2009 YAMAHA YZ250F clutch

2-12
TIGHTENING TORQUES
CHASSIS
△- marked portion shall be checked for torque tightening after break-in or before each race.
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 8.7Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
△Upper bracket and outer tube M8 × 1.25 4 21 2.1 15
△Lower bracket and outer tube M8 × 1.25 4 21 2.1 15
△Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
△Handlebar upper holder and handlebar lower holder M8 × 1.25 4 28 2.8 20
△Handlebar lower holder and upper bracket M10 × 1.25 2 34 3.4 25
△Steering stem and steering ring nut M28 × 1.0 1 Refer to TIP.
Front fork and damper assembly M51 × 1.5 2 30 3.0 22
Front fork and adjuster M22 × 1.25 2 55 5.5 40
Damper assembly and base valve M42 × 1.5 2 29 2.9 21
Adjuster and damper assembly M12 × 1.25 2 29 2.9 21
Front fork bleed screw and base valve M5 × 0.8 2 1 0.1 0.7
△Front fork and front fork protector M6 × 1.0 6 5 0.5 3.6
△Lower bracket and brake hose guide M6 × 1.0 1 4 0.4 2.9
△Front fork protector and brake hose holder M6 × 1.0 2 8 0.8 5.8
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
△Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever holder M6 × 1.0 2 5 0.5 3.6
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Clutch lever position lock nut M5 × 0.8 1 5 0.5 3.6
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△Front brake hose union bolt M10 × 1.25 2 30 3.0 22
△Front brake caliper M8 × 1.25 2 28 2.8 20
Pad pin plug M10 × 1.0 2 3 0.3 2.2
△Front brake caliper and pad pin M10 × 1.0 1 18 1.8 13
△Rear brake caliper and pad pin M10 × 1.0 1 18 1.8 13

2-18
CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose
2. Radiator hose 1
3. Connector cover
4. Cylinder head breather hose
5. Radiator hose 4
6. Clutch cable
7. Throttle position sensor lead
8. Carburetor breather hose
9. Upper engine bracket10. Hot starter cable
11. Fuel hose
12. Carburetor overflow hose
A. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Install the connector cover so
that it does not come in between
the radiator hose 1 and radiator.C. Aligh the paint mark on the cylin-
der head breather hose with the
front end of the hose guide.
D. Pass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and then between the
radiator 4 and frame.
E. Pass the clutch cable through
the cable guide.

2-19
CABLE ROUTING DIAGRAM
F. Pass the clutch cable in front of
the radiator mounting boss.
G. Pass the fuel hose on the out-
side of throttle position sensor
lead.
H. Pass the carburetor breater hos-
es so that they are not pinched
between the upper engine
bracket and carburetor.
I. Pass the carburetor breather
hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.

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)]

2-24
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Hot starter cable
4. Clutch cable
5. Engine stop switch lead
6. Cable guide
7. Brake hose
8. Hose guide
A. Fasten the engine stop switch
lead to the handlebar.B. Pass the clutch cable and hot
starter cable through the cable
guide.
C. Pass the brake hose in front of
the number plate.
D. Pass the throttle cables through
the cable guide.
E. Pass the clutch cable and hot
starter cable through the cable
guide on the number plate.

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

3-4
MAINTENANCE INTERVALS
STEERING HEAD
Inspect free play and retighten●●
Clean and lube●Lithium base grease
Replace bearing●
TIRE, WHEELS
Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness●●
Retighten sprocket bolt●●
Inspect bearings●
Replace bearings●
Lubricate●Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection●●
Lubricate●●Yamaha cable lube or SAE 10W-30
motor oil
Inspect and clean (throttle ca-
ble)●●Inspect dirt and wear on the throttle
cable on the carburetor side.
HOT STARTER, CLUTCH LEVER
Inspect free play● ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks