2008 YAMAHA YZ250F maintenance

2-8
MAINTENANCE SPECIFICATIONS
CHASSISHeight
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) 0.58 L (0.51 Imp qt, 0.61 US qt)----
Water pump Type Single-suction centrifugal pump----
Item
StandardLimit
Item StandardLimit
Steering system: Steering bearing type Taper roller bearing----
Front suspension: Front fork travel 300 mm (11.8 in)----
Fork spring free length 454 mm (17.9 in)449 mm (17.7
in)
Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in)----
Optional spring Yes----
Oil capacity 521 cm
3 (18.3 lmp oz, 17.6 US oz)----
Oil grade Suspension oil "S1"----
Inner tube outer diameter 48 mm (1.89 in)----
Front fork top end 5 mm (0.20 in)----
Rear suspension: USA, CDN, AUS, NZ,
ZA EUROPE
Shock absorber travel 131.5 mm (5.18 in)
←----
Spring free length Approx.275 mm (10.83 in)
←----
Fitting length One I.D. mark 268 mm (10.55 in) 262 mm (10.31 in) ----
Two I.D. marks 274 mm (10.79 in) 268 mm (10.55 in) ----
Three I.D. marks 265.5 mm (10.45 in) 259.5 mm (10.22 in) ----
One I.D. mark 255.5–273.5 mm (10.06–10.77 in)
←----
Two I.D. marks 261.5–279.5 mm
(10.30–11.00 in)
←----
Three I.D. marks 253.0–271.0 mm (9.96–
10.67 in)
←----
Spring rate, STD K = 52.0 N/mm (5.30 kg/ mm, 296.8 lb/in)
←----
Optional spring Yes
←----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2,
142 psi)←----
Swingarm: Swingarm free play limitEnd ---- 1.0 mm (0.04 in)
Wheel: Front wheel type Spoke wheel----

2-9
MAINTENANCE SPECIFICATIONS
ELECTRICALRear wheel type
Spoke wheel----
Front rim size/material 21 × 1.60/Aluminum----
Rear rim size/material 19 × 1.85/Aluminum----
Rim runout limit: Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain: Type/manufacturer DID520DMA2 SDH/DAIDO ----
Number of links 111 links + joint----
Chain slack 48–58 mm (1.9–2.3 in)----
Chain length (15 links) ----242.9 mm
(9.563 in)
Front disc brake: Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in)250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in)1.0 mm (0.04
in)
Master cylinder inside dia. 9.5 mm (0.374 in)----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2----
Brake fluid type DOT #4----
Rear disc brake: Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in)245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ----0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in)1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in)----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1----
Brake fluid type DOT #4----
Brake lever and brake pedal: Brake lever position 95 mm (3.74 in)----
Brake pedal height (vertical height above footrest
top) 5 mm (0.20 in)
----
Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in)----
Throttle grip free play 3–5 mm (0.12–0.20 in)----
Item
StandardLimit
Item StandardLimit
Ignition system: Advancer type Electrical----
CDI: Magneto-model (stator)/manufacturer 5XC-G0/YAMAHA----
Charging coil 1 resistance (color) 720–1,080
Ωat 20 °C (68 °F) (Green–
Brown) ----
Charging coil 2 resistance (color) 44–66
Ωat 20 °C (68 °F) (Black–Pink) ----

3-1
MAINTENANCE INTERVALS
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.
Item After
break- in Every
race
Every
third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks
ENGINE OIL Replace
●●
Inspect●●
OIL FILTER ELEMENT, OIL
STRAINERClean
●
VALVESCheck the valve clearances
●●The engine must be cold.
Inspect
●Check the valve seats and valve
stems for wear.
Replace
●
VALVE SPRINGS Inspect
●Check the free length and the tilt.
Replace
●
VALVE LIFTERS Inspect
●Check for scratches and wear.
Replace
●
CAMSHAFTS Inspect the camshaft surface.
Inspect
●Inspect the decompression system.
Replace
●
TIMING CHAIN SPROCKETS,
TIMING CHAIN Inspect
●Check for wear on the teeth and for
damage.
Replace
●
PISTON Inspect
●●Inspect crack.
Clean
●Inspect carbon deposits and eliminate
them.
Replace
●
PISTON RING Inspect
●Check ring end gap.
Replace
●●
PISTON PIN Inspect
●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean
●Change gasket.
3

3-2
MAINTENANCE INTERVALS
CYLINDERInspect and clean
●Inspect score marks.
Replace
●Inspect wear.
CLUTCH Inspect and adjust
●●Inspect housing, friction plate, clutch
plate and spring.
Replace
●
TRANSMISSION Inspect
●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BARInspect
●Inspect wear.
ROTOR NUT Retighten
●●
EXHAUST PIPE, SILENCER,
PROTECTORInspect and retighten
●●
Clean●
Replace●* Whichever comes first
CRANK Inspect and clean
●●
CARBURETORInspect, adjust and clean
●●
SPARK PLUGInspect and clean
●●
Replace●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment
●●Chain slack: 48–58 mm (1.9–2.3 in)
Replace
●
COOLING SYSTEM Check coolant level and leakage
●●
Check radiator cap operation●
Replace coolant●Every two years
Inspect hoses
●
OUTSIDE NUTS AND BOLTS Retighten
●●Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER Clean and lubricate
●●Use foam air-filter oil or equivalent oil.
Replace
●
OIL FILTER Replace
●●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-3
MAINTENANCE INTERVALS
OIL STRAINERClean
●
FRAMEClean and inspect
●●
FUEL TANK, COCKClean and inspect
●●
BRAKESAdjust lever position and pedal
height
●●
Lubricate pivot point●●
Check brake disc surface●●
Check fluid level and leakage●●
Retighten brake disc bolts, cali-
per 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 seal
●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube
●●Lithium base grease
PROTECTOR GUIDE Replace
●
REAR SHOCK ABSORBERInspect and adjust
●●
Lube●
(After rain
ride)
●Molybdenum disulfide grease
Replace spring seat
●Every one year
Retighten
●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect
●●
SWINGARMInspect, lube and retighten
●●Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten
●●Molybdenum disulfide grease
STEERING HEAD Inspect free play and retighten
●●
Clean and lube●Lithium base grease
Replace bearing
●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-4
MAINTENANCE INTERVALS
TIRE, WHEELSInspect air pressure, wheel run-
out, tire wear and spoke loose-
ness
●●
Retighten sprocket bolt●●
Inspect bearings●
Replace bearings●
Lubricate●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection
●●
Lubricate●●Yamaha cable lube or SAE 10W-30
motor oil
Inspect and clean (throttle ca-
ble)
●●Inspect dirt and wear on the throttle
cable on the carburetor side.
HOT STARTER, CLUTCH LEVER Inspect free play
●
Item After
break-
in Every
race
Every third
(or 500 km) Every
fifth (or 1,000 km)
As re-
quired Remarks

3-5
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCEItem RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-6 – 7
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage. P.1-8 – 9
Engine oil Check that the oil level is correct. Check the crankcase and oil line
for leakage. P.3-8 – 10
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-7
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary. P.3-7 – 8
Brakes Check the play of front brake and effect of front and rear brake. P.3-14 – 16
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly. P.3-17
Wheels Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play. P.3-20
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play. P.3-20 – 21
Front forks and rear shock
absorber Check that they operate smoothly and there is no oil leakage.
P.3-18 – 20
Cables (wires) Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.4-3 – 4
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-16 – 17
Lubrication Check for smooth operation. Lubricate if necessary. P.3-22
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-11
Lead connectors Check that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly. P.1-3
Settings Is the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs be-
fore racing? Are inspection and maintenance completely done?
P.7-1 – 10

3-8
ENGINE
2. Apply:• Lithium soap base greaseOn the throttle cable end "a".
3. Install: • Throttle grip cap
• Screw (throttle grip cap)
• Cover (grip cap)
• Cover (throttle cable cap)
ADJUSTING THE HOT STARTER
LEVER FREE PLAY
1. Check: • Hot starter lever free play "a"Out of specification
→Adjust.
2. Adjust: • Hot starter lever free play
Hot starter lever free play adjust-
ment steps:
a. Loosen the locknut "1".
b. Turn the adjuster "2" until free play "a" is within the specified lim-
its.
c. Tighten the locknut.
After adjustment, check proper oper-
ation of hot starter.
CLEANING THE AIR FILTER
ELEMENT
Proper air filter maintenance is the
biggest key to preventing premature
engine wear and damage.
Never run the engine without the
air filter element in place; this
would allow dirt and dust to enter
the engine and cause rapid wear
and possible engine damage.
1. Remove: •Seat
• Fitting bolt "1"
•Washer "2"
• Air filter element "3"
• Air filter guide "4"
2. Clean: • Air filter elementClean them with solvent.
After cleaning, remove the remaining
solvent by squeezing the element.
• Do not twist the element when
squeezing the element.
• Leaving too much of solvent in
the element may result in poor
starting.
3. Inspect:• Air filter element
Damage
→Replace.
4. Apply: • Foam-air-filter oil or equivalent oil
to the element
Squeeze out the excess oil. Element
should be wet but not dripping.
5. Install:• Air filter guide "1"
Align the projection "a" on filter guide
with the hole "b" in air filter element.
6. Apply:• Lithium soap base grease On the matching surface "a" on air
filter element.
7. Install: • Air filter element "1"
• Washer
• Fitting bolt
Align the projection "a" on filter guide
with the hole "b" in air filter case.
CHECKING THE ENGINE OIL
LEVEL
1. Start the engine, warm it up for several minutes, and then turn off
the engine and wait for five min-
utes.
2. Place the machine on a level place and hold it up on upright po-
sition by placing the suitable
stand under the engine.
3. Inspect:
• Oil levelOil should be up to the full level in
the check window "1".
Level check window is not full.
→
Add 0.2 L (0.18 Imp qt, 0.21 US
qt) of oil.
Screw (throttle grip cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Hot starter lever free play
"a": 3–6 mm (0.12–0.24 in)
Locknut: 4 Nm (0.4 m•kg, 2.9
ft•lb)
Fitting bolt:
2 Nm (0.2 m•kg, 1.4
ft•lb)