2008 YAMAHA YZ250F engine oil

FOREWARD
INTRODUCTION
Congratulations on your purchase of
a Yamaha YZ series. This model is
the culmination of Yamaha's vast ex-
perience in the production of paceset-
ting racing machines. It represents
the highest grade of craftsmanship
and reliability that have made Yama-
ha a leader.
This manual explains operation, in-
spection, basic maintenance and tun-
ing of your machine. If you have any
questions about this manual or your
machine, please contact your Yama-
ha dealer.
Yamaha continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If you
have any questions concerning this
manual, please consult your Yamaha
dealer.
PLEASE READ THIS MANUAL
CAREFULLY AND COMPLETELY
BEFORE OPERATING THIS MA-
CHINE. DO NOT ATTEMPT TO OP-
ERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTO-
RY KNOWLEDGE OF ITS CON-
TROLS AND OPERATING
FEATURES AND UNTIL YOU HAVE
BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE,
ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU
SAFETY ENJOY THE CAPABILI-
TIES AND THE RELIABILITY OF
THIS MACHINE.
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means AT-
TENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instruc-
tions could result in severe injury or
death to the machine operator, a by-
stander, or a person inspecting or re-
pairing the machine. A CAUTION indicates special pre-
cautions that must be taken to avoid
damage to the machine.
A NOTE provides key information to
make procedures easier or clearer.
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED
STRICTLY FOR COMPETITION
USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine
to be operated on any public street,
road, or highway. Off-road use on
public lands may be illegal. Please
check local regulations before riding.
1. THIS MACHINE IS TO BE OP-
ERATED BY AN EXPERI-
ENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power
until you are totally familiar
with its characteristics.
2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OP-
ERATOR ONLY.
Do not carry passengers on
this machine.
3. ALWAYS WEAR PROTEC- TIVE APPAREL.
When operating this ma-
chine, always wear an ap-
proved helmet with goggles
or a face shield. Also wear
heavy boots, gloves, and pro-
tective clothing. Always wear
proper fitting clothing that
will not be caught in any of
the moving parts or controls
of the machine.
4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER
WORKING ORDER.
For safety and reliability, the
machine must be properly
maintained. Always perform
the pre-operation checks in-
dicated in this manual. Cor-
recting a mechanical problem
before you ride may prevent
an accident.
5. GASOLINE IS HIGHLY FLAM-MABLE.
Always turn off the engine
while refueling. Take care to
not spill any gasoline on the
engine or exhaust system.
Never refuel in the vicinity of
an open flame, or while
smoking.
6. GASOLINE CAN CAUSE IN- JURY.
If you should swallow some
gasoline, inhale excess gaso-
line vapors, or allow any gas-
oline to get into your eyes,
contact a doctor immediately.
If any gasoline spills onto
your skin or clothing, imme-
diately wash skin areas with
soap and water, and change
your clothes.
7. ONLY OPERATE THE MA- CHINE IN AN AREA WITH AD-
EQUATE VENTILATION.
Never start the engine or let it
run for any length of time in
an enclosed area. Exhaust
fumes are poisonous. These
fumes contain carbon mon-
oxide, which by itself is odor-
less and colorless. Carbon
monoxide is a dangerous gas
which can cause uncon-
sciousness or can be lethal.
8. PARK THE MACHINE CARE- FULLY; TURN OFF THE EN-
GINE.
Always turn off the engine if
you are going to leave the
machine. Do not park the ma-
chine on a slope or soft
ground as it may fall over.
9. THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL
TANK WILL BE VERY HOT
AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them
or to allow any clothing item
to contact them during in-
spection or repair.

HOW TO READ DESCRIPTIONS
To help identify parts and clarify pro-
cedure steps, there are exploded dia-
grams at the start of each removal
and disassembly section.
1. An easy-to-see exploded diagram "1" is provided for removal and
disassembly jobs.
2. Numbers "2" are given in the or- der of the jobs in the exploded di-
agram. A number that is enclosed
by a circle indicates a disassem-
bly step.
3. An explanation of jobs and notes is presented in an easy-to-read
way by the use of symbol marks
"3". The meanings of the symbol
marks are given on the next page. 4. A job instruction chart "4" accom-
panies the exploded diagram,
providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more informa- tion, the step-by-step format sup-
plements "5" are given in addition
to the exploded diagram and job
instruction chart.
ILLUSTRATED SYMBOLS (Refer to
the illustration) Illustrated symbols "1" to "7" are used
to identify the specifications appear-
ing in the text.
1. With engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening
6. Specified value, Service limit
7. Resistance (
Ω), Voltage (V),
Electric current (A)
Illustrated symbols "8" to "13" in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Brake fluid
11. Apply lightweight lithium-soap
base grease
12. Apply molybdenum disulfide
grease
13. Silicone grease
Illustrated symbols "14" to "15" in the
exploded diagrams indicate where to
apply a locking agent and where to in-
stall new parts. 14. Apply locking agent (LOC-
TITE
®)
15. Use new one
1
2 3
4 5

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION .................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
STARTING AND
BREAK-IN ........................ 1-8
TORQUE-CHECK
POINTS........................... 1-11
CLEANING AND
STORAGE ...................... 1-12
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-10
LUBRICATION
DIAGRAMS .................... 2-16
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR INSPEC-
TION AND AD-JUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-23
CHAPTER 4 ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-5
CARBURETOR................. 4-7
CAMSHAFTS.................. 4-14
CYLINDER HEAD........... 4-19
VALVES AND VALVE
SPRINGS ........................ 4-21
CYLINDER AND
PISTON ........................... 4-25
CLUTCH ......................... 4-29
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-34
BALANCER .................... 4-38
OIL PUMP ....................... 4-40
KICK SHAFT AND
SHIFT SHAFT ................. 4-44
CDI MAGNETO............... 4-49
ENGINE REMOVAL ....... 4-51
CRANKCASE AND
CRANKSHAFT ............... 4-55
TRANSMISSION, SHIFT
CAM AND SHIFT
FORK .............................. 4-61
CHAPTER 5CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................5-1
FRONT BRAKE AND
REAR BRAKE ..................5-6
FRONT FORK ................. 5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-32
REAR SHOCK
ABSORBER ....................5-37
CHAPTER 6
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........6-1
IGNITION SYSTEM...........6-2
THROTTLE POSITION
SENSOR SYSTEM ...........6-5
CHAPTER 7
TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6

1-1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1. Clutch lever
2. Hot starter lever
3. Front brake lever
4. Throttle grip
5. Radiator cap
6. Fuel tank cap
7. Engine stop switch
8. Kickstarter crank
9. Fuel tank
10. Radiator
11. Coolant drain bolt
12. Rear brake pedal
13. Valve joint14. Fuel cock
15. Cold starter knob
16. Drive chain
17. Air filter
18. Oil level check window
19. Shift pedal
20. Front fork
1

1-11
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame constructionFrame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp

1-12
CLEANING AND STORAGE
CLEANING AND STORAGE
CLEANING
Frequent cleaning of your machine
will enhance its appearance, maintain
good overall performance, and ex-
tend the life of many components.
1. Before washing the machine, block off the end of the exhaust
pipe to prevent water from enter-
ing. A plastic bag secured with a
rubber band may be used for this
purpose.
2. If the engine is excessively greasy, apply some degreaser to
it with a paint brush. Do not apply
degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only
enough pressure to do the job.
Excessive hose pressure may
cause water seepage and contami-
nation of wheel bearings, front
forks, brakes and transmission
seals. Many expensive repair bills
have resulted from improper high
pressure detergent applications
such as those available in coin-op-
erated car washers.
4. After the majority of the dirt has been hosed off, wash all surfaces
with warm water and a mild deter-
gent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediate- ly with clean water, and dry all
surfaces with a soft towel or cloth.
6. Immediately after washing, re- move excess water from the
chain with a paper towel and lubri-
cate the chain to prevent rust.
7. Clean the seat with a vinyl uphol- stery cleaner to keep the cover
pliable and glossy.
8. Automotive wax may be applied to all painted or chromed surfac-
es. Avoid combination cleaner-
waxes, as they may contain abra-
sives.
9. After completing the above, start the engine and allow it to idle for
several minutes.
STORAGE
If your machine is to be stored for 60
days or more, some preventive mea-
sures must be taken to avoid deterio-
ration. After cleaning the machine
thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
2. Remove the spark plug, pour a ta- blespoon of SAE 10W-30 motor
oil in the spark plug hole, and re-
install the plug. With the engine
stop switch pushed in, kick the en-
gine over several times to coat the
cylinder walls with oil.
3. Remove the drive chain, clean it thoroughly with solvent, and lubri-
cate it. Reinstall the chain or store
it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the
wheels off the ground.
6. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
7. If the machine is to be stored in a
humid or salt-air environment,
coat all exposed metal surfaces
with a film of light oil. Do not apply
oil to rubber parts or the seat cov-
er.
Make any necessary repairs before
the machine is stored.

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name:YZ250FX (USA, CDN, AUS, NZ)
YZ250F (EUROPE, ZA)
Model code number: 5XCL (USA,CDN)
5XCM (EUROPE)
5XCP (AUS, NZ, ZA)
Dimensions: USA, CDN, ZA, AUS, NZEUROPE
Overall length 2,162 mm (85.12 in) 2,165 mm (85.24 in)
Overall width 825 mm (32.48 in)
←
Overall height1,300 mm (51.18 in)←
Seat height 985 mm (38.78 in)997 mm (39.25 in)
Wheelbase 1,469 mm (57.83 in)
←
Minimum ground clearance370 mm (14.57 in)372 mm (14.65 in)
Dry weight: Without oil and fuel 92.7 kg (204 lb)
Engine: Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 249 cm
3 (8.76 Imp oz, 8.42 US oz)
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 13.5 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade: Engine oil (For USA and CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)
SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
API service SG type or higher,
JASO standard MA
Oil capacity: Engine oilPeriodic oil change 1.05 L (0.92 Imp qt, 1.11 US qt)
With oil filter replacement 1.15 L (1.01 Imp qt, 1.22 US qt)
Total amount 1.30 L (1.14 Imp qt, 1.37 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
2

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