2009 YAMAHA YZ250F air filter

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

1-8
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch "1" is located
on the left handlebar. Continue push-
ing the engine stop switch till the en-
gine comes to a stop.
CLUTCH LEVER
The clutch lever "1" is located on the
left handlebar; it disengages or en-
gages the clutch. Pull the clutch lever
to the handlebar to disengage the
clutch, and release the lever to en-
gage the clutch. The lever should be
pulled rapidly and released slowly for
smooth starts.
SHIFT PEDAL
The gear ratios of the constant-mesh
5 speed transmission are ideally
spaced. The gears can be shifted by
using the shift pedal "1" on the left
side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank "1" away
from the engine. Push the starter
down lightly with your foot until the
gears engage, then kick smoothly
and forcefully to start the engine. This
model has a primary kickstarter crank
so the engine can be started in any
gear if the clutch is disengaged. In
normal practices, however, shift to
neutral before starting.THROTTLE GRIP
The throttle grip "1" is located on the
right handlebar; it accelerates or de-
celerates the engine. For accelera-
tion, turn the grip toward you; for
deceleration, turn it away from you.
FRONT BRAKE LEVER
The front brake lever "1" is located on
the right handlebar. Pull it toward the
handlebar to activate the front brake.
REAR BRAKE PEDAL
The rear brake pedal "1" is located on
the right side of the machine. Press
down on the brake pedal to activate
the rear brake.
FUEL COCK
The fuel cock supplies fuel from the
tank to carburetor and also filters the
fuel. The fuel cock has the two posi-
tions:
OFF:
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
ON:
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.COLD STARTER KNOB
When cold, the engine requires a
richer air-fuel mixture for starting. A
separate starter circuit, which is con-
trolled by the cold starter knob "1",
supplies this mixture. Pull the cold
starter knob out to open the circuit for
starting. When the engine has
warmed up, push it in to close the cir-
cuit.
HOT STARTER LEVER
The hot starter lever "1" is used when
starting a warm engine. Use the hot
starter lever when starting the engine
again immediately after it was
stopped (the engine is still warm).
Pulling the hot starter lever injects
secondary air to thin the air-fuel mix-
ture temporarily, allowing the engine
to be started more easily.
STARTING AND BREAK-IN
FUEL
Always use the recommended fuel as
stated below. Also, be sure to use
new gasoline the day of a race.
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to the engine inter-
nal parts such as valves, piston
rings, and exhaust system, etc.
Recommended fuel:
Premium unleaded
gasoline only with a re-
search octane number
of 95 or higher.

1-9
STARTING AND BREAK-IN
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
• For refueling, be sure to stop the
engine and use enough care not
to spill any fuel. Also be sure to
avoid refueling close to a fire.
• Refuel after the engine, exhaust
pipe, etc. have cooled off.
HANDLING NOTE
Never start or run the engine in a
closed area. The exhaust fumes
are poisonous; they can cause
loss of consciousness and death
in a very short time. Always oper-
ate the machine in a well-ventilated
area.
• The carburetor on this machine
has a built-in accelerator pump.
Therefore, when starting the en-
gine, do not operate the throttle
or the spark plug will foul.
• Unlike a two-stroke engine, this
engine cannot be kick started
when the throttle is open be-
cause the kickstarter may kick
back. Also, if the throttle is open
the air/fuel mixture may be too
lean for the engine to start.
• Before starting the machine, per-
form the checks in the pre-opera-
tion check list.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR
FILTER ELEMENT" section in the
CHAPTER 3, apply the foam-air-filter
oil or its equivalent to the element.
(Excess oil in the element may ad-
versely affect engine starting.)
STARTING A COLD ENGINE
1. Inspect the coolant level.
2. Turn the fuel cock to "ON".
3. Shift the transmission into neutral.
4. Fully open the cold starter knob
"1".
5. Kick the kickstarter crank.
Do not open the throttle while kick-
ing the kickstarter crank. Other-
wise, the kickstarter crank may
kick back.
6. Return the cold starter knob to its
original position and run the en-
gine at 3,000–5,000 r/min for 1 or
2 minutes.
Since this model is equipped with an
accelerator pump, if the engine is
raced (the throttle opened and
closed), the air/fuel mixture will be too
rich and the engine may stall. Also
unlike a two-stroke engine, this model
can idle.
Do not warm up the engine for ex-
tended periods of time.
STARTING A WARM ENGINE
Do not operate the cold starter knob
and throttle. Pull the hot starter lever
"1" and start the engine by kicking
the kickstarter crank forcefully with a
firm stroke. As soon as the engine
starts, release the hot starter lever to
close the air passage.
Restarting an engine after a fall
Pull the hot starter lever and start the
engine. As soon as the engine starts,
release the hot starter lever to close
the air passage.The engine fails to start
Pull the hot starter lever all the way
out and while holding the lever, kick
the kickstarter crank 10 to 20 times to
clear the engine. Then, restart the en-
gine. Refer to "Restarting an engine
after a fall".
Observe the following break-in
procedures during initial operation
to ensure optimum performance
and avoid engine damage.
Thrott
le
grip
oper-
ation*Cold
start-
er
knobHot
start-
er le-
ver
Star
ting
a
cold
en-
gineAir tem-
perature =
less than
5 °C (41
°F)Open
3 or 4
timesON OFF
Air tem-
perature =
more than
5 °C (41
°F)None ON OFF
Air tem-
perature
(normal
tempera-
ture) = be-
tween 5
°C (41 °F)
and 25 °C
(77 °F)NoneON/
OFFOFF
Air tem-
perature =
more than
25 °C (77
°F)None OFF OFF
Starting an en-
gine after a long
period of timeNone ON OFF
Restarting a
warm engineNone OFF ON
Restarting an
engine after a
fallNone OFF ON
* Operate the throttle grip before kick
starting.

2-2
GENERAL SPECIFICATIONS
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a research octane
number of 95 or higher.
Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission: USA, CDN EUROPE, AUS, NZ, ZA
Primary reduction system Gear←
Primary reduction ratio 57/17 (3.353)←
Secondary reduction system Chain drive←
Secondary reduction ratio 49/13 (3.769) 51/13 (3.923)
Transmission type Constant mesh, 5-speed←
Operation Left foot operation←
Gear ratio:
1st 30/14 (2.143)←
2nd 28/16 (1.750)←
3rd 29/20 (1.450)←
4th 27/22 (1.227)←
5th 25/24 (1.042)←
Chassis: USA, CDN EUROPE AUS, NZ, ZA
Frame type Semi double cra-
dle←←
Caster angle 27.2° 26.9° 27.1°
Trail 117.8 mm (4.64
in)115.0 mm (4.53
in)117.2 mm (4.61
in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 100/90-19 57M
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)

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

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

3-8
ENGINE
b. Loosen the locknut "1".
c. Turn the adjuster "2" until the
specified free play is obtained.
d. Tighten the locknut.
Before adjusting the throttle cable
free play, the engine idle speed
should be adjusted.
After adjusting the throttle cable
free play, start the engine and turn
the handlebar to right and left and
make sure that the engine idling
does not run faster.
LUBRICATING THE THROTTLE
1. Remove:
• Cover (throttle cable cap) "1"
• Cover (grip cap) "2"
• Throttle grip cap "3"
2. Apply:
• Lithium soap base grease
On 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 element
Clean 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. Locknut:
4 Nm (0.4 m•kg, 2.9
ft•lb)
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)

3-9
ENGINE
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 level
Oil 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.
• Engine oil also lubricates the
clutch and the wrong oil types or
additives could cause clutch
slippage. Therefore, do not add
any chemical additives or use en-
gine oils with a grade of CD "a"
or higher and do not use oils la-
beled "ENERGY CONSERVING
II" "b"• Do not allow foreign materials to
enter the crankcase.
(For USA and CDN)
(Except for USA and CDN)
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 strainer
Clogged→Blow.
7. If the oil filter is to be replaced dur-
ing this oil change, remove the fol-
lowing parts and reinstall them. Fitting bolt:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Recommended oil:
Yamalube 4, SAE10W-
40 or SAE20W-50
Yamalube 4-R,
SAE10W-50
API service SG type or
higher, JASO standard
MA
Recommended oil:
SAE10W-30, SAE10W-
40, SAE15W-40,
SAE20W-40 or
SAE20W-50
API service SG type or
higher, JASO standard
MA
4