2010 YAMAHA YZ250F maintenance

2-8
MAINTENANCE SPECIFICATIONS
CHASSISLubrication 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 sizeWidth 121.4 mm (4.8 in)----
Height 235 mm (9.3 in)----
Thickness 28 mm (1.1 in)----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi)----
Radiator capacity (total) 0.64 L (0.56 Imp qt, 0.68 US qt)----
Water pump Type Single-suction centrifugal pump----
Item
StandardLimit
Item StandardLimit
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 541 cm
3 (19.0 lmp oz,
18.3 US oz) 528 cm3 (18.6 lmp oz,
17.9 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 250 mm (9.84 in)←
Preload length
1.5–20 mm (0.06–0.79
in) ←
----
Spring rate, STD K = 52.0 N/mm (5.30 kg/
mm, 296.8 lb/in) ←
----
Optional spring Yes← ----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2,
142 psi) ←
----

2-9
MAINTENANCE SPECIFICATIONS
Swingarm:Swingarm free play limitEnd ---- 1.0 mm (0.04
in)
Wheel: Front wheel type Spoke wheel----
Rear wheel type Spoke wheel----
Front rim size/materia l 21 × 1.60/Aluminum ----
Rear rim size/materia l 19 × 1.85/Aluminum ----
Rim runout limit: Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain: USA, CDN EUROPE, AUS, NZ, ZA
Type/manufacturer DID520DMA2 SDH/
DAIDO ←
----
Number of links 111 links + joint 113 links + joint ----
Chain slack 50–60 mm (2.0–2.4 in)←----
Chain length (15 links) ----←242.9 mm
(9.563 in)
Front disc brake: Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in)250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in)1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in)----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4----
Rear disc brake: Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in)245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ----0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in)1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in)----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1----
Brake fluid type DOT #4----
Brake lever and brake pedal: Brake lever position 95 mm (3.74 in)----
Brake pedal height (vertical height above footrest
top) Zero mm (Zero in)
----
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
StandardLimit

3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to mainten ance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
If you are a doubt as to what intervals to follow in mainta ining and lubricating your machine, consult your Yamaha dealer
• Periodic inspection is essential in making full use of the ma chine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below.
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
ENGINE OIL Replace ●●
Inspect ●●
OIL FILTER ELEMENT, OIL
STRAINER Clean ●
VALVES Check the valve clearances ●● The engine must be cold.
Inspect ●Check the valve seats and valve
stems for wear.
Replace ●
VALVE SPRINGS Inspect ●Check the free length and the tilt.
Replace ●
VALVE LIFTERS Inspect ●Check for scratches and wear.
Replace ●
CAMSHAFTS Inspect the camshaft surface.
Inspect ●Inspect the decompression system.
Replace ●
TIMING CHAIN SPROCKETS,
TIMING CHAIN Inspect ●Check for wear on the teeth and for
damage.
Replace ●
PISTON Inspect ●●Inspect crack.
Clean ●Inspect carbon deposits and eliminate
them.
Replace ●It is recommended that the piston pin
and ring are also replaced at the same
time.
PISTON RING Inspect ●Check ring end gap.
Replace ●●
3

3-2
MAINTENANCE INTERVALS
PISTON PINInspect ●
Replace ●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean ●Change gasket.
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 ●
Replace fiber ●●** When the exhaust sound becomes
louder or when a performance drop is
felt
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 ●
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

3-3
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

3-4
MAINTENANCE INTERVALS
REAR SHOCK ABSORBERInspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Replace spring seat ●Every one year
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
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-40
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 ●
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

3-8
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)