2008 YAMAHA YZ250F cooling

1-5
SPECIAL TOOLS
Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352These tools are used for checking
the cooling system.
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.
Cap bolt wrench
YM-01500, 90890-01500 This tool is used to loosen or tighten
the base valve.
Cap bolt ring wrench
YM-01501, 90890-01501 This tool is used to loosen or tighten
the damper assembly.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Tool name/Part number
How to useIllustration

2-7
MAINTENANCE SPECIFICATIONS
Quantity8----
Warp limit ----0.1 mm (0.004
in)
Clutch spring free length 35.7 mm (1.41 in)34.7 mm (1.37
in)
Quantity 5----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push----
Shifter: Shifter type Cam drum and guide bar----
Guide bar bending limit ----0.05 mm (0.002
in)
Kickstarter: Type Kick and ratchet type----
Carburetor: Type/manufacturer FCR-MX37/KEIHIN----
I. D. mark 5XCL L0----
Main jet (M.J) #178----
Main air jet (M.A.J) ø2.0----
Jet needle-clip position (J.N) NFPR-5----
Cutaway (C.A) 1.5----
Pilot jet (P.J) #42----
Pilot air jet (P.A.J) #105----
Pilot outlet (P.O) ø0.9----
Pilot screw (example) (P.S) 2-3/8----
Bypass (B.P) ø1.0----
Valve seat size (V.S) ø3.8----
Starter jet (G.S) #72----
Leak jet (Acc.P) #70----
Float height (F.H) 8 mm (0.31 in)----
Engine idle speed 1,900–2,100 r/min----
Intake vacuum 29.3–34.7 kPa (220–260 mmHg, 8.66–
9.45 inHg) ----
Hot starter lever free play 3–6 mm (0.12–0.24 in)----
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 sizeWidth 120.2 mm (4.7 in)----
Item
StandardLimit

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

3-6
ENGINE
ENGINE
CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level place, and hold it in an upright po-
sition.
2. Remove: • Radiator cap
3. Check: • Coolant level "a"Coolant level low
→Add coolant.
1. Radiator
CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en- gine.
2. Remove: • Coolant drain bolt "1"
3. Remove: •Radiator capDrain the coolant completely.
4. Clean:
• Cooling systemThoroughly flush the cooling sys-
tem with clean tap water.
5. Install: • Copper washer
• Coolant drain bolt
6. Fill: •Radiator
•EngineTo specified level.
• Do not mix more than one type of ethylene glycol antifreeze con-
taining corrosion inhibitors for
aluminum engine.
• Do not use water containing im-
purities or oil.
Handling notes of coolant:
The coolant is harmful so it should be
handled with special care.
• When coolant splashes to your eye.
Thoroughly wash your eye with
water and see your doctor.
• When coolant splashes to your
clothes.
Quickly wash it away with water
and then with soap.
• When coolant is swallowed. Quickly make him vomit and take
him to a doctor.
7. Install:•Radiator capStart the engine and warm it up
for a several minutes.
8. Check:
• Coolant levelCoolant level low
→Add coolant.
CHECKING THE RADIATOR CAP
1. Inspect: • Seal (radiator cap) "1"
• Valve and valve seat "2"
Crack/damage
→Replace.
Exist fur deposits "3"
→Clean or
replace.
CHECKING THE RADIATOR CAP
OPENING PRESSURE
1. Attach: • Radiator cap tester "1" and adapt-
er "2"
Apply water on the radiator cap seal.
3. Radiator cap
Coolant drain bolt: 10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant: High quality ethylene
glycol anti-freeze con-
taining anti-corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio: 50%/50%
Coolant capacity:
0.99 L (0.87 Imp qt, 1.05
US qt)
Radiator cap tester:YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352

3-7
ENGINE
2. Apply the specified pressure.
3. Inspect:•PressureImpossible to maintain the speci-
fied pressure for 10 seconds
→
Replace.
CHECKING THE COOLING
SYSTEM
1. Inspect: • Coolant level
2. Attach: • Radiator cap tester "1" and adapt-
er "2"
3. Apply the specified pressure.
ΠDo not apply pressure more than
specified pressure.
• Radiator should be filled fully.
4. Inspect: •Pressure
Impossible to maintain the speci-
fied pressure for 10 seconds
→
Repair.
• Radiator "1"
• Radiator hose joint "2" Coolant leakage
→Repair or re-
place.
• Radiator hose "3" Swelling
→Replace. ADJUSTING THE CLUTCH CABLE
FREE PLAY
1. Check:
• Clutch lever free play "a"
Out of specification
→Adjust.
2. Adjust: • Clutch lever free play
Clutch lever free play adjustment
steps:
a. Loosen the locknuts "1".
b. Turn the adjuster "2" until free play "a" is within the specified lim-
its.
c. Tighten the locknuts.
ΠBefore adjustment, expose the ad-
juster by moving the boot "3" and
cap "4" away.
• Make minute adjustment on the le- ver side using the adjuster "5".
• After adjustment, check proper op-
eration of clutch lever.
3. Install:•Cap "1"
•Boot "2"
Place the tip "a" of the cap in the boot.
ADJUSTING THE THROTTLE
CABLE FREE PLAY
1. Check:• Throttle grip free play "a"
Out of specification
→Adjust.
2. Adjust: • Throttle grip free play
Throttle grip free play adjustment
steps:
a. Slide the adjuster cover.
b. Loosen the locknut "1".
c. Turn the adjuster "2" until the specified free play is obtained.
d. Tighten the locknut.
Before adjusting the throttle cable
free play, the engine idle speed
should be adjusted.
After adjusting the throttle cable
free play, start the engine and turn
the handlebar to right and left and
make sure that the engine idling
does not run faster.
LUBRICATING THE THROTTLE
1. Remove: • Cover (throttle cable cap) "1"
• Cover (grip cap) "2"
• Throttle grip cap "3"
Radiator cap opening
pressure:
110 kPa (1.1 kg/cm
2,
15.6 psi)
Radiator cap tester: YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352
Standard pressure: 180 kPa (1.8 kg/cm
2,
25.6 psi)
Clutch lever free play "a"
: 8–13 mm (0.31–0.51 in)
Locknut: 4 Nm (0.4 m•kg, 2.9
ft•lb)Throttle grip free play
"a":3–5 mm (0.12–0.20 in)
Locknut: 4 Nm (0.4 m•kg, 2.9
ft•lb)