2009 YAMAHA YZ250F radiator cap

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

1-5
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, 90890-01500This tool is used to loosen or tighten
the base valve.
Cap bolt ring wrench
YM-01501, 90890-01501This 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.
Spoke nipple wrench
YM-01521, 90890-01521 This tool is used to tighten the
spoke.
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 use Illustration

2-8
MAINTENANCE SPECIFICATIONS
CHASSISIntake 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 size
Width 120.2 mm (4.7 in) ----
Height 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 Standard Limit
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE, AUS, NZ, ZA
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)K = 4.5 N/mm (0.459 kg/
mm, 25.7 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 EUROPE, AUS, NZ, ZA
Shock absorber travel 131.5 mm (5.18 in)←----
Spring free length 260 mm (10.24 in)←----
Fitting length 251 mm (9.88 in) 248 mm (9.76 in)
Preload length
1.5–13 mm (0.06–0.51
in)←----

2-10
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
Clutch lever free play (lever end) 7–12 mm (0.28–0.47 in) ----
Throttle grip free play 3–5 mm (0.12–0.20 in) ----Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 5XC-10/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) ----
Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ----
CDI unit-model/manufacturer 5XC-R0/YAMAHA (For USA and CDN) ----
5XC-S0/YAMAHA (Except for USA and
CDN)----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11
Cylinder head (bolt) M9 × 1.25 4 38 3.8 27
Cylinder head (nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 10 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2

2-20
CABLE ROUTING DIAGRAM
1. Hot starter cable
2. Radiator hose 2
3. Clamp
4. Ignition coil lead
5. Throttle position sensor lead
6. Hump (frame)
7. Oil hose
8. Hose guide
9. Neutral switch lead
10. CDI magneto lead
11. Clutch cable12. Radiator breather hose
13. Engine stop switch lead
14. Sub-wire harness
15. CDI unit bracket
16. CDI unit
17. Throttle cable
18. Cylinder head breather hose
19. Hot starter cable protector
20. Rubber capA. Fasten the hot starter cable,
throttle cables, throttle position
sensor lead and ignition coil
lead.
B. Fasten the neutral switch lead
on the oil hose.
C. Pass the neutral switch lead on
the inside of the oil hose.
D. Fasten the neutral switch lead,
CDI magneto lead and radiator
breather hose.

2-21
CABLE ROUTING DIAGRAM
E. Fasten the neutral switch lead,
CDI magneto lead, radiator
breather hose and clutch cable
over the radiator mounting boss.
F. Pass the radiator breather hose
in front of the radiator, on the left
of the chassis, and then be-
tween the frame and radiator
hose 4.
G. Fasten the sub-wire harness
and engine stop switch lead to
the CDI unit bracket at the white-
taped portion of the subwire har-
ness and with the clamp ends
facing downward.
H. Locate the clamp ends in the ar-
rowed range.
I. Fasten the neutral switch lead
and CDI magneto lead over the
hump of the frame.
J. Fasten the hot starter cable and
throttle cable onto the frame.
K. Fasten the throttle position sen-
sor lead and the hot starter ca-
ble.
L. Locate the clamp between the
hot starter cable protector and
rubber cap.
M. Locate the clamp ends under
the throttle cable, and after
clamping, leave the other end as
is and do not cut it. [clamp:L=
270mm (10.6 in)]

3-2
MAINTENANCE INTERVALS
CYLINDER
Inspect 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 BAR
Inspect●Inspect wear.
ROTOR NUT
Retighten●●
EXHAUST PIPE, SILENCER,
PROTECTOR
Inspect and retighten●●
Clean●
Replace●* Whichever comes first
CRANK
Inspect and clean●●
CARBURETOR
Inspect, adjust and clean●●
SPARK PLUG
Inspect and clean●●
Replace●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment●●Chain slack: 50–60 mm (2.0–2.4 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●● ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks

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 MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage.P.3-6 – 7
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.P.1-8 – 9
Engine oilCheck that the oil level is correct. Check the crankcase and oil line
for leakage.P.3-9 – 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-7
Throttle grip/HousingCheck 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 chainCheck drive chain slack and alignment. Check that the drive chain
is lubricated properly.P.3-17 – 18
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-20 – 21
SteeringCheck that the handlebar can be turned smoothly and have no ex-
cessive play.P.3-21 – 22
Front forks and rear shock
absorberCheck 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 connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-3
SettingsIs 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 – 11