2005 YAMAHA YZ250F valve

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ENGVALVES AND VALVE SPRINGS
INSPECTION
Valve
1. Measure:
Stem-to-guide clearance
Out of specification → Replace the valve
guide. Stem-to-guide clearance =
valve guide inside diameter
a –
valve stem diameter
b
Clearance (stem to guide):
Intake:
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
: 0.08 mm (0.003 in)
Exhaust:
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
: 0.10 mm (0.004 in)
2. Replace:
Valve guide
Replacement steps:
NOTE:
To ease guide removal, installation and to
maintain correct fit heat the cylinder head in
an over to 100 °C (212 °F).
Remove the valve guide using a valve
guide remover 1.
Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
After installing the valve guide, bore the
valve guide using a valve guide reamer 3
to obtain proper stem-to-guide clearance.

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ENGVALVES AND VALVE SPRINGS
Valve guide remover:
Intake: 4.0 mm (0.16 in)
YM-4111/90890-04111
Exhaust: 4.5 mm (0.18 in)
YM-4116/90890-04116
Valve guide installer:
Intake: 4.0 mm (0.16 in)
YM-4112/90890-04112
Exhaust: 4.5 mm (0.18 in)
YM-4117/90890-04117
Valve guide reamer:
Intake: 4.0 mm (0.16 in)
YM-4113/90890-04113
Exhaust: 4.5 mm (0.18 in)
YM-4118/90890-04118
NOTE:
After replacing the valve guide reface the
valve seat.
3. Inspect:
Valve face
Pitting/wear → Grind the face.
Valve stem end
Mushroom shape or diameter larger than
the body of the stem → Replace.
4. Measure:
Margin thickness a
Out of specification → Replace.
Margin thickness:
Intake:
0.8 mm (0.0315 in)
Exhaust:
0.7 mm (0.0276 in)

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ENGVALVES AND VALVE SPRINGS
5. Measure:
Runout (valve stem)
Out of specification → Replace.
NOTE:
When installing a new valve always replace
the guide.
If the valve is removed or replaced always
replace the oil seal.
6. Eliminate:
Carbon deposits
(from the valve face and valve seat)
7. Inspect:
Valve seat
Pitting/wear → Reface the valve seat.
Runout limit:
0.01 mm (0.0004 in)
8. Measure:
Valve 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:
Apply Mechanic’s blueing dye (Dykem) b
to the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat
must be refaced.

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ENGVALVES AND VALVE SPRINGS
9. Lap:
Valve face
Valve 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:
Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
Apply molybdenum disulfide oil to the
valve stem.
Install the valve into the cylinder head.
Turn 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.
Apply 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.
Apply Mechanic’s blueing dye (Dykem) to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.

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ENGVALVES AND VALVE SPRINGS
Valve spring
1. Measure:
Valve spring free length a
Out of specification → Replace.
2. Measure:
Compressed spring force a
Out of specification → Replace.
b
Installed length
Free length (valve spring):
Intake:
37.81 mm (1.49 in)
: 36.81 mm (1.45 in)
Exhaust:
37.54 mm (1.48 in)
: 36.54 mm (1.44 in)
Compressed spring force:
Intake:
99 ~ 114 N at 29.13 mm
(9.9 ~ 11.4 kg at 29.13 mm,
22.27 ~ 25.57 lb at 1.15 in)
Exhaust:
126 ~ 144 N at 29.30 mm
(12.6 ~ 14.4 kg at 29.30 mm,
28.44 ~ 32.41 lb at 1.15 in)
3. Measure:
Spring tilt a
Out of specification → Replace.
Spring tilt limit:
Intake:
2.5°/1.7 mm (0.067 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve lifter
1. Inspect:
Valve lifter
Scratches/damage → Replace both lift-
ers and cylinder head.

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ENGVALVES AND VALVE SPRINGS
ASSEMBLY AND INSTALLATION
Valve and valve spring
1. Apply:
Molybdenum disulfide oil
Onto the valve stem and valve stem seal.
2. Install:
Valve 1
Valve spring seat 2
Valve stem seal 3
Valve spring 4
Valve spring retainer 5
To cylinder head.
NOTE:
Make 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
Install the valve springs with the larger pitch
c facing upward.
d
Smaller pitch
3. Install:
Valve cotter
NOTE:
While compressing the valve spring with a
valve spring compressor 1 install the valve
cotters.
4. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
Valve spring compressor:
YM-4019/90890-04019

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ENGVALVES AND VALVE SPRINGS
5. Install:
Adjusting pad 1
Valve lifter 2
NOTE:
Apply the molybdenum disulfide oil on the
valve stem end.
Apply the engine oil on the valve lifters.
Valve lifter must turn smoothly when rotated
with a finger.
Be careful to reinstall valve lifters and pads in
their original place.

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CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:
1 Oil seal removal
2 Damper assembly removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1Adjuster 1 Drain the fork oil. Use special tool.
Refer to “REMOVAL POINTS”.
2Fork spring 1
3Dust seal 1
Refer to “REMOVAL POINTS”.
4Stopper ring 1
5Inner tube 1
6Outer tube 1
7Piston metal 1
8Slide metal 1
9Oil seal washer 1
0Oil seal 1
ABase valve 1
Drain the fork oil. Use special tool.
Refer to “REMOVAL POINTS”.
BDamper assembly 1
1
2