2002 YAMAHA YZ250F engine

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9. Tighten:
Screw (throttle position sensor) 1
NOTE:
Tighten the screws (throttle position sensor)
using the T20 bit (tamper resistant fastener
type).
10. Stop the engine.
THROTTLE POSITION SENSOR INPUT
VOLTAGE INSPECTION
1. Disconnect the throttle position sensor
coupler.
2. Start the engine.
3. Inspect:
Throttle position sensor input voltage
Out of specification → Replace the CDI
unit.
Tester (+) lead → Blue lead 1
Tester (–) lead → Black/Blue lead 2
Throttle posi-
tion sensor
input voltageTester selector
position
4 ~ 6 V DCV-20
THROTTLE POSITION SENSOR SYSTEM

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EC700000
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EC710000
ENGINE
Carburetor setting

The air/fuel mixture will vary depending on
atmospheric conditions. Therefore, it is nec-
essary to take into consideration the air pres-
sure, ambient temperature, humidity, etc.,
when adjusting the carburetor.

Perform a test run to check for proper engine
performance (e.g., throttle response) and
spark plug(-s) discoloration or fouling. Use
these readings to determine the best possi-
ble carburetor setting.
NOTE:

It is recommended to keep a record of all car-
buretor settings and external conditions (e.g.,
atmospheric conditions, track/surface condi-
tions, lap times) to make future carburetor set-
ting easier.
WARNING


The carburetor is a part of the fuel line.
Therefore, be sure to install it in a well-
ventilated area, away from flammable
objects and any sources of fire.

Never look into the carburetor intake.
Flames may shoot out from the pipe if the
engine backfires while it is being started.
Gasoline may be discharged from the
accelerator pump nozzle when the carbu-
retor has been removed.
SETTING

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CAUTION:


The carburetor is extremely sensitive to
foreign matter (dirt, sand, water, etc.).
During installation, do not allow foreign
matter to get into the carburetor.

Always handle the carburetor and its
components carefully. Even slight
scratches, bends or damage to carbure-
tor parts may prevent the carburetor from
functioning correctly. Carefully perform
all servicing with the appropriate tools
and without applying excessive force.

When the engine is stopped or when
riding at no load, do not open and close
the throttle unnecessarily. Otherwise, too
much fuel may be discharged, starting
may become difficult or the engine may
not run well.

After installing the carburetor, check that
the throttle operates correctly and opens
and closes smoothly.
Atmospheric conditions and carburetor
settings
The air density (i.e., concentration of oxygen
in the air) determines the richness or lean-
ness of the air/fuel mixture. Therefore, refer
to the above table for mixture settings.
That is:

Higher temperature expands the air with its
resultant reduced density.

Higher humidity reduces the amount of oxy-
gen in the air by so much of the water vapor
in the same air.

Lower atmospheric pressure (at a high alti-
tude) reduces the density of the air.
Air temp. HumidityAir
pressure
(altitude)Mixture Setting
High High Low (high) Richer Leaner
Low Low High (low) Leaner Richer
SETTING

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SETTING
1
Jet needle
2
Main air jet
3
Pilot air jet
4
Needle jet
5
Main jet
6
Pilot jet
7
Pilot screw
Main jet adjustment
The richness of the air-fuel mixture at full throt-
tle can be set by changing the main jet
1
.
If the air-fuel mixture is too rich or too lean, the
engine power will drop, resulting in poor accel-
eration.
Effects of changing the main jet (reference)
Å
Idle
ı
Fully open
Standard main jet #178
1/4 1/2 3/4
+10%
#178
–10%
#188
#168
Åı

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SETTING
Pilot screw adjustment
The richness of the air-fuel mixture with the
throttle fully closed to 1/4 open can be set by
turning the pilot screw
1
. Turning in the pilot
screw will make the mixture lean at low
speeds, and turning it out will enrich it.
*For EUROPE
NOTE:


If the engine idling speed fluctuates, turn the
pilot screw only 1/2 of a turn in either direc-
tion.

To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num-
ber as the factory-set number of turns out.
Effects of adjusting the pilot screw (reference)
Å
Idle
ı
Fully open
1
2-1/8 turns out
2
1-1/8 turns out
3
1-5/8 turns out
Standard pilot
screw position1-5/8
*1-1/2
(example)
1/4 1/2 3/4
+5%
–5%
1
23
Åı

Pilot jet adjustment
The richness of the air-fuel mixture with the
throttle open 1/4 or less can be set by adjust-
ing the pilot jet
1
.
Standard pilot jet #40

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SETTING
Effects of adjusting the pilot jet (reference)
Å
Idle
ı
Fully open
1/4 1/2 3/4
+5%
–5%
#42
#38#40
Å
ı

Jet needle groove position adjustment
Adjusting the jet needle
1
position affects the
acceleration when the throttle is 1/8 to 3/4
open.
1. Too rich at intermediate speeds
Rough engine operation is felt and the
engine will not pick up speed smoothly. In
this case, step up the jet needle clip by
one groove and move down the needle to
lean out the mixture.
2. Too lean at intermediate speeds
The engine breathes hard and will not
pick up speed quickly.
Step down the jet needle clip by one
groove and move up the needle to enrich
the mixture.
Effects of changing the jet needle groove
position (reference)
ÅIdle
ıFully open
1No.5 groove
2No.3 groove
3No.4 groove
Standard clip position No.4 groove
1/4 1/2 3/4
+10%
–10%
1
23
ı Å

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Leak jet adjustment (accelerator pump
adjustment)
The leak jet 1 is a setting part that adjusts the
flow of fuel discharged by the accelerator
pump. Since the accelerator pump operates
only when throttle is open, the leak jet is used
to adjust a fuel mixture ratio for quick throttle
opening and is therefore different from other
setting parts that adjust a fuel mixture for each
throttle opening (each engine speed).
1. The engine breathes hard in quick throt-
tle opening.
Select a leak jet having lower calibrating
No. than standard to enrich the mixture.
#100 → #90
2. Rough engine operation is felt in quick
throttle opening.
Select a leak jet having higher calibrating
No. than standard to lean out the mixture.
#100 → #110
*For EUROPEStandard leak jet#100
* #951
Relationship with throttle opening
The flow of the fuel through the carburetor
main system is controlled by the main jet and
then, it is further regulated by the area
between the main nozzle and the jet needle.
The fuel flow relates to the diameter of the
straight portion of the jet needle with the throt-
tle 1/8 to 1/4 open and relates to the clip posi-
tion with the throttle 1/8 to 3/4 open.
Therefore, the fuel flow is balanced at each
stage of throttle opening by the combination of
the jet needle straight portion diameter and
clip position.
SETTING

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Examples of carburetor setting depending on symptom
This should be taken simply for an example. It is necessary to set the carburetor while checking
the operating conditions of the engine.
Symptom Setting Checking
At full throttle
Hard breathing
Shearing noise
Whitish spark plug
Lean mixtureIncrease main jet calibration no.
(Gradually)Discoloration of spark plug →
If tan color, it is in good condition.
If cannot be corrected:
Clogged float valve seat
Clogged fuel hose
Clogged fuel cock
Check that the accelerator pump oper-
ates smoothly.
At full throttle
Speed pick-up stops
Slow speed pick-up
Slow response
Sooty spark plug
Rich mixtureDecrease main jet calibration no.
(Gradually)Discoloration of spark plug →
If tan color, it is in good condition.
If cannot be corrected:
Clogged air filter
Fuel overflow from carburetor
Lean mixture Lower jet needle clip position.
(1 groove down)
The clip position is the jet needle
groove on which the clip is installed.
The positions are numbered from the
top.
Check that the accelerator pump oper-
ates smoothly. (except for rich mixture
symptom). Rich mixture Raise jet needle clip position.
(1 groove up)
1/4 ~ 3/4 throttle
Hard breathing
Lack of speedLower jet needle clip position.
(1 groove down)
1/4 ~ 1/2 throttle
Slow speed pick-up
Poor accelerationRaise jet needle clip position.
(1 groove up)
Closed to 1/4 throttle
Hard breathing
Speed downUse jet needle with a smaller diameter. Slow-speed-circuit passage
Clogged → Clean.
Overflow from carburetor
Closed to 1/4 throttle
Poor accelerationUse jet needle with a larger diameter.
Raise jet needle clip position. (1 groove
up)
Poor response in the low to
intermediate speedsRaise jet needle clip position.
If this has no effect, lower the jet needle
clip position.
Poor response when throttle
is opened quicklyCheck overall settings.
Use main jet with a lower calibration no.
Raise jet needle clip position.
(1 groove up)
If these have no effect, use a main jet
with a higher calibration no. and lower
the jet needle clip position.Check air filter for fouling.
Check that the accelerator pump oper-
ates smoothly.
Jet needleClip
Groobe 7 Groobe 6
Groobe 5
Groobe 4
Groobe 3
Groobe 2
Groobe 1
Leaner
↑
(Standard)
↓
Richer
*
SETTING