oil YAMAHA YZ250F 2012 User Guide

2-2
GENERAL SPECIFICATIONS
Carburetor:Type FCR-MX39
Manufacturer KEIHIN
Spark plug: Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission: USA, CDN EUROPE, AUS, NZ, ZA Primary reduction system Gear ←
Primary reduction ratio 3.353 (57/17) ←
Final drive Chain ←
Secondary reduction ratio 3.846 (50/13) 3.923 (51/13)
Transmission type Constant mesh, 5-speed ←
Operation Left foot operation ←
Gear ratio:
1st 2.143 (30/14) ←
2nd 1.750 (28/16) ←
3rd 1.444 (26/18) ←
4th 1.222 (22/18) ←
5th 1.042 (25/24) ←
Chassis: USA, CDN EUROPE AUS, NZ, ZA
Frame type Semi double cra-
dle ←←
Caster angle 27.21°27.12°27.32°
Trail 121.3 mm (4.78
in) 119.9 mm (4.72
in)122.1 mm (4.81
in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 100/90-19 57M
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension: Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber: Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel: USA, CDN EUROPE, AUS, NZ, ZA Front wheel travel 300 mm (11.8 in) ←
Rear wheel travel 317 mm ( 12.5 in) 312 mm (12.3 in)
Electrical: Ignition system CDI magneto

2-6
MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm
(0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ----
End gap (installed) 0.15–0.25 mm (0.006–0.010 in) 0.50 mm (0.020
in)
Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005
in)
2nd ring:
Type Taper ----
Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ----
End gap (installed) 0.30–0.45 mm (0.012–0.018 in) 0.80 mm (0.031
in)
Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005
in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ----
End gap (installed) 0.10–0.40 mm (0.004–0.016 in) ----
Crankshaft:
Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ----
Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002
in)
Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02
in)
Small end free play "F" 0.4–1.0 mm (0.016–0.039 in) 2.0 mm (0.08
in) Item Standard Limit

2-8
MAINTENANCE SPECIFICATIONS
CHASSISLubrication 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 121.4 mm (4.8 in) ----
Height 235 mm (9.3 in) ----
Thickness 28 mm (1.1 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.64 L (0.56 Imp qt, 0.68 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
Item Standard Limit
Steering system:
Steering bearing typeTaper 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 = 4.5 N/mm (0.459 kg/
mm, 25.7 lb/in)←----
Optional spring Yes←----
Oil capacity 543 cm
3 (19.1 lmp oz,
18.4 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 132.0 mm (5.20 in)←----
Spring free length 260 mm (10.24 in)←----
Fitting length 250 mm (9.84 in)←
Preload length
1.5–20 mm (0.06–0.79
in)←----
Spring rate, STD K = 52.0 N/mm (5.30 kg/
mm, 296.8 lb/in)←----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2,
142 psi)←----

2-10
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 17D-51/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 17D-90/YAMAHA ----
Ignition coil:
Model/manufacturer 5UL-20/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) ----
ItemThread
sizeQ'ty Tightening torque Remarks
Spark plug M10S 1 13 Nm (1.3 m•kg, 9.4 ft•lb)
Camshaft cap M6 10 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head blind plug screw M12 1 28 Nm (2.8 m•kg, 20 ft•lb)
Cylinder head (stud bolt) M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Cylinder head (stud bolt) M8 1 15 Nm (1.5 m•kg, 11 ft•lb)
Cylinder head (bolt) M9 4 38 Nm (3.8 m•kg, 27 ft•lb)
Cylinder head (nut) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head cover M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Balancer weight M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Balancer shaft driven gear M14 1 50 Nm (5.0 m•kg, 36 ft•lb) Lock washer
Timing chain guide (intake side) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Impeller M8 1 14 Nm (1.4 m•kg, 10 ft•lb)
Radiator hose clamp M6 10 2 Nm (0.2 m•kg, 1.4 ft•lb)
Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)Copper
washer
Water pump housing M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator pipe M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump cover M4 1 1.7 Nm (0.17 m•kg, 1.2 ft•lb)
Oil pump M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil filter element drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

2-11
TIGHTENING TORQUES
Oil filter element cover M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil strainer (crankcase) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil delivery pipe 1 (M10) M10 1 20 Nm (2.0 m•kg, 14 ft•lb)Copper
washer
Oil delivery pipe 1 (M8) M8 2 18 Nm (1.8 m•kg, 13 ft•lb)Copper
washer
△Oil hose M6 3 8 Nm (0.8 m•kg, 5.8 ft•lb)
Oil hose clamp — 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Oil strainer (oil tank) M6 1 9 Nm (0.9 m•kg, 6.5 ft•lb)
Oil tank drain bolt M8 1 18 Nm (1.8 m•kg, 13 ft•lb)
Oil tank (upper) M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Oil tank and frame M6 3 9 Nm (0.9 m•kg, 6.5 ft•lb)
Carburetor joint clamp M5 1 3 Nm (0.3 m•kg, 2.2 ft•lb)
Air filter joint clamp M6 1 3 Nm (0.3 m•kg, 2.2 ft•lb)
Throttle cable (pull) M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable (return) M12 1 11 Nm (1.1 m•kg, 8.0 ft•lb)
Throttle cable cover M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Hot starter plunger M12 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Hot starter cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
△Air filter case M6 2 8 Nm (0.8 m•kg, 5.8 ft•lb)
Air filter joint and air filter case M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Air filter element M6 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Exhaust pipe M8 2 20 Nm (2.0 m•kg, 14 ft•lb)
△Exhaust pipe protector M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
△Silencer M8 2 30 Nm (3.0 m•kg, 22 ft•lb)
Silencer clamp M8 1 14 Nm (1.4 m•kg, 10 ft•lb)
Crankcase M6 11 12 Nm (1.2 m•kg, 8.7 ft•lb)
Crankcase bearing stopper M6 11 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase bearing stopper (crankshaft) M6 4 14 Nm (1.4 m•kg, 10 ft•lb) Stake.
Left crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Right crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch cover M6 7 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase oil drain bolt M10 1 20 Nm (2.0 m•kg, 14 ft•lb)Copper
washer
△Crankshaft end accessing screw M32 1 —
△Timing mark accessing screw M14 1 —
△Drive chain sprocket cover M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Kick shaft ratchet wheel guide M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb) Lock washer
Kickstarter crank M8 1 33 Nm (3.3 m•kg, 24 ft•lb)
Primary drive gear M18 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Clutch spring M6 5 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch boss M16 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Clutch cable locknut M8 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Clutch cable adjust bolt and locknutM6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Push lever shaft M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) ItemThread
sizeQ'ty Tightening torque Remarks

2-12
TIGHTENING TORQUES
CHASSIS
△- marked portion shall be checked for torque tightening after break-in or before each race.
Drive sprocket M18 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Drive axle oil seal stopper M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Segment M8 1 30 Nm (3.0 m•kg, 22 ft•lb)
Shift guide M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Stopper lever M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Shift pedal M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)ItemThread
sizeQ'ty Tightening torque Remarks
ItemThread
sizeQ'ty Tightening torque Remarks
△Upper bracket and outer tube M84 21 Nm (2.1 m•kg, 15 ft•lb)
△Lower bracket and outer tube M8 4 21 Nm (2.1 m•kg, 15 ft•lb)
△Upper bracket and steering stem M24 1 145 Nm (14.5 m•kg, 105 ft•lb)
△Handlebar upper holder and handlebar
lower holderM8 4 28 Nm (2.8 m•kg, 20 ft•lb)
△Handlebar lower holder and upper brack-
etM10 2 34 Nm (3.4 m•kg, 25 ft•lb)
△Steering stem and steering ring nut M28 1 Refer to TIP.
Front fork and damper assembly M51 2 30 Nm (3.0 m•kg, 22 ft•lb)
Front fork and adjuster M22 2 55 Nm (5.5 m•kg, 40 ft•lb)Copper
washer
Damper assembly and base valve M42 2 29 Nm (2.9 m•kg, 21 ft•lb)
Adjuster and damper assembly M12 2 29 Nm (2.9 m•kg, 21 ft•lb)
Front fork bleed screw and base valve M5 2 1 Nm (0.1 m•kg, 0.7 ft•lb)
△Front fork and front fork protector M6 6 5 Nm (0.5 m•kg, 3.6 ft•lb)
△Lower bracket and brake hose guide M6 1 9 Nm (0.9 m•kg, 6.5 ft•lb)
△Front fork protector and brake hose hold-
erM6 2 8 Nm (0.8 m•kg, 5.8 ft•lb)
Throttle grip cap M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
△Front brake master cylinder M6 29 Nm (0.9 m•kg, 6.5 ft•lb)
Brake lever mounting bolt M6 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Brake lever mounting nut M6 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Brake lever position locknut M6 1 5 Nm (0.5 m•kg, 3.6 ft•lb)
Clutch lever holder M6 2 5 Nm (0.5 m•kg, 3.6 ft•lb)
Clutch lever mounting nut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Clutch lever position lock nut M5 1 5 Nm (0.5 m•kg, 3.6 ft•lb)
Hot starter lever holder M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Hot starter lever mounting nut M5 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Front brake master cylinder cap M4 2 2 Nm (0.2 m•kg, 1.4 ft•lb)
△
Front brake hose union bolt M10 2 30 Nm (3.0 m•kg, 22 ft•lb)Copper
washer
△Front brake caliper M8 2 28 Nm (2.8 m•kg, 20 ft•lb)
Pad pin plug M10 2 3 Nm (0.3 m•kg, 2.2 ft•lb)

2-16
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1. Oil filter element
2. Oil pump
3. Drive axle
4. Main axle
5. Intake camshaft
6. Exhaust camshaft
7. Oil tank
8. Oil delivery pipe
A. To oil tank

2-17
LUBRICATION DIAGRAMS
1. Crankshaft
2. Oil filter element
3. Oil tank
4. Oil hose
A. From oil pump

2-20
CABLE ROUTING DIAGRAM
1. Sub-wire harness
2. Hot starter cable
3. Oil hose
4. Neutral switch lead
5. Radiator hose 2
6. Clamp
7. Ignition coil lead
8. CDI magneto lead
9. Neutral switch lead coupler
10. CDI unit lead coupler11. Radiator breather hose
12. Hot starter cable protector
13. Rubber cap
14. Throttle position sensor lead
15. Cylinder head breather hose
16. Throttle position sensor lead
coupler
17. Tension pipe
18. Radiator mounting boss
19. Cylinder head breather hose20. Throttle position sensor tube
clamp
E K
E F GHH
F IJ A
AB
D
D CJ
C
G
B
K
E
M
M
H-H
K-K
E-E
D-D
M-M
F-F
A-A
I
L
L

2-21
CABLE ROUTING DIAGRAM
A. Pass the hot starter cable over
the radiator mounting boss.
B. Pass the throttle position sensor
lead under the hot starter cable.
C. Fasten the throttle position sen-
sor lead and the hot starter ca-
ble.
D. Locate the clamp between the
hot starter cable protector and
rubber cap.
E. Fasten the neutral switch lead
below the oil hose. and pass the
neutral switch lead on the inside
of the oil hose.
F. Pass the neutral switch lead on
the inside of the oil hose.
G. Fasten the neutral switch lead,
CDI magneto lead, and radiator
breather hose onto the frame.
They should all be clamped
above the engine bracket to the
left of the downtube of the
frame. The clamp ends should
face backward and the rest out-
side of the frame.
H. Pass the clutch cable through
the cable guide.
I. Pass the neutral switch lead and
CDI magneto lead behind the
frame.
J. Pass the hot starter cable on the
inside of the cylinder head
breather hose.
K. Fit the coupler projection into the
hole in the cover.
L. Fasten the sub-wire harness on
the CDI unit bracket.
M. Fasten the sub-wire harness at
the position-taped portion.
N. Pass each lead under the
clamp. Locate the CDI magneto
lead on the outside of the igni-
tion coil lead. Locate the throttle
position sensor lead, neutral
switch lead, CDI magneto lead
and ignition coil lead so that they
do not lie one on another.
O. Fasten the sub-wire harness to
the CDI unit bracket with the
clamp ends located under the
bracket.
P. Fasten the neutral switch lead,
throttle position sensor lead,
CDI magneto lead and ignition
coil lead. Fasten them around
the periphery of the recess be-
tween the tension pipe and radi-
ator mounting boss on the
frame.
Q. Locate the clamp ends within
the arrowed range. Assure that
the clamp end does not contact
the cylinder head breather hose.R. Pass the radiator breather hose
on the outside of the CDI mag-
neto lead and neutral switch
lead.
S. Fasten the throttle position sen-
sor lead and hot starter cable.
Fasten them between the cylin-
der head breather hose and
throttle position sensor tube
clamp. Fasten the clamp with its
ends toward the right-side of the
frame and cut off the other end
with 3 to 5 clamp holes left in it.
T. Locate the radiator breather
hose end above the down tube
and between the oil hose and
engine guard.
U. Fasten the neutral switch lead
above the oil hose, and pass the
neutral switch lead on the inside
of the oil hose.