2009 YAMAHA YZ250F check engine light

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

3-10
ENGINE
Replacement steps:
a. Remove the oil filter element cov-
er "1" and oil filter element "2".
b. Check the O-rings "3", if cracked
or damaged, replace them with a
new one.
c. Install the oil filter element and oil
filter element cover.
8. Install:
• O-ring "1"
• Oil strainer "2"
•Oil hose
• Bolt (oil hose)
• Oil hose clamp
9. Install:
• Copper washer
• Oil filter element drain bolt
• Crankcase oil drain bolt• Oil tank drain bolt
• Lower engine guard
10. Fill:
• Engine oil
11. Check:
• Oil leakage
12. Install:
• Oil filler cap
• Washer (oil tank)
• Bolt (oil tank)
13. Check:
• Engine oil level
CHECKING THE OIL PRESSURE
1. Check:
• Oil pressure
Checking steps:
a. Slightly loosen the oil pressure
check bolt "1".
b. Start the engine and keep it idling
until oil starts to seep from the oil
pressure check bolt. If no oil
comes out after one minute, turn
the engine off so it will not seize.
c. Check oil passages and oil pump
for damage or leakage.
d. Start the engine after solving the
problem(s) and recheck the oil
pressure.e. Tighten the oil pressure check
bolt.
ADJUSTING THE PILOT SCREW
1. Adjust:
•Pilot screw "1"
Adjustment steps:
To optimize the fuel flow at a smaller
throttle opening, each machine's pilot
screw has been individually set at the
factory. Before adjusting the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
a. Turn in the pilot screw until it is
lightly seated.
b. Turn out the pilot screw by the
factory-set number of turns.
ADJUSTING THE ENGINE IDLING
SPEED
1. Start the engine and thoroughly
warm it up.
2. Adjust:
• Engine idling speed
Adjustment steps:
a. Adjust the pilot screw.
Refer to "ADJUSTING THE PI-
LOT SCREW" section.
b. Turn the throttle stop screw "1"
until the specified engine idling
speed. Oil filter element cover:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Oil strainer:
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (oil hose):
8 Nm (0.8 m•kg, 5.8
ft•lb)
Oil hose clamp:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Oil filter element drain
bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Crankcase oil drain bolt:
20 Nm (2.0 m•kg, 14
ft•lb)
Oil tank drain bolt:
18 Nm (1.8 m•kg, 13
ft•lb)
Lower engine guard:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Oil quantity:
Periodic oil change:
1.05 L (0.92 Imp qt,
1.11 US qt)
With oil filter replace-
ment:
1.15 L (1.01 Imp qt,
1.22 US qt)
Total amount:
1.30 L (1.14 Imp qt,
1.37 US qt)
Bolt (oil tank):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Oil pressure check bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Pilot screw (example):
2 turns out

3-24
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw "1"
2. Attach:
• Timing light
• Digital tachometer
To the ignition coil lead (orange
lead"1").
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range→Check ro-
tor and pickup assembly.
5. Install:
• Timing mark accessing screw Spark plug gap:
0.7–0.8 mm (0.028–
0.031 in)
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:
YM-33277-A/90890-
03141

4-17
CAMSHAFTS
4. Measure:
• Camshaft-to-cap clearance
Out of specification→Measure
camshaft outside diameter.
Measurement steps:
a. Install the camshaft onto the cylin-
der head.
b. Position a strip of Plastigauge
®
"1" onto the camshaft.
c. Install the clip, dowel pins and
camshaft caps.
• Tighten the bolts (camshaft cap) in
a crisscross pattern from innermost
to outer caps.
• Do not turn the camshaft when
measuring clearance with the Plas-
tigauge
®.
d. Remove the camshaft caps and
measure the width of the Plasti-
gauge
® "1".
5. Measure:
• Camshaft outside diameter "a"
Out of specification→Replace the
camshaft.
Within specification→Replace
camshaft case and camshaft
caps as a set.CHECKING THE CAMSHAFT
SPROCKET
1. Inspect:
• Camshaft sprocket "1"
Wear/damage→Replace the
camshaft assembly and timing
chain as a set.
CHECKING THE
DECOMPRESSION SYSTEM
1. Check:
• Decompression system
Checking steps:
a. Check that the decompression
mechanism cam "1" moves
smoothly.
b. Check that the decompression
mechanism cam lever pin "2"
projects from the camshaft.
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver "1" and wind the ten-
sioner rod up fully clockwise.
• When releasing the screwdriver
by pressing lightly with fingers,
make sure that the tensioner rod
will come out smoothly.
• If not, replace the tensioner as-
sembly.INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
• Apply the molybdenum disulfide oil
on the camshafts.
• Apply the engine oil on the decom-
pression system.
• Squeezing the decompression le-
ver allows the crankshaft to be
turned easily.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
c. Fit the timing chain "3" onto both
camshaft sprockets and install the
camshafts on the cylinder head. Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
:0.08 mm (0.003
in)
Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Camshaft outside diame-
ter:
21.959–21.972 mm
(0.8645–0.8650 in)

4-24
VALVES AND VALVE SPRINGS
2. Measure:
• Compressed spring force "a"
Out of specification→Replace.
b. Installed length
3. Measure:
• Spring tilt "a"
Out of specification→Replace.
CHECKING THE VALVE LIFTERS
1. Inspect:
• Valve lifter
Scratches/damage→Replace
both lifters and cylinder head.INSTALLING THE VALVES
1. Apply:
• Molybdenum disulfide oil
Onto the valve stem and valve
stem seal.
2. Install:
•Valve "1"
• Valve spring seat "2"
• Valve stem seal "3"
• Valve spring "4"
• Valve spring retainer "5"
To cylinder head.
• Make sure that each valve is in-
stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": Orange
Intake (right/left) "b": Green
Exhaust "c": Purple
• Install the valve springs with the
larger pitch "d" facing upward.
e. Smaller pitch
3. Install:
• Valve cotter
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto
the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:
• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil
on the valve stem end.
• Apply the engine oil on the valve lift-
ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
Compressed spring
force:
Intake:
99–114 N at 29.13 mm
(9.9–11.4 kg at 29.13
mm, 22.27–25.57 lb at
1.15 in)
Exhaust:
126–144 N at 29.30
mm (12.6–14.4 kg at
29.30 mm, 28.44–
32.41 lb at 1.15 in)
Spring tilt limit:
Intake:
2.5°/1.7 mm (0.067 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

4-56
CRANKCASE AND CRANKSHAFT
DISASSEMBLING THE
CRANKCASE
1. Separate:
• Right crankcase
• Left crankcase
Separation steps:
a. Remove the crankcase bolts "1",
hose guide "2" and clutch cable
holder "3".
Loosen each bolt 1/4 of a turn at a
time and after all the bolts are loos-
ened, remove them.
b. Remove the right crankcase "4".
• Place the crankcase with its left half
downward and split the right half
apart while lifting it horizontally by
lightly tapping the projection "a" on
it using a soft hammer.
• When splitting it, leave the crank-
shaft and transmission with the left
half.
Use soft hammer to tap on the
case half. Tap only on reinforced
portions of case. Do not tap on
gasket mating surface. Work slow-
ly and carefully. Make sure the
case halves separate evenly. If the
cases do not separate, check for a
remaining case bolt or fitting. Do
not force.
c. Remove the dowel pins and O-
ring.
REMOVING THE CRANKSHAFT
1. Remove:
• Crankshaft "1"
Use the crankcase separating
tool "2".
Do not use a hammer to drive out
the crankshaft.
REMOVING THE CRANKCASE
BEARING
1. Remove:
• Bearing "1"
• Remove the bearing from the
crankcase by pressing its inner
race.
• Do not use the removed bearing.
CHECKING THE TIMING CHAIN
AND TIMING CHAIN GUIDE
1. Inspect:
•Timing chain
Cracks/stiff→Replace the timing
chain and camshaft sprocket as a
set.
2. Inspect:
• Timing chain guide
Wear/damage→Replace.CHECKING THE CRANKCASE
1. Inspect:
• Contacting surface "a"
Scratches→Replace.
• Engine mounting boss "b", crank-
case
Cracks/damage→Replace.
2. Inspect:
• Bearing
Rotate inner race with a finger.
Rough spot/seizure→Replace.
3. Inspect:
•Oil seal
Damage→Replace.
CHECKING THE CRANKSHAFT
1. Measure:
• Runout limit "a"
• Small end free play limit "b"
• Connecting rod big end side
clearance "c"
• Crank width "d"
Out of specification→Replace.
Use the dial gauge and a thick-
ness gauge.
Crankcase separating
tool:
YU-1135-A/90890-
01135
Dial gauge and stand:
YU-3097/90890-01252
Standard
Runo
ut lim-
it:0.03 mm (0.0012
in)0.05
mm
(0.002
in)
Small
end
free
play:0.4–1.0 mm
(0.016–0.039 in)2.0 mm
(0.08 in)
Side
clear-
ance:0.15–0.45 mm
(0.0059–0.0177
in)0.50
mm
(0.02 in)
Crack
width:55.95–56.00
mm (2.203–
2.205 in)—

4-58
CRANKCASE AND CRANKSHAFT
5. Install:
• Dowel pin "1"
• O-ring "2"
• Right crankcase
To left crankcase.
• Apply the lithium soap base grease
on the O-ring.
• Fit the right crankcase onto the left
crankcase. Tap lightly on the case
with soft hammer.
• When installing the crankcase, the
connecting rod should be posi-
tioned at TDC (top dead center).
6. Tighten:
• Hose guide "1"
• Clutch cable holder "2"
• Bolt (crankcase) "3"
Tighten the crankcase tightening
bolts in stage, using a crisscross pat-
tern.
7. Install:
• Oil delivery pipe 2 "1"
• O-ring "2"
• Bolt (oil delivery pipe 2) "3"
Apply the lithium soap base grease
on the Orings.
8. Install:
• Timing chain "1"
• Timing chain guide (intake side)
"2"
• Bolt (timing chain guide) "3"
9. Remove:
•Sealant
Forced out on the cylinder mating
surface.
10. Apply:
• Engine oil
To the crank pin, bearing and oil
delivery hole.
11. Check:
• Crankshaft and transmission op-
eration.
Unsmooth operation→Repair. Bolt (crankcase):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Bolt (oil delivery pipe 2):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain guide):
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 jetCONSTRUCTION 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-
tyAir
pres-
sure
(alti-
tude)Mix-
tureSet-
ting
High HighLow
(high)Rich-
erLean-
er
Low LowHigh
(low)Lean-
erRich-
er
Standard main jet #178