Timing YAMAHA YZ250F 2012 Owners Manual

1-10
SPECIAL TOOLS
Timing light
YM-33277-A, 90890-03141 This tool is necessary for checking
ignition timing.
Valve spring compressor
YM-4019, 90890-04019 This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
YM-91042, 90890-04086This tool is used to hold the clutch
when removing or installing the
clutch boss securing nut.
Valve guide remover
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4111, 90890-04111
YM-4116, 90890-04116This tool is needed to remove and
install the valve guide.
Valve guide installer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4112, 90890-04112
YM-4117, 90890-04117This tool is needed to install the
valve guide.
Valve guide reamer
Intake 4.0 mm (0.16 in)
Exhaust 4.5 mm (0.18 in)
YM-4113, 90890-04113
YM-4118, 90890-04118This tool is needed to rebore the
new valve guide. Tool name/Part number How to use Illustration

2-3
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm (0.002
in)
Cylinder:
Bore size 77.00–77.01 mm (3.0315–3.0319 in) ----
Out of round limit ---- 0.05 mm (0.002
in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
Cam dimensions
Intake "A" 30.330–30.430 mm (1.1941–1.1980 in) 30.230 mm
(1.1902 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)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
Timing chain:
Timing chain type/No. of links 92RH2010-114M/114 ----
Timing chain adjustment method Automatic ----

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

3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below.
ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
ENGINE OIL
Replace●●
Inspect●●
OIL FILTER ELEMENT, OIL
STRAINER
Clean●
VALVES
Check the valve clearances●●The engine must be cold.
Inspect●Check the valve seats and valve
stems for wear.
Replace●
VALVE SPRINGS
Inspect●Check the free length and the tilt.
Replace●
VALVE LIFTERS
Inspect●Check for scratches and wear.
Replace●
CAMSHAFTS Inspect the camshaft surface.
Inspect●Inspect the decompression system.
Replace●
TIMING CHAIN SPROCKETS,
TIMING CHAIN
Inspect●Check for wear on the teeth and for
damage.
Replace●
PISTON
Inspect●●Inspect crack.
Clean●Inspect carbon deposits and eliminate
them.
Replace●It is recommended that the piston pin
and ring are also replaced at the same
time.
PISTON RING
Inspect●Check ring end gap.
Replace●●
3

3-11
ENGINE
b. Turn the throttle stop screw "1"
until the specified engine idling
speed.
Using a digital engine tachometer for
idle speed adjustment, detect the en-
gine idling speed by bringing the
sensing element "c" of the engine ta-
chometer close to the ignition coil "2".
ADJUSTING THE VALVE
CLEARANCE
• This section is intended for those
who have basic knowledge and skill
concerning the servicing of Yama-
ha motorcycles (e.g., Yamaha deal-
ers, service engineers, etc.) Those
who have little knowledge and skill
concerning servicing are requested
not to undertake inspection, adjust-
ment, disassembly, or reassembly
only by reference to this manual. It
may lead to servicing trouble and
mechanical damage.
• The valve clearance should be ad-
justed when the engine is cool to
the touch.
• The piston must be at Top Dead
Center (T.D.C.) on compression
stroke to check or adjust the valve
clearance.
1. Remove:
•Seat
•Fuel tank
Refer to "SEAT, FUEL TANK
AND SIDE COVERS" section in
the CHAPTER 4.
2. Remove:
• Spark plug
• Cylinder head cover
Refer to "CAMSHAFTS" section
in the CHAPTER 4.
3. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
• O-ring
4. Check:
• Valve clearance
Out of specification→Adjust.
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.
c. Measure the valve clearance "e"
using a feeler gauge "1".
Record the measured reading if the
clearance is incorrect.
5. Adjust:
• Valve clearance
Adjustment steps:
a. Remove the camshaft (intake and
exhaust).
Refer to "CAMSHAFTS" section
in the CHAPTER 4.
b. Remove the valve lifters "1" and
the pads "2".
• Place a rag in the timing chain
space to prevent pads from falling
into the crankcase.
• Identity each valve lifter and pad
position very carefully so that they
can be reinstalled in their original
place.
To increase idle speed→Turn the
throttle stop screw "1" in "a".
To decrease idle speed→Turn the
throttle stop screw "1" out "b".
Engine idling speed:
1,900–2,100 r/min
Valve clearance (cold):
Intake valve:
0.12–0.17 mm
(0.0047–0.0067 in)
Exhaust valve:
0.17–0.22 mm
(0.0067–0.0087 in)

3-24
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw "1"
2. Attach:
• Timing light
• Digital tachometer
To the ignition coil lead (orange
lead"1").
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range→Check ro-
tor and pickup assembly.
5. Install:
• Timing mark accessing screw Spark plug gap:
0.7–0.8 mm
(0.028–0.031 in)
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:
YM-33277-A/90890-
03141

4-15
CARBURETOR
17. Install:
• O-ring "1"
• Valve lever housing cover "2"
• Bolt (valve lever housing cover)
"3"
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 play
Refer to "ADJUSTING THE
THROTTLE GRIP 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:
0.7 mm (0.028 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)

4-16
CAMSHAFTS
CAMSHAFTS
REMOVING THE CYLINDER HEAD
COVER
Order 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

4-17
CAMSHAFTS
REMOVING THE CAMSHAFTS
Order Part name Q'ty Remarks
1 Timing mark accessing screw1 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.