2009 YAMAHA YZ250F oil

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: YZ250FY (USA, CDN, AUS, NZ)
YZ250F (EUROPE, ZA)
Model code number: 5XCR (USA,CDN)
5XCS (EUROPE)
5XCU (AUS, NZ, ZA)
Dimensions: USA, CDN EUROPE AUS, NZ, ZA
Overall length 2,163 mm (85.16
in)2,172 mm (85.51
in)2,170 mm (85.43
in)
Overall width 825 mm (32.48 in)←←
Overall height 1,299 mm (51.14
in)1,300 mm (51.18
in)←
Seat height 984 mm (38.74 in) 997 mm (39.25 in) 985 mm (38.78 in)
Wheelbase 1,469 mm (57.83
in)1,476 mm (58.11
in)←
Minimum ground clearance 370 mm (14.57 in) 372 mm (14.65 in) 371 mm (14.61 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, SAE10W-40 or SAE20W-50
Yamalube 4-R, SAE10W-50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)
SAE10W-30, SAE10W-40, SAE15W-40,
SAE20W-40 or SAE20W-50
API service SG type or higher,
JASO standard MA
Oil capacity:
Engine oil
Periodic 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)
2

2-3
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINEShock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel: USA, CDN EUROPE, AUS, NZ, ZA
Front wheel travel 300 mm (11.8 in)←
Rear wheel travel 307 mm (12.1 in) 310 mm (12.2 in)
Electrical:
Ignition system CDI magneto
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm (0.002
in)
Cylinder:
Bore size 77.00–77.01 mm (3.0315–3.0319 in) ----
Out of round limit ---- 0.05 mm (0.002
in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
Cam dimensions
Intake "A" 30.246–30.346 mm (1.1908–1.1947 in) 30.146 mm
(1.1869 in)
Intake "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm
(0.8799 in)
Exhaust "A" 30.399–30.499 mm (1.1968–1.2007 in) 30.299 mm
(1.1929 in)
Exhaust "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm
(0.8799 in)

2-6
MAINTENANCE SPECIFICATIONS
Piston:
Piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) 0.1 mm (0.004
in)
Piston size "D" 76.955–76.970 mm (3.0297–3.0303 in) ----
Measuring point "H" 8 mm (0.31 in) ----
Piston off-set 0.5 mm (0.020 in)/IN-side ----
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm
(0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm
(0.6288 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ----
End gap (installed) 0.15–0.25 mm (0.006–0.010 in) 0.50 mm (0.020
in)
Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005
in)
2nd ring:
Type Taper ----
Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ----
End gap (installed) 0.30–0.45 mm (0.012–0.018 in) 0.80 mm (0.031
in)
Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005
in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ----
End gap (installed) 0.10–0.40 mm (0.004–0.016 in) ----
Crankshaft:
Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ----
Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002
in)
Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02
in) Item Standard Limit

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

2-11
TIGHTENING TORQUES
Radiator pipe M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 1.7 0.17 1.2
Oil pump M6 × 1.0 3 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil strainer (crankcase) M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14
Oil delivery pipe 1 (M8) M8 × 1.25 2 18 1.8 13
Oil hose M6 × 1.0 2 8 0.8 5.8
△Oil hose clamp — 1 2 0.2 1.4
Oil strainer (oil tank) M6 × 1.0 1 9 0.9 6.5
Oil tank drain bolt M8 × 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
△Silencer M8 × 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 screw M14 × 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 7.2Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

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