2010 YAMAHA YZ250F check engine

3-3
MAINTENANCE INTERVALS
COOLING SYSTEMCheck 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 ●●
OIL STRAINER Clean ●
ENGINE GUARD Replace ●Breakage
FRAME Clean and inspect ●●
FUEL TANK, COCK Clean and inspect ●●
BRAKES Adjust lever position and pedal
height ●●
Lubricate pivot point ●●
Check brake disc surface ●●
Check fluid level and leakage ●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts ●●
Replace pads ●
Replace brake fluid ●Every one year
FRONT FORKS Inspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
Item
After
break- in Every
race
(about 2.5
hours)
Every third
(about 7.5
hours) Every
fifth
(about 12.5
hours)
As re-
quired Remarks

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 RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-6 – 7
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage. P.1-13
Engine oil Check that the oil level is correct. Check the crankcase and oil line
for leakage.
P.3-9 – 10
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-7
Throttle grip/Housing Check 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 ef fect of front and rear brake. P.3-14 – 16
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly.
P.3-17 – 18
Wheels Check for excessive wear and ti
re pressure. Check for loose
spokes and have no excessive play. P.3-20 – 21
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play. P.3-21 – 22
Front forks and rear shock
absorber Check that they operate smooth
ly 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 whee l sprocket tightening bolt is not loose.P.3-17
Lubrication Check for smooth operation. Lubricate if necessary. P.3-23
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-15
Lead connectors Check that the CDI magneto, CDI
unit, and ignition coil are con-
nected tightly. P.1-7
Settings Is 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 – 10

3-6
ENGINE
ENGINE
CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level place, and hold it in an upright po-
sition.
2. Remove: • Radiator cap
3. Check: • Coolant level "a"Coolant level low →Add coolant.
1. Radiator
CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en- gine.
2. Remove: • Coolant drain bolt "1"
3. Remove: • Radiator capDrain the coolant completely.
4. Clean:
• Cooling systemThoroughly flush the cooling sys-
tem with clean tap water.
5. Install: • Copper washer
• Coolant drain bolt
6. Fill: • Radiator
•EngineTo specified level.
• Do not mix more than one type of
ethylene glycol antifreeze con-
taining corrosion inhibitors for
aluminum engine.
• Do not use water containing im- purities or oil.
Handling notes of coolant:
The coolant is harmful so it should be
handled with special care.
• When coolant splashes to your
eye.
Thoroughly wash your eye with
water and see your doctor.
• When coolant splashes to your clothes.
Quickly wash it away with water
and then with soap.
• When coolant is swallowed. Quickly make him vomit and take
him to a doctor.
7. Install:• Radiator cap
Start the engine and warm it up
for a several minutes.
8. Check:
• Coolant levelCoolant level low →Add coolant.
CHECKING THE RADIATOR CAP
1. Inspect: • Seal (radiator cap) "1"
• Valve and valve seat "2"Crack/damage →Replace.
Exist fur deposits "3" →Clean or
replace.
CHECKING THE RADIATOR CAP
OPENING PRESSURE
1. Attach: • Radiator cap tester "1" and adapt-er "2"
Apply water on the radiator cap seal.
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant: High quality ethylene
glycol anti-freeze con-
taining anti -corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio: 50%/50%
Coolant capacity: 1.00 L (0.88 Imp qt, 1.06
US qt)
Radiator cap tester:
YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352

3-7
ENGINE
3. Radiator cap
2. Apply the specified pressure.
3. Inspect: • PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Replace.
CHECKING THE COOLING
SYSTEM
1. Inspect: • Coolant level
2. Attach: • Radiator cap tester "1" and adapt-
er "2"
3. Apply the specified pressure.
• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.
4. Inspect: • PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Repair.
•Radiator "1"
• Radiator hose joint "2" Coolant leakage →Repair or re-
place.
• Radiator hose "3" Swelling →Replace. ADJUSTING THE CLUTCH LEVER
POSITION
1. Adjust:
• Clutch lever position
Clutch lever position adjustment
steps:
a. Loosen the locknuts "1".
b. Turn the adjusting bolt "2" until the clutch lever position "a" is in the
desiered position .
c. Tighten the locknuts.
2. Adjust: • Clutch cable free play
Refer to "ADJUSTING THE
CLUTCH CABLE FREE PLAY".
ADJUSTING THE CLUTCH CABLE
FREE PLAY
1. Check: • Clutch lever free play "a"Out of specification →Adjust.
2. Adjust: • Clutch lever free play
Clutch lever free play adjustment
steps:
a. Loosen the locknuts "1".
b. Turn the adjuster "2" until free play "a" is within the specified lim-
its.
c. Tighten the locknuts.
• Before adjustment, expose the ad- juster by moving the boot "3" and
cap "4" away.
• Make minute adjustment on the le- ver side using the adjuster "5".
• After adjustment, check proper op-
eration of clutch lever.
3. Install:•Cap "1"
• Boot "2"
Place the tip "a" of the cap in the boot.
ADJUSTING THE THROTTLE
CABLE FREE PLAY
1. Check:• Throttle grip free play "a"
Out of specification →Adjust.
Radiator cap opening
pressure:
110 kPa (1.1 kg/cm
2,
15.6 psi)
Radiator cap tester: YU-24460-01/90890-
01325
Radiator cap tester
adapter:
YU-33984/90890-01352
Standard pressure: 180 kPa (1.8 kg/cm
2,
25.6 psi)
Locknut: 5 Nm (0.5 m•kg, 3.6
ft•lb)
Clutch lever free play "a"
: 7–12 mm (0.28–0.47 in)
Locknut: 4 Nm (0.4 m•kg, 2.9
ft•lb)
Throttle grip free play
"a": 3–5 mm (0.12–0.20 in)

3-8
ENGINE
2. Adjust:• Throttle grip free play
Throttle grip free play adjustment
steps:
a. Slide the adjuster cover.
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 greaseOn 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, remo ve 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 elementDamage →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.
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
6. Apply:• Lithium soap base grease On the matching surface "a" on air
filter element.
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 levelThe engine oil level should be be-
tween the minimum level mark "a"
and maximum level mark "b".
Below the minimum level mark →
Add the recommended engine oil
to the proper level.
• 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 or
higher and do not use oils la-
beled "ENERGY CONSERVING
II".
• Do not allow fore ign materials to
enter the crankcase.
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 strainerClogged →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 brand:
YAMALUBE
Recommended engine
oil typeSAE10W-30, SAE 10W-
40, SAE 10W-50, SAE
15W-40, SAE 20W-40 or
SAE 20W-50
Recommended engine
oilgrade API service SG type or
higher, JASO standard
MA

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.
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:0.95 L (0.84 Imp qt,
1.00 US qt)
With oil filter replace-
ment:
1.05 L (0.92 Imp qt,
1.11 US qt)
Total amount:
1.20 L (1.06 Imp qt,
1.27 US qt)
Bolt (oil tank): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Oil pressure check bolt: 10 Nm (1.0 m•kg, 7.2
ft•lb)
Pilot screw (example): 1-3/4 turns out

3-11
ENGINE
b. Turn the throttle stop screw "1" until the specified engine idling
speed.
Using a digital engine tachometer for
idle speed adjustment, detect the en-
gine idling speed by bringing the
sensing element "c" of the engine ta-
chometer close to the ignition coil "2".
ADJUSTING THE VALVE
CLEARANCE
• This section is intended for those who have basic knowledge and skill
concerning the servicing of Yama-
ha motorcycles (e.g., Yamaha deal-
ers, service engineers, etc.) Those
who have little knowledge and skill
concerning servicing are requested
not to undertake inspection, adjust-
ment, disassembly, or reassembly
only by reference to this manual. It
may lead to servicing trouble and
mechanical damage.
• The valve clearance should be ad-
justed when the engine is cool to
the touch.
• The piston must be at Top Dead
Center (T.D.C.) on compression
stroke to check or adjust the valve
clearance.
1. Remove:•Seat
•Fuel tankRefer to "SEAT, FUEL TANK
AND SIDE COVERS" section in
the CHAPTER 4.
2. Remove:
• Spark plug
• Cylinder head coverRefer to "CAMSHAFTS" section
in the CHAPTER 4.
3. Remove: • Timing mark accessing screw "1"
• Crankshaft end accessing screw "2"
• O-ring
4. Check: • Valve clearanceOut of specification →Adjust.
Checking steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
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.
In order to be sure that the piston is at
Top Dead Center, the punch mark "c"
on the exhaust camshaft and the
punch mark "d" on the intake cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion.
c. Measure the valve clearance "e" using a feeler gauge "1".
Record the measured reading if the
clearance is incorrect.
5. Adjust:
• Valve clearance
Adjustment steps:
a. Remove the camshaft (intake and exhaust).
Refer to "CAMSHAFTS" section
in the CHAPTER 4.
b. Remove the valve lifters "1" and the pads "2".
• Place a rag in the timing chain
space to prevent pads from falling
into the crankcase.
• Identity each valve lifter and pad
position very carefully so that they
can be reinstalled in their original
place.
To increase idle speed →Turn the
throttle stop screw "1" in "a".
To decrease idle speed →Turn the
throttle stop screw "1" out "b".
Engine idling speed:1,900–2,100 r/min
Valve clearance (cold):Intake valve:
0.12–0.17 mm
(0.0047–0.0067 in)
Exhaust valve: 0.17–0.22 mm
(0.0067–0.0087 in)