OWNER’S SE

MANUEL

WARTUN

MANUALE D

YZ250F(X)

5XC-28199-34-E0

2008

OWNER’S SERVICE MANUAL

YZ250F(X)

OWNER'S SERVICE MANUAL

©2007 by Yamaha Motor Co., Ltd.

1st Edition, April 2007

All rights reserved.Any reprinting or

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

FOREWARD

INTRODUCTION

Congratulations on your purchase of

a Yamaha YZ series. This model is

the culmination of Yamaha's vast ex-

perience in the production of paceset-

ting racing machines. It represents

the highest grade of craftsmanship

and reliability that have made Yama-

ha a leader.

This manual explains operation, in-

spection, basic maintenance and tun-

ing of your machine. If you have any

questions about this manual or your

machine, please contact your Yama-

ha dealer.

Yamaha continually seeks advance-

ments in product design and quality.

Therefore, while this manual contains

the most current product information

available at the time of printing, there

may be minor discrepancies between

your machine and this manual. If you

have any questions concerning this

manual, please consult your Yamaha

dealer.

PLEASE READ THIS MANUAL

CAREFULLY AND COMPLETELY

BEFORE OPERATING THIS MA-

CHINE. DO NOT ATTEMPT TO OP-

ERATE THIS MACHINE UNTIL YOU

HAVE ATTAINED A SATISFACTO-

RY KNOWLEDGE OF ITS CON-

TROLS AND OPERATING

FEATURES AND UNTIL YOU HAVE

BEEN TRAINED IN SAFE AND

PROPER RIDING TECHNIQUES.

REGULAR INSPECTIONS AND

CAREFUL MAINTENANCE,

ALONG WITH GOOD RIDING

SKILLS, WILL ENSURE THAT YOU

SAFETY ENJOY THE CAPABILI-

TIES AND THE RELIABILITY OF

THIS MACHINE.

PARTICULARLY IMPORTANT

INFORMATION

The Safety Alert Symbol means AT-

TENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instruc-

tions could result in severe injury or

death to the machine operator, a by-

stander, or a person inspecting or re-

pairing the machine.

A CAUTION indicates special pre-

cautions that must be taken to avoid

damage to the machine.

A NOTE provides key information to

make procedures easier or clearer.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED

STRICTLY FOR COMPETITION

USE, ONLY ON A CLOSED

COURSE. It is illegal for this machine

to be operated on any public street,

road, or highway. Off-road use on

public lands may be illegal. Please

check local regulations before riding.

1. THIS MACHINE IS TO BE OP-

ERATED BY AN EXPERI-

ENCED RIDER ONLY.

Do not attempt to operate this

machine at maximum power

until you are totally familiar

with its characteristics.

2. THIS MACHINE IS DESIGNED

TO BE RIDDEN BY THE OP-

ERATOR ONLY.

Do not carry passengers on

this machine.

3. ALWAYS WEAR PROTEC-

TIVE APPAREL.

When operating this ma-

chine, always wear an ap-

proved helmet with goggles

or a face shield. Also wear

heavy boots, gloves, and pro-

tective clothing. Always wear

proper fitting clothing that

will not be caught in any of

the moving parts or controls

of the machine.

4. ALWAYS MAINTAIN YOUR

MACHINE IN PROPER

WORKING ORDER.

For safety and reliability, the

machine must be properly

maintained. Always perform

the pre-operation checks in-

dicated in this manual. Cor-

recting a mechanical problem

before you ride may prevent

an accident.

5. GASOLINE IS HIGHLY FLAM-

MABLE.

Always turn off the engine

while refueling. Take care to

not spill any gasoline on the

engine or exhaust system.

Never refuel in the vicinity of

an open flame, or while

smoking.

6. GASOLINE CAN CAUSE IN-

JURY.

If you should swallow some

gasoline, inhale excess gaso-

line vapors, or allow any gas-

oline to get into your eyes,

contact a doctor immediately.

If any gasoline spills onto

your skin or clothing, imme-

diately wash skin areas with

soap and water, and change

your clothes.

7. ONLY OPERATE THE MA-

CHINE IN AN AREA WITH AD-

EQUATE VENTILATION.

Never start the engine or let it

run for any length of time in

an enclosed area. Exhaust

fumes are poisonous. These

fumes contain carbon mon-

oxide, which by itself is odor-

less and colorless. Carbon

monoxide is a dangerous gas

which can cause uncon-

sciousness or can be lethal.

8. PARK THE MACHINE CARE-

FULLY; TURN OFF THE EN-

GINE.

Always turn off the engine if

you are going to leave the

machine. Do not park the ma-

chine on a slope or soft

ground as it may fall over.

9. THE ENGINE, EXHAUST

PIPE, MUFFLER, AND OIL

TANK WILL BE VERY HOT

AFTER THE ENGINE HAS

BEEN RUN.

Be careful not to touch them

or to allow any clothing item

to contact them during in-

spection or repair.

TO THE NEW OWNER

This manual will provide you with a

good basic understanding of fea-

tures, operation, and basic mainte-

nance and inspection items of this

machine. Please read this manual

carefully and completely before oper-

ating your new machine. If you have

any questions regarding the opera-

tion or maintenance of your machine,

please consult your Yamaha dealer.

This manual should be considered a

permanent part of this machine and

should remain with it even if the ma-

chine is subsequently sold.

NOTICE

Some data in this manual may be-

come outdated due to improve-

ments made to this model in the

future. If there is any question you

have regarding this manual or your

machine, please consult your

Yamaha dealer.

F.I.M. MACHINE WEIGHTS

Weights of machines without fuel

The minimum weights for motocross

machines are:

for the class 125 cc: minimum 88 kg

(194 lb)

for the class 250 cc: minimum 98 kg

(216 lb)

for the class 500 cc: minimum 102 kg

(225 lb)

In modifying your machine (e.g., for

weight reduction), take note of the

above limits of weight.

HOW TO USE THIS MANUAL

FINDING THE REQUIRED PAGE

1. This manual consists of seven

chapters; "General Information",

"Specifications", "Regular inspec-

tion and adjustments", "Engine",

"Chassis", "Electrical" and "Tun-

ing"

2. The table of contents is at the be-

ginning of the manual. Look over

the general layout of the book be-

fore finding then required chapter

and item.

Bend the book at its edge, as

shown, to find the required fore

edge symbol mark and go to a

page for required item and de-

scription.

MANUAL FORMAT

All of the procedures in this manual

are organized in a sequential, step-

by-step format. The information has

been complied to provide the me-

chanic with an easy to read, handy

reference that contains comprehen-

sive explanations of all disassembly,

repair, assembly, and inspection op-

erations.

In this revised format, the condition of

a faulty component will precede an

arrow symbol and the course of ac-

tion required will follow the symbol,

e.g.,

• Bearings

Pitting/damage →Replace.

10. PROPERLY SECURE THE

MACHINE BEFORE TRANS-

PORTING IT.

When transporting the ma-

chine in another vehicle, al-

ways be sure it is properly

secured and in an upright po-

sition and that the fuel cock is

in the "OFF" position. Other-

wise, fuel may leak out of the

carburetor or fuel tank.

HOW TO READ DESCRIPTIONS

To help identify parts and clarify pro-

cedure steps, there are exploded dia-

grams at the start of each removal

and disassembly section.

1. An easy-to-see exploded diagram

"1" is provided for removal and

disassembly jobs.

2. Numbers "2" are given in the or-

der of the jobs in the exploded di-

agram. A number that is enclosed

by a circle indicates a disassem-

bly step.

3. An explanation of jobs and notes

is presented in an easy-to-read

way by the use of symbol marks

"3". The meanings of the symbol

marks are given on the next page.

4. A job instruction chart "4" accom-

panies the exploded diagram,

providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more informa-

tion, the step-by-step format sup-

plements "5" are given in addition

to the exploded diagram and job

instruction chart.

ILLUSTRATED SYMBOLS (Refer to

the illustration)

Illustrated symbols "1" to "7" are used

to identify the specifications appear-

ing in the text.

1.

With engine mounted

2.

Filling fluid

3.

Lubricant

4.

Special tool

5.

Tightening

6.

Specified value, Service limit

7.

Resistance (Ω), Voltage (V),

Electric current (A)

Illustrated symbols "8" to "13" in the

exploded diagrams indicate grade of

lubricant and location of lubrication

point.

8.

Apply engine oil

9.

Apply molybdenum disulfide oil

10.

Brake fluid

11.

Apply lightweight lithium-soap

base grease

12.

Apply molybdenum disulfide

grease

13.

Silicone grease

Illustrated symbols "14" to "15" in the

exploded diagrams indicate where to

apply a locking agent and where to in-

stall new parts.

14.

Apply locking agent (LOC-

TITE^®)

15.

Use new one

1

2

3

4

5

TABLE OF CONTENTS

GENERAL INFORMATION

1

SPECIFICATIONS

2

REGULAR INSPECTION AND

ADJUSTMENTS

3

ENGINE

4

CHASSIS

5

ELECTRICAL

6

TUNING

7

CONTENTS

CHAPTER 1

GENERAL INFOR-

MATION

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 INSPEC-

TION AND AD-

JUSTMENTS

MAINTENANCE

INTERVALS......................3-1

PRE-OPERATION

INSPECTION AND

MAINTENANCE................3-5

ENGINE ............................3-6

CHASSIS ........................3-14

ELECTRICAL .................3-23

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.......4-34

BALANCER....................4-38

OIL PUMP.......................4-40

KICK SHAFT AND

SHIFT SHAFT.................4-44

CDI MAGNETO...............4-49

ENGINE REMOVAL .......4-51

CRANKCASE AND

CRANKSHAFT ...............4-55

TRANSMISSION, SHIFT

CAM AND SHIFT

FORK..............................4-61

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 ....................5-32

REAR SHOCK

ABSORBER....................5-37

CHAPTER 6

ELECTRICAL

ELECTRICAL

COMPONENTS AND

WIRING DIAGRAM...........6-1

IGNITION SYSTEM...........6-2

THROTTLE POSITION

SENSOR SYSTEM ...........6-5

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 joint

14.

Fuel cock

15.

Cold starter knob

16.

Drive chain

17.

Air filter

18.

Oil level check window

19.

Shift pedal

20.

Front fork

1

1-2

MACHINE IDENTIFICATION

MACHINE IDENTIFICATION

There are two significant reasons for

knowing the serial number of your

machine:

1. When ordering parts, you can

give the number to your Yamaha

dealer for positive identification of

the model you own.

2. If your machine is stolen, the au-

thorities will need the number to

search for and identify your ma-

chine.

VEHICLE IDENTIFICATION

NUMBER

The vehicle identification number "1"

is stamped on the right of the steering

head pipe.

ENGINE SERIAL NUMBER

The engine serial number "1" is

stamped into the elevated part of the

right-side of the engine.

MODEL LABEL

The model label "1" is affixed to the

frame under the rider's seat. This in-

formation will be needed to order

spare parts.

INCLUDED PARTS

DETACHABLE SIDESTAND

This sidestand "1" is used to support

only the machine when standing or

transporting it.

• Never apply additional force to

the sidestand.

• Remove this sidestand before

starting out.

VALVE JOINT

This valve joint "1" prevents fuel from

flowing out and is installed to the fuel

tank breather hose.

In this installation, make sure the

arrow faces the fuel tank and also

downward.

SPARK PLUG WRENCH

This spark plug wrench "1" is used to

remove and install the spark plug.

NIPPLE WRENCH

This nipple wrench "1" is used to

tighten the spoke.

JET NEEDLE PULL-UP TOOL

The jet needle pull-up tool "1" is used

to pull the jet needle out of the carbu-

retor.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

AND DISASSEMBLY

1. Remove all dirt, mud, dust, and

foreign material before removal

and disassembly.

• When washing the machine with

high pressured water, cover the

parts follows.

Silencer exhaust port

Side cover air intake port

Water pump housing hole at the

bottom

Drain hole on the cylinder head

(right side)

2. Use proper tools and cleaning

equipment. Refer to "SPECIAL

TOOLS" section.

3. When disassembling the ma-

chine, keep mated parts together.

They include gears, cylinders,

pistons, and other mated parts

that have been "mated" through

normal wear. Mated parts must

be reused as an assembly or re-

placed.

1-3

CHECKING OF CONNECTION

4. During the machine disassembly,

clean all parts and place them in

trays in the order of disassembly.

This will speed up assembly time

and help assure that all parts are

correctly reinstalled.

5. Keep away from fire.

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha

genuine parts for all replace-

ments. Use oil and/or grease rec-

ommended by Yamaha for

assembly and adjustment.

GASKETS, OIL SEALS AND O-

RINGS

1. All gaskets, oil seals, and O-rings

should be replaced when an en-

gine is overhauled. All gasket sur-

faces, oil seal lips, and O-rings

must be cleaned.

2. Properly oil all mating parts and

bearings during reassembly. Ap-

ply grease to the oil seal lips.

LOCK WASHERS/PLATES AND

COTTER PINS

1. All lock washers/plates "1" and

cotter pins must be replaced

when they are removed. Lock

tab(s) should be bent along the

bolt or nut flat(s) after the bolt or

nut has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) "1" and oil

seal(s) "2" with their manufactur-

er's marks or numbers facing out-

ward. (In other words, the

stamped letters must be on the

side exposed to view.) When in-

stalling oil seal(s), apply a light

coating of lightweight lithium base

grease to the seal lip(s). Oil the

bearings liberally when installing.

Do not use compressed air to spin

the bearings dry. This causes dam-

age to the bearing surfaces.

CIRCLIPS

1. All circlips should be inspected

carefully before reassembly. Al-

ways replace piston pin clips after

one use. Replace distorted cir-

clips. When installing a circlip "1",

make sure that the sharp-edged

corner "2" is positioned opposite

to the thrust "3" it receives. See

the sectional view.

CHECKING OF

CONNECTION

Dealing with stains, rust, moisture,

etc. on the connector.

1. Disconnect:

ΠConnector

2. Dry each terminal with an air

blower.

3. Connect and disconnect the con-

nector two or three times.

4. Pull the lead to check that it will

not come off.

5. If the terminal comes off, bend up

the pin "1" and reinsert the termi-

nal into the connector.

6. Connect:

ΠConnector

The two connectors "click" together.

7. Check for continuity with a tester.

• If there in no continuity, clean the

terminals.

• Be sure to perform the steps 1 to 7

listed above when checking the

wire harness.

• For a field remedy, use a contact re-

vitalizer available on the market.

• Use the tester on the connector as

shown.

1-4

SPECIAL TOOLS

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will

help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for

the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".

• For others, use part number starting with "90890-".

Tool name/Part number

How to use

Illustration

Crankcase separating tool

YU-1135-A, 90890-01135

These tool is used to remove the

crankshaft from either case.

Flywheel puller

YM-1189, 90890-01189

This tool is used to remove the fly-

wheel magneto.

Rotor holding tool

YU-1235, 90890-01235

This tool is used when loosening or

tightening the flywheel magneto se-

curing nut.

Dial gauge and stand

YU-3097, 90890-01252

Stand

YU-1256

These tools are used to check each

part for runout or bent.

Crankshaft installing tool

Crankshaft installing pot

YU-90050, 90890-01274

Crankshaft installing bolt

YU-90050, 90890-01275

Spacer (crankshaft installer)

YU-91044, 90890-04081

Adapter (M12)

YU-90063, 90890-01278

These tools are used to install the

crankshaft.

Piston pin puller set

YU-1304, 90890-01304

This tool is used to remove the pis-

ton pin.

1-5

SPECIAL TOOLS

Radiator cap tester

YU-24460-01, 90890-01325

Radiator cap tester adapter

YU-33984, 90890-01352

These 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, 90890-01500

This tool is used to loosen or tighten

the base valve.

Cap bolt ring wrench

YM-01501, 90890-01501

This 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.

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