2001 YAMAHA YZ250F ad blue

4 - 22
ENGCAMSHAFTS
5. Remove:
lExhaust camshaft 1
lIntake camshaft 2
NOTE:
Attach a wire 3 to the timing chain to prevent
it from falling into the crankcase.
INSPECTION
Camshaft
1. Inspect:
lCam lobe
Pitting/scratches/blue discoloration ®
Replace.
2. Measure:
lCam lobe length a and b
Out of specification ® Replace.
Cam lobes length:
Intake:
a30.296 ~ 30.346 mm
(1.1923 ~ 1.1947 in)
: 30.196 mm
(1.1888 in)
b22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)
: 22.35 mm
(0.8799 in)
Exhaust:
a30.399 ~ 30.499 mm
(1.1968 ~ 1.2007 in)
: 30.299 mm
(1.1929 in)
b22.45 ~ 22.55 mm
(0.8839 ~ 0.8878 in)
: 22.35 mm
(0.8799 in)
3. Measure:
lRunout (camshaft)
Out of specification ® Replace.
Runout (camshaft):
Less than 0.03 mm (0.0012 in)

4 - 36
ENGVALVES AND VALVE SPRINGS
5. Measure:
lRunout (valve stem)
Out of specification ® Replace.
NOTE:
lWhen installing a new valve always replace
the guide.
lIf the valve is removed or replaced always
replace the oil seal.
6. Eliminate:
lCarbon deposits
(from the valve face and valve seat)
7. Inspect:
lValve seat
Pitting/wear ® Reface the valve seat.
Runout limit:
0.01 mm (0.0004 in)
8. Measure:
lValve seat width a
Out of specification ® Reface the valve
seat.
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)
Measurement steps:
lApply Mechanic’s blueing dye (Dykem) b
to the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
lIf the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat
must be refaced.

4 - 37
ENGVALVES AND VALVE SPRINGS
9. Lap:
lValve face
lValve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
lApply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
lApply molybdenum disulfide oil to the
valve stem.
lInstall the valve into the cylinder head.
lTurn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
lApply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
lApply Mechanic’s blueing dye (Dykem) to
the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.

4 - 39
ENGVALVES AND VALVE SPRINGS
Combination of cylinder head and valve lifter
1. Combination:
For this combination, match the paint color
on the cylinder head with that on the valve
lifter according to the chart below.
NOTE:
When you purchase a cylinder head, you can-
not designate its size. Choose the valve lifter
that matches the above chart.Combination
Cylinder head mark
a (color)Valve lifter mark b
(color)
Red Red
Blue Blue
Yellow Yellow
Purple Black
ab
ASSEMBLY AND INSTALLATION
Valve and valve spring
1. Apply:
lMolybdenum disulfide oil
Onto the valve stem and valve stem
seal.
2. Install:
lValve 1
lValve spring seat 2
lValve stem seal 3
lValve spring 4
lValve spring retainer 5
To cylinder head.
NOTE:
lMake sure that each valve is installed in its
original place, also referring to the painted
color as follows.
Intake (middle) a: yellow
Intake (right/left) b: white
Exhaust: no paint
lInstall the valve springs with the larger pitch
c facing upward.
dSmaller pitch

4 - 45
ENGCYLINDER AND PISTON
Piston pin
1. Inspect:
lPiston pin
Blue discoloration/grooves ® Replace,
then inspect the lubrication system.
2. Measure:
lPiston pin-to-piston clearance
ASSEMBLY AND INSTALLATION
Piston ring and piston
1. Install:
lPiston ring
Onto the piston.
NOTE:
lBe sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
lLubricate the piston and piston rings liberally
with engine oil. Measurement steps:
lMeasure the outside diameter (piston pin)
a.
If out of specification, replace the piston
pin.
Outside diameter (piston pin):
15.991 ~ 16.000 mm
(0.6296 ~ 0.6299 in)
lMeasure the inside diameter (piston) b.
Inside diameter (piston):
16.002 ~ 16.013 mm
(0.6300 ~ 0.6304 in)
lCalculate the piston pin-to-piston clear-
ance with the following formula.
Piston pin-to-piston clearance =
Inside diameter (piston) b –
Outside diameter (piston pin) a
lIf out of specification, replace the piston.
Piston pin-to-piston clearance:
0.002 ~ 0.022 mm
(0.0001 ~ 0.0009 in)
: 0.07 mm (0.003 in)

6 - 1
–+ELEC

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
Engine stop switch
2
Throttle position sensor
3
Neutral switch
4
CDI magneto
5
Spark plug
6
Ignition coil
7
CDI unit
COLOR CODE
B...................... Black
Br .................... Brown
G ..................... Green
L ...................... Blue
O ..................... Orange
P...................... Pink
R ..................... Red
EC612000
WIRING DIAGRAM
7
16
5
2 3 4
LY
BYL
B/LL
G
P
W
R
Y
B
G
BR PBrWG
RB Br WP
R/W WL/W SbW R/W Sb L/WY
B/LL Sb B OY
LB/L B OSbSb
L/WR/W
WSb
B/L
B/WB/W
B/WB/W
Br
BB
LBBY
O

Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
B/L ................... Black/Blue
B/W .................. Black/White
L/W .................. Blue/White
R/W .................. Red/White





6

6 - 6
–+ELECIGNITION SYSTEM
2. Inspect:
lCharging coil 1 resistance
Out of specification ® Replace.
3. Inspect:
lCharging coil 2 resistance
Out of specification ® Replace. Tester (+) lead ® Brown lead 1
Tester (–) lead ® Green lead 2
Charging coil 1
resistanceTester selector
position
720 ~ 1,080 W
at 20 ˚C (68 ˚F)W ´ 100
Tester (+) lead ® Pink lead 1
Tester (–) lead ® Black lead 2
Charging coil 2
resistanceTester selector
position
44 ~ 66 W at
20 ˚C (68 ˚F)W ´ 10
NEUTRAL SWITCH INSPECTION
1. Inspect:
lNeutral switch conduct
No continuous while in neutral ® Replace.
Continuous while in gear ® Replace.
EC628000
CDI UNIT INSPECTION
Check all electrical components. If no fault is
found, replace the CDI unit. Then check the
electrical components again.Tester (+) lead ® Sky blue lead 1
Tester (–) lead ® Ground 2
Sb
1Ground
2Tester selec-
tor position
NEUTRALW ´ 1IN GEAR

6 - 8
–+ELECTHROTTLE POSITION SENSOR SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
lCouplers and leads connection
Rust/dust/looseness/short-circuit ®
Repair or replace.
THROTTLE POSITION SENSOR COIL
INSPECTION
1. Inspect:
lThrottle position sensor coil resistance
Out of specification ® Replace.
2. Loosen:
lThrottle stop screw 1
NOTE:
Turn out the throttle stop screw until the throt-
tle shaft is in the full close position.Tester (+) lead ® Blue lead 1
Tester (–) lead ® Black lead 2
Throttle posi-
tion sensor coil
resistanceTester selector
position
4 ~ 6 kW at
20 ˚C (68 ˚F)kW ´ 1
3. Inspect:
lThrottle position sensor coil variable
resistance
Check that the resistance in increased
as the throttle grip is moved from the
full close position to the full open posi-
tion.
Out of specification ® Replace.
Tester (+) lead ® Yellow lead 1
Tester (–) lead ® Black lead 2
Throttle position sen-
sor coil variable
resistanceTester
selector
position
Full closedFull opened
kW ´ 1 Zero ~ 3 kW
at 20 ˚C
(68 ˚F)4 ~ 6 kW at
20 ˚C
(68 ˚F)