YAMAHA YZ250F 2011 Owners Manual

4-17
CAMSHAFTS
4. Measure:
• Camshaft-to-cap clearance
Out 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
Plastigauge
®.
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" proj-
ects 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 installing 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:
• Crankshaft
Counterclockwise several turns.4. Check:
• Rotor T.D.C. mark
Align 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 HEAD
Order Part name Q'ty Remarks
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Exhaust pipe and silencerRefer 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 head
Scratches/damage→Replace.
Replace the titanium valves with the
cylinder head.
Refer to "CHECKING THE
VALVE".
3. Measure:
• Cylinder head warpage
Out 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"
First tighten the union bolts temporar-
ily. Then retighten them with the width
"a" across flats of the oil delivery pipe
held tight with a spanner.
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 SPRINGS
Order 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

4-22
VALVES AND VALVE SPRINGS
REMOVING THE VALVE LIFTER
AND VALVE COTTER
1. Remove:• Valve lifter "1"
• Pad "2"
Identify each lifter "1" and pad "2" po-
sition very carefully so that they can
be reinstalled in their original place.
2. Check:• Valve sealingLeakage at the valve seat →In-
spect the valve face, valve seat
and valve seat width.
Checking steps:
a. Pour a clean solvent "1" into the intake and exhaust ports.
b. Check that the valve seals prop- erly.
There should be no leakage at the
valve seat "2".
3. Remove:• Valve cotter
Attach a valve spring compressor "1"
between the valve spring retainer and
the cylinder head to remove the valve
cotters.
CHECKING THE VALVE
1. Measure:
• Stem-to-guide clearance
Out of specification →Replace the
valve guide.
2. Replace: • Valve guide
Replacement steps:
To ease guide removal, installation
and to maintain correct fit heat the
cylinder head in an over to 100 °C
(212 °F).
a. Remove the valve guide using a valve guide remover "1". b. Install the new valve guide using a
valve guide remover "1" and valve
guide installer "2".
c. After installing the valve guide, bore the valve guide using a valve
guide reamer "3" to obtain proper
stem-to-guide clearance.
After replacing the valve guide reface
the valve seat.
Valve spring compres-
sor:
YM-4019/90890-04019
Stem-to-guide clearance = valve guide inside diameter "a" -
valve stem diameter "b"
Clearance (stem to
guide):Intake:0.010–0.037 mm
(0.0004–0.0015 in)
:0.08 mm
(0.003 in)
Exhaust:
0.025–0.052 mm
(0.0010–0.0020 in)
:0.10 mm
(0.004 in)Valve guide installation
height "a": Intake:11.8–12.2 mm
(0.46–0.48 in)
Exhaust: 11.3–11.7 mm
(0.44–0.46 in)
Valve guide remover: Intake:4.0 mm (0.16 in)YM-4111/90890-04111
Exhaust:4.5 mm (0.18
in) YM-4116/90890-04116
Valve guide installer: Intake:4.0 mm (0.16 in)YM-4112/90890-04112
Exhaust:4.5 mm (0.18
in) YM-4117/90890-04117
Valve guide reamer: Intake:4.0 mm (0.16 in)YM-4113/90890-04113
Exhaust:4.5 mm (0.18
in) YM-4118/90890-04118

4-23
VALVES AND VALVE SPRINGS
3. Inspect:• Valve facePitting/wear →Grind the face.
• Valve stem end
Mushroom shape or diameter
larger than the body of the stem →
Replace.
4. Measure: • Margin thickness "a"Out of specification →Replace.
5. Measure: • Runout (valve stem)Out of specification →Replace.
• When installing a new valve always
replace the guide.
• If the valve is removed or replaced always replace the oil seal.
6. Eliminate:• Carbon deposits(from the valve face and valve
seat)
7. Inspect: • Valve seat
Pitting/wear →Reface the valve
seat.
8. Measure:
• Valve seat width "a"Out of specification →Reface the
valve seat.
Measurement steps:
a. Apply Mechanic's blueing dye
(Dykem) "b" to the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve
guide and onto the valve seat to
make a clear pattern.
d. Measure the valve seat width.
Where the valve seat and valve
face made contact, blueing will
have been removed.
e. If the valve seat is too wide, too narrow, or the seat is not cen-
tered, the valve seat must be
refaced.
9. Lap: • Valve face
• Valve seat
This model uses titanium intake
and exhaust valves. Titanium
valves that have been used to lap
the valve seats must not be used.
Always replace lapped valves with
new valves.
• When replacing the cylinder head, replace the valves without lapping
the valve seats and valve faces. • When replacing the valves or valve
guides, use new valves to lap the
valve seats, and then replace them
with new valves.
Lapping steps:
a. Apply a coarse lapping compound to the valve face.
Do not let the co mpound enter the
gap between the valve stem and
the guide.
b. Apply molybdenum disulfide oil to
the valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face
and valve seat are evenly pol-
ished, then clean off all of the
compound.
For best lapping results, lightly tap
the valve seat while rotating the valve
back and forth between your hands.
e. Apply a fine lapping compound to the valve face and repeat the
above steps.
After every lapping operation be sure
to clean off all of the compound from
the valve face and valve seat.
f. Apply Mechanic's blueing dye (Dykem) to the valve face.
g. Install the valve into the cylinder
head.
Margin thickness:
Intake:0.8 mm (0.0315 in)
Exhaust:
0.7 mm (0.0276 in)
Runout limit: 0.01 mm (0.0004 in)
Valve seat width:Intake:0.9–1.1 mm
(0.0354–0.0433 in)
:1.6 mm
(0.0630 in)
Exhaust: 0.9–1.1 mm
(0.0354–0.0433 in)
:1.6 mm
(0.0630 in)

4-24
VALVES AND VALVE SPRINGS
h. Press the valve through the valve guide and onto the valve seat to
make a clear pattern.
i. Measure the valve seat width
again. If the valve seat width is out
of specification, reface and relap
the valve seat.
CHECKING THE VALVE SPRINGS
1. Measure:• Valve spring free length "a"Out of specification →Replace.
2. Measure: • Compressed spring force "a"Out of specification →Replace.
b. Installed length
3. Measure: • Spring tilt "a"
Out of specification →Replace. CHECKING THE
VALVE LIFTERS
1. Inspect: • Valve lifterScratches/damage →Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply: • Molybdenum disulfide oilOnto the valve stem and valve
stem seal.
2. Install: • Valve "1"
• Valve spring seat "2"
• Valve stem seal "3"
• Valve spring "4"
• Valve spring retainer "5"
To cylinder head.
• Make sure that each valve is in-stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": Sky blue
Intake (right/left) "b": not paint
Exhaust "c": Purple
• Install the valve springs with the larger pitch "d" facing upward.
e. Smaller pitch
3. Install:
• Valve cotter
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil on the valve stem end.
• Apply the engine oil on the valve lift- ers.
• Valve lifter must turn smoothly when rotated with a finger.
• Be careful to reinstall valve lifters and pads in their original place.
Free length (valve
spring):
Intake:39.76 mm (1.57 in)
: 38.76 mm
(1.53 in)
Exhaust:
37.78 mm (1.49 in)
: 36.78 mm
(1.45 in)
Compressed spring
force: Intake:99–114 N at 28.98 mm
(9.9–11.4 kg at 28.98
mm, 22.27–25.57 lb at
1.14 in)
Exhaust: 126–145 N at 28.30
mm (12.6–14.5 kg at
28.30 mm,
28.44–31.97 lb at 1.11
in)
Spring tilt limit: Intake:2.5°/1.7 mm (0.067 in)
Exhaust: 2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

4-25
CYLINDER AND PISTON
CYLINDER AND PISTON
REMOVING THE CYLINDER AND PISTON
Order Part name Q'ty Remarks
Cylinder head Refer to "CYLINDER HEAD" section.
1 Bolt (cylinder) 1
2 Cylinder 1
3 Piston pin clip 2 Refer to removal section.
4 Piston pin 1 Refer to removal section.
5 Piston 1 Refer to removal section.
6 Piston ring set 1 Refer to removal section.

4-26
CYLINDER AND PISTON
REMOVING THE PISTON AND
PISTON RING
1. Remove:
• Piston pin clip "1"
• Piston pin "2"
• Piston "3"
• Put identification marks on each
piston head for reference during re-
installation.
• Before removing each piston pin,
deburr the clip groove and pin hole
area. If the piston pin groove is de-
burred and the piston pin is still dif-
ficult to remove, use the piston pin
puller set "4".
Do not use a hammer to drive the
piston pin out.
2. Remove:
• Piston ring "1"
Spread the end gaps apart while at
the same time lifting the piston ring
over the top of the piston crown, as
shown in the illustration.
CHECKING THE CYLINDER AND
PISTON
1. Inspect:
• Cylinder and piston walls
Vertical scratches→Replace cyl-
inder and piston.
2. Measure:
• Piston-to-cylinder clearance
Measurement steps:
a. Measure the cylinder bore "C"
with a cylinder bore gauge.
Measure the cylinder bore "C" in par-
allel to and at right angles to the
crankshaft. Then, find the average of
the measurements.
b. If out of specification, replace the
cylinder, and replace the piston
and piston rings as set.
c. Measure the piston skirt diameter
"P" with a micrometer.a. 8 mm (0.31 in) from the piston
bottom edge
d. If out of specification, replace the
piston and piston rings as a set.
e. Calculate the piston-to-cylinder
clearance with following formula:
f. If out of specification, replace the
cylinder, and replace the piston
and piston rings as set.
CHECKING THE PISTON RING
1. Measure:
• Ring side clearance
Use a feeler gauge "1".
Out of specification→Replace the
piston and rings as a set.
Clean carbon from the piston ring
grooves and rings before measuring
the side clearance.
Piston pin puller set:
YU-1304/90890-01304
Cylinder bore
"C"77.00–77.01
mm
(3.0315–3.0319
in)
Taper limit "T"0.05 mm (0.002
in)
Out of round
"R"0.05 mm (0.002
in)
"C" = Maximum D
"T" = (Maximum D
1 or D2) - (Max-
imum D
5 or D6)
"R" = (Maximum D
1, D3 or D5) -
(Minimum D
2, D4 or D6)
Piston size "P"
Standard76.955–76.970
mm
(3.0297–3.0303
in)
Piston-to-cylinder clearance =
Cylinder bore "C" - Piston skirt
diameter "P"
Piston-to-cylinder clear-
ance:
0.030–0.055 mm
(0.0012–0.0022 in)
:0.1 mm (0.004
in)
Side clearance:
Standard
Top
ring0.030–0.065
mm
(0.0012–0.0026
in)0.12
mm
(0.005
in)
2nd
ring0.020–0.055
mm
(0.0008–0.0022
in)0.12
mm
(0.005
in)