2006 YAMAHA YZ250F oil filter

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS...................................4-1
EXHAUST PIPE AND SILENCER..............4-3
RADIATOR.................................................4-6
CARBURETOR...........................................4-9
CAMSHAFTS............................................4-22
CYLINDER HEAD.....................................4-31
VALVES AND VALVE SPRINGS.............4-34
CYLINDER AND PISTON.........................4-43
CLUTCH....................................................4-50
OIL FILTER ELEMENT, WATER PUMP
AND RIGHT CRANKCASE COVER........4-57
BALANCER..............................................4-64
OIL PUMP.................................................4-67
KICK SHAFT AND SHIFT SHAFT...........4-73
CDI MAGNETO.........................................4-80
ENGINE REMOVAL..................................4-84
CRANKCASE AND CRANKSHAFT.........4-89
TRANSMISSION, SHIFT CAM
AND SHIFT FORK....................................4-98
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL........5-1
FRONT BRAKE AND REAR BRAKE......5-10
FRONT FORK...........................................5-26
HANDLEBAR............................................5-43
STEERING................................................5-49
SWINGARM..............................................5-54
REAR SHOCK ABSORBER.....................5-62

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Engine stop switch
8Kickstarter crank
9Fuel tank
0Radiator
ACoolant drain bolt
BRear brake pedal
CValve joint
DFuel cock
ECold starter knob
FDrive chain
GAir filter
HOil level check window
IShift pedal
JFront forkNOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.

SPEC
2 - 2 Oil type or grade:
Engine oil (For USA and CDN)
At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE 20W-40 type
SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE 10W-30 type
SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
(Except for USA and CDN)
API “SG” or higher grade
Oil capacity:
Engine oil
Periodic oil change 1.15 L (1.01 Imp qt, 1.22 US qt)
With oil filter replacement 1.25 L (1.10 Imp qt, 1.32 US qt)
Total amount 1.40 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
-20
-4-10
140
3010
5020
6830
8640 50
104
122 ˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40
GENERAL SPECIFICATIONS

2

SPEC
2 - 9 Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Side clearance 0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Housing and rotor clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.0067 in)
Cooling:
Radiator core size
Width 120.2 mm (4.7 in) ----
Height 240 mm (9.4 in) ----
Thickness 22 mm (0.9 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.60 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 10 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
(stud bolt) M8 × 1.25 1 15 1.5 11
(bolt) M9 × 1.25 4 38 3.8 27
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 10 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator guard M6 × 1.0 2 10 1.0 7.2
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer (crankcase) M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
(M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil hose clamp—120.21.4
Oil strainer (oil tank) M6 × 1.0 1 9 0.9 6.5
Oil tank drain bolt M8 × 1.25 1 18 1.8 13
Oil tank (upper) M6 × 1.0 1 7 0.7 5.1
Oil tank and frame M6 × 1.0 3 9 0.9 6.5
Carburetor joint clamp M4 × 0.7 2 3 0.3 2.2
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
MAINTENANCE SPECIFICATIONS

SPEC
2 - 11
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Air filter element M6 × 1.0 1 2 0.2 1.4
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Crankcase M6 × 1.0 11 12 1.2 8.7
Crankcase bearing stopper M6 × 1.0 11 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 10 1.0 7.2
Oil level check window holder M6 × 1.0 1 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase oil drain bolt M10 × 1.25 1 20 2.0 14
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Primary drive gear M18 × 1.0 1 75 7.5 54
Clutch spring M6 × 1.0 5 10 1.0 7.2
Clutch boss M16 × 1.0 1 60 6.0 43
Clutch cable locknut M8 × 1.25 1 7 0.7 5.1
Clutch cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Push lever shaft M6 × 1.0 1 10 1.0 7.2
Drive sprocket M18 × 1.0 1 75 7.5 54
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Shift pedal M6 × 1.0 1 12 1.2 8.7 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
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.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
Inspect
OIL FILTER ELEMENT, OIL STRAINER
Clean
VALVES
The engine must be cold.
Check the valve seats
and valve stems for wear. Check the valve clearances
Inspect
Replace
VALVE SPRINGS
Check the free length and
the tilt. Inspect
Replace
VALVE LIFTERS
Check for scratches and
wear. Inspect
Replace
CAMSHAFTS Inspect the camshaft sur-
face.
Inspect the decompres-
sion system. Inspect
Replace
TIMING CHAIN SPROCKETS, TIMING
CHAIN
Check for wear on the
teeth and for damage. Inspect
Replace
PISTON
Inspect
Inspect crack
Inspect carbon deposits
and eliminate them. Clean
Replace
PISTON RING
InspectCheck ring end gap
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEAD Inspect carbon deposits
and eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean
Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect housing, friction
plate, clutch plate and
spring Inspect and adjust
Replace
TRANSMISSION
Inspect
Replace bearing

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear
ROTOR NUT
Retighten
EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace * Whichever comes first
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1. Retighten
AIR FILTER
Clean and lubricate
Use foam air-filter oil or
equivalent oil
Replace
OIL FILTER
Replace
OIL STRAINER
Clean
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid Every one year
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil sealItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks


3