2008 YAMAHA YZ250F oil level

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

2-11
TIGHTENING TORQUES
Oil tank drain boltM8 × 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
△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 M8 × 1.25 2 20 2.0 14
△Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
△SilencerM8 × 1.25 2 30 3.0 22
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 14 1.4 10
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
△Crankshaft end accessing screw M32 × 1.5 1 — — —
△Timing mark accessing screwM14 × 1.5 1 — — —
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

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

3-5
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

3-6
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

3-8
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)

3-9
ENGINE
(For USA and CDN)
• Do not add any chemical addi-tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
• Do not allow foreign material to
enter the crankcase.
(Except for USA and CDN)
• Do not add any chemical addi-tives or use oils with a grade of
CD "a" or higher.
• Do not use oils labeled "ENERGY CONSERVING II" "b" or higher.
Engine oil also lubricates the
clutch and additives could cause
clutch slippage.
• Do not allow foreign material to enter the crankcase.
4. Install:• Oil tank cap
5. Start the engine and let it warm up
for several minutes.
6. Turn off the engine and inspect the oil level once again.
Wait a few minutes until the oil settles
before inspecting the oil level.
CHANGING THE ENGINE OIL
1. Start the engine and warm it up
for several minutes, and then turn
off the engine and wait for five
minute.
2. Place the machine on a level place and hold it on upright posi-
tion by placing the suitable stand
under the engine.
3. Place a suitable container under the engine.
4. Remove: • Lower engine guard "1"
• Bolt (oil tank) "2"
•Washer "3"
• Oil filler cap "4"
• Oil tank drain bolt "5"
• Crankcase oil drain bolt "6"
• Oil filter element drain bolt "7"Drain the crankcase and oil tank
of its oil. 5. Remove:
• Oil hose clamp "1"
• Bolt (oil hose)
•Oil hose "2"
• Oil strainer "3"
6. Inspect: • Oil strainerClogged
→Blow.
7. If the oil filter is to be replaced dur- ing this oil change, remove the fol-
lowing parts and reinstall them.
Replacement steps:
a. Remove the oil filter element cov-
er "1" and oil filter element "2".
b. Check the O-rings "3", if cracked or damaged, replace them with a
new one.
c. Install the oil filter element and oil filter element cover.
8. Install:• O-ring "1"
• Oil strainer "2"
•Oil hose
• Bolt (oil hose)
Recommended oil:
Yamalube 4,
SAE10W30 or
SAE20W40
Yamalube 4-R,
SAE10W50
API service SG type or
higher, JASO standard
MA
Recommended oil: SAE10W30,
SAE10W40,
SAE15W40, SAE20W40
or SAE20W50
API service SG type or
higher, JASO standard
MA
Oil filter element cover:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Oil strainer: 9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (oil hose): 8 Nm (0.8 m•kg, 5.8
ft•lb)