2008 YAMAHA YZ250F run flat

4-50
CDI MAGNETO
REMOVING THE ROTOR
1. Remove:• Nut (rotor) "1"
• Washer "2"Use the rotor holding tool "3".
2. Remove: • Rotor "1"Use the flywheel puller "2".
When installing the flywheel puller,
turn it counterclockwise.
CHECKING THE CDI MAGNETO
1. Inspect:• Rotor inner surface "a"
• Stator outer surface "b"
Damage
→Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magne-
to and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect: • Woodruff key "1"Damage
→Replace. INSTALLING THE CDI MAGNETO
1. Install:
•Stator "1"
• Screw (stator) "2"
• Apply the sealant on the grommet of the CDI magneto lead.
• Tighten the screws using the T30 bit.
2. Install:
• Woodruff key "1"
•Rotor "2"
• Clean the tapered portions of the crankshaft and rotor.
• When installing the woodruff key, make sure that its flat surface "a" is
in parallel with the crankshaft center
line "b".
• When installing the rotor, align the keyway "c" of the rotor with the
woodruff key.
3. Install:•Washer "1"
• Nut (rotor) "2"
Use the rotor holding tool "3". 4. Connect:
• CDI magneto leadRefer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
5. Install: • Dowel pin
• Gasket (left crankcase cover)
• Left crankcase cover "1"
• Hose guide (cylinder head breath-er hose) "2"
• Bolt (left crankcase cover)
Tighten the bolts in stage, using a
crisscross pattern.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller: YM-1189/90890-01189
Screw (stator):
10 Nm (1.0 m•kg,
7.2ft•lb)
YAMAHA Bond No. 1215
(ThreeBond
® No. 1215):
90890-85505
Nut (rotor): 56 Nm (5.6 m•kg, 40
ft•lb)
Rotor holding tool: YU-1235/90890-01235
Bolt (left crankcase cov-
er):10 Nm (1.0 m•kg, 7.2
ft•lb)

7-1
ENGINE
TUNING
ENGINE
CARBURETOR SETTING
• The air/fuel mixture will vary de-pending on atmospheric conditions.
Therefore, it is necessary to take
into consideration the air pressure,
ambient temperature, humidity,
etc., when adjusting the carburetor.
• Perform a test run to check for prop- er engine performance (e.g., throt-
tle response) and spark plug(-s)
discoloration or fouling. Use these
readings to determine the best pos-
sible carburetor setting.
It is recommended to keep a record of
all carburetor settings and external
conditions (e.g., atmospheric condi-
tions, track/surface conditions, lap
times) to make future carburetor set-
ting easier.
• The carburetor is a part of the fuel line. Therefore, be sure to in-
stall it in a wellventilated area,
away from flammable objects
and any sources of fire.
• Never look into the carburetor in- take. Flames may shoot out from
the pipe if the engine backfires
while it is being started. Gasoline
may be discharged from the ac-
celerator pump nozzle when the
carburetor has been removed.
• The carburetor is extremely sen-sitive to foreign matter (dirt,
sand, water, etc.). During instal-
lation, do not allow foreign mat-
ter to get into the carburetor.
• Always handle the carburetor and its components carefully.
Even slight scratches, bends or
damage to carburetor parts may
prevent the carburetor from
functioning correctly. Carefully
perform all servicing with the ap-
propriate tools and without ap-
plying excessive force.
• When the engine is stopped or when riding at no load, do not
open and close the throttle un-
necessarily. Otherwise, too
much fuel may be discharged,
starting may become difficult or
the engine may not run well.
• After installing the carburetor,
check that the throttle operates correctly and opens and closes
smoothly.
ATMOSPHERIC CONDITIONS AND
CARBURETOR SETTINGS
The air density (i.e., concentration of
oxygen in the air) determines the rich-
ness or leanness of the air/fuel mix-
ture.
• Higher temperature expands the air
with its resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so
much of the water vapor in the
same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of
the air.
EFFECT OF SETTING PARTS IN
RELATION TO THROTTLE VALVE
OPENING
A. Closed
B. Fully open
1. Pilot screw/pilot jet
2. Throttle valve cutaway
3. Jet needle
4. Main jet CONSTRUCTION OF
CARBURETOR AND SETTING
PARTS
The FLATCR carburetor has a prima-
ry main jet. This type of main jet is
perfect for racing machines since it
supplies an even flow of fuel, even at
full load. Use the main jet and the jet
needle to set the carburetor.
The FLATCR carburetor is manufac-
tured with a pilot screw. The pilot
screw adjustment ranges from fully
closed throttle to 1/4 open throttle.
1. Jet needle
2. Pilot air jet
3. Needle jet
4. Main jet
5. Pilot jet
6. Pilot screw
ADJUSTING THE MAIN JET
The richness of the air-fuel mixture at
full throttle can be set by changing the
main jet "1".
If the air-fuel mixture is too rich or too
lean, the engine power will drop, re-
sulting in poor acceleration.
Effects of changing the main jet
(reference)
A. Idle
B. Fully open
1. #180
2. #175
3. #178
Air
tem p. Hu-
midi- ty Air
pres-
sure
(alti-
tude) Mix-
ture Set-
ting
High High Low
(high) Rich-
er Lean-
er
Low Low High
(low) Lean-
er Rich-
er
Standard main jet #178
7

7-6
CHASSIS
CHASSIS
SELECTION OF THE SECONDARY
REDUCTION RATIO (SPROCKET)
ondary gear reduction ratio>
• It is generally said that the second-ary gear ratio should be reduced for
a longer straight portion of a speed
course and should be increased for
a course with many corners. Actual-
ly, however, as the speed depends
on the ground condition of the day
of the race, be sure to run through
the circuit to set the machine suit-
able for the entire course.
• In actuality, it is very difficult to achieve settings suitable for the en-
tire course and some settings may
be sacrificed. Thus, the settings
should be matched to the portion of
the course that has the greatest ef-
fect on the race result. In such a
case, run through the entire course
while making notes of lap times to
find the best balance; then, deter-
mine the secondary reduction ratio.
• If a course has a long straight por-
tion where a machine can run at
maximum speed, the machine is
generally set such that it can devel-
op its maximum revolutions toward
the end of the straight line, with care
taken to avoid the engine over-rev-
ving.
Riding technique varies from rider to
rider and the performance of a ma-
chine also vary from machine to ma-
chine. Therefore, do not imitate other
rider's settings from the beginning but
choose your own setting according to
the level of your riding technique.
DRIVE AND REAR WHEEL
SPROCKETS SETTING PARTS
TIRE PRESSURE
Tire pressure should be adjust to suit
the road surface condition of the cir-
cuit.
• Under a rainy, muddy, sandy, or slippery condition, the tire pressure
should be lower for a larger area of
contact with the road surface.
• Under a stony or hard road condi- tion, the tire pressure should be
higher to prevent a flat tire.
FRONT FORK SETTING
The front fork setting should be made
depending on the rider's feeling of an
actual run and the circuit conditions. The front fork setting includes the fol-
lowing three factors:
1. Setting of air spring characteris-
tics
• Change the fork oil amount.
2. Setting of spring preload • Change the spring.
3. Setting of damping force • Change the compression damp-ing.
• Change the rebound damping. The spring acts on the load and
the damping force acts on the
cushion travel speed.
CHANGE IN AMOUNT AND
CHARACTERISTICS OF FORK OIL
Damping characteristic near the final
stroke can be changed by changing
the fork oil amount.
Adjust the oil amount in 5 cm3 (0.2
Imp oz, 0.2 US oz) increments or
decrements. Too small oil amount
causes the front fork to produce a
noise at full rebound or the rider to
feel some pressure on his hands
or body. Alternatively, too large oil
amount will cause the air spring
characteristics to have a tendency
to be stiffer with the consequent
deteriorated performance and
characteristics. Therefore, adjust
the front fork within the specified
range.
A. Air spring characteristics in relation to oil amount change
B. Load
Secondary reduction ratio =
Number of rear wheel sprocket
teeth/Number of drive sprocket
teeth
Standard secondary
reduction ratio 49/13
(3.769)
Part name Size Part number
Drive
sprocket "1" (STD) 13T 9383B-13218
Rear wheel
sprocket "2" 47T 1C3-25447-00
48T 1C3-25448-00
(STD) 49T 1C3-25449-00 50T 1C3-25450-00
51T 1C3-25451-00
52T 1C3-25452-00
Standard tire pressure: 100 kPa (1.0 kgf/cm
2,
15 psi)
Extent of adjustment: 60–80 kPa (0.6–0.8 kgf/
cm
2, 9.0–12 psi)
Extent of adjustment: 100–120 kPa (1.0–1.2
kgf/cm
2, 15–18 psi)
Standard oil amount:330 cm3 (11.6 Imp oz,
11.2 US oz)
Extent of adjustment: 300–375 cm
3(10.6–13.2
Imp oz, 10.1–12.7 US
oz)