm (4.7 in) ----
Height 240 mm (9.4 in) ----
Thickness 22 mm (0.9 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.58 L (0.51 Imp qt, 0.61 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE, AUS, NZ, ZA
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 = 4.4 N/mm (0.449 kg/
mm, 25.1 lb/in)K = 4.5 N/mm (0.459 kg/
mm, 25.7 lb/in)----
Optional spring Yes←----
Oil capacity 521 cm
3 (18.3 lmp oz,
17.6 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 EUROPE, AUS, NZ, ZA
Shock absorber travel 131.5 mm (5.18 in)←----
Spring free length 260 mm (10.24 in)←----
Fitting length 251 mm (9.88 in) 248 mm (9.76 in)
Preload length
1.5–13 mm (0.06–0.51
in)←----

2-10
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
Clutch lever free play (lever end) 7–12 mm (0.28–0.47 in) ----
Throttle grip free play 3–5 mm (0.12–0.20 in) ----Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 5XC-10/YAMAHA ----
Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F) (Green–
Brown)----
Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black–Pink) ----
Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ----
CDI unit-model/manufacturer 5XC-R0/YAMAHA (For USA and CDN) ----
5XC-S0/YAMAHA (Except for USA and
CDN)----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11
Cylinder head (bolt) M9 × 1.25 4 38 3.8 27
Cylinder head (nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 10 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2

2-11
TIGHTENING TORQUES
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 1.7 0.17 1.2
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer (crankcase) M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
Oil delivery pipe 1 (M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
△Oil hose clamp — 1 2 0.2 1.4
Oil strainer (oil tank) M6 × 1.0 1 9 0.9 6.5
Oil tank drain bolt M8 × 1.25 1 18 1.8 13
Oil tank (upper) M6 × 1.0 1 7 0.7 5.1
Oil tank and frame M6 × 1.0 3 9 0.9 6.5
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
△Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Air filter element M6 × 1.0 1 2 0.2 1.4
Exhaust pipe M8 × 1.25 2 20 2.0 14
△Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
△Silencer M8 × 1.25 2 30 3.0 22
Silencer clamp M8 × 1.25 1 16 1.6 11
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 14 1.4 10
Oil level check window holder M6 × 1.0 1 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
△Crankshaft end accessing screw M32 × 1.5 1 — — —
△Timing mark accessing screw M14 × 1.5 1 — — —
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 10 1.0 7.2Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-14
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering 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).
ELECTRICALSeat 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 5.1Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
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

2-18
CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose
2. Radiator hose 1
3. Connector cover
4. Cylinder head breather hose
5. Radiator hose 4
6. Clutch cable
7. Throttle position sensor lead
8. Carburetor breather hose
9. Upper engine bracket10. Hot starter cable
11. Fuel hose
12. Carburetor overflow hose
A. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Install the connector cover so
that it does not come in between
the radiator hose 1 and radiator.C. Aligh the paint mark on the cylin-
der head breather hose with the
front end of the hose guide.
D. Pass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and then between the
radiator 4 and frame.
E. Pass the clutch cable through
the cable guide.

2-19
CABLE ROUTING DIAGRAM
F. Pass the clutch cable in front of
the radiator mounting boss.
G. Pass the fuel hose on the out-
side of throttle position 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
19. Hot starter cable protector
20. Rubber capA. Fasten the hot starter cable,
throttle cables, throttle position
sensor lead and ignition coil
lead.
B. Fasten the neutral switch lead
on the oil hose.
C. Pass the neutral switch lead on
the inside of the oil hose.
D. Fasten the neutral switch lead,
CDI magneto lead and radiator
breather hose.