2010 YAMAHA YZ250F check engine

6-3
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*marked: Only when the ignition checker is used.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
Spark gap test Spark→ *Clean or replace spark plug.
No spark ↓
Check entire ignition system for connection.
(couplers, leads and ignition coil) No good
→
Repair or replace.
OK ↓
Check engine stop switch. No good→Replace.
OK ↓
Check ignition coil. (primary coil and secondary
coil) No good
→
Replace.
OK ↓
Check CDI magneto. (pickup coil and charging
coil) No good
→
Replace.
OK ↓
Check neutral switch. No good→Repair or replace.
OK ↓
Replace CDI unit.
Dynamic spark tester: YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112

6-4
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the ignition coil from spark plug.
2. Remove the ignition coil cap.
3. Connect the dynamic spark tester "1" (ignition ch ecker "2") as
shown.
• Ignition coil "3"
• Spark plug "4"
A. For USA and CDN
B. Except for USA and CDN
4. Kick the kickstarter crank.
5. Check the ignition spark gap.
6. Start engine, and increase spark gap until misfire occurs. (for USA
and CDN only)
CHECKING THE COUPLERS,
LEADS AND IGNITION COIL
CONNECTION
1. Check: • Couplers and leads connection
Rust/dust/looseness/short-circuit
→ Repair or replace.
• Ignition coil and spark plug as
they are fitted
Push in the ignition coil until it
closely contacts the spark plug
hole in the cylinder head cover. CHECKING THE ENGINE STOP
SWITCH
1. Inspect:
• Engine stop switch conduction
Not conductive while it is pushed →
Replace.
Conductive while it is freed →Re-
place.
Set the tester selection position to " Ω
× 1".
CHECKING THE IGNITION COIL
1. Remove the ignition coil cap.
2. Inspect: • Primary coil resistance
Out of specification →Replace. 3. Inspect:
• Secondary coil resistanceOut of specification →Replace.
4. Inspect: • Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"Wear →Replace.
CHECKING THE CDI MAGNETO
1. Inspect: • Pickup coil resistance
Out of specification →Replace.
Minimum spark gap:
6.0 mm (0.24 in)
Tester (+) lead →Black/White lead
"1"
Tester (-) lead →Black lead "2"
Result Conductive (while the
engine stop switch is
pushed)
Tester (+) lead →Orange lead "1"
Tester (-) lead →Black lead "2"
Primary
coil resis-
tance Tester se-
lector posi-
tion
0.08–0.10
Ω at 20 °C (68 °F) Ω × 1
/W
BB
Tester (+) lead →Orange lead "1"
Tester (-) lead →Spark plug termi-
nal "2"
Secondary coil resis- tance Tester se-
lector posi- tion
4.6–6.8
k Ωat 20 °C
(68 °F) k
Ω × 1
Tester (+) lead →Red lead "1"
Tester (-) lead →White lead "2"
Pickup coil resistance Tester se-
lector posi-
tion
248-372 Ω
at 20 °C (68 °F) Ω
×100
B
WBr
G P
R

6-7
THROTTLE POSITION SENSOR SYSTEM
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check: • Couplers and leads connectionRust/dust/looseness/short-circuit
→ Repair or replace.
CHECKING THE THROTTLE
POSITION SENSOR COIL
1. Inspect: • Throttle position sensor coil resis-tance
Out of specification →Replace.
2. Loosen: • Throttle stop screw "1"
Turn out the throttle stop screw until
the throttle shaft is in the full close po-
sition.
3. Inspect:• Throttle position sensor coil vari-able resistance
Check that the resistance in in-
creased as the throttle grip is
moved from the full close position
to the full open position.
Out of specification →Replace.
CHANGING AND ADJUSTING THE
THROTTLE POSI TION SENSOR
1. Remove: • Throttle position sensor coupler
• Carburetor
2. Remove: • Screw (throttle position sensor) "1"
• Throttle position sensor "2"
Loosen the screw (throttle position
sensor) using the T25 bit.
3. Replace: • Throttle position sensor 4. Install:
• Throttle position sensor "1"
• Screw (throttle position sensor) "2"
• Align the slot "a" in the throttle posi-
tion sensor with the projection "b"
on the carburetor.
• Temporarily tighten the screw
(throttle position sensor).
5. Install:•Carburetor
• Throttle position sensor coupler
6. Adjust: • Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section in
the CHAPTER 3.
7. Insert the thin electric conductors "2" (lead) into the throttle position
sensor coupler "1", as shown, and
connect the tester to them.
• Do not insert the electric conduc-
tors more than required because
it may reduce the waterproof
function of the coupler.
• Make sure that a short-circuit does not develop between the
terminals because it may cause
damage to electrical compo-
nents.
Tester (+) lead →Blue lead "1"
Tester (-) lead →Black lead "2"
Throttle po- sition sen-
sor coil
resistance Tester se-
lector posi- tion
4–6 k Ω at
20°C (68 °F) k
Ω×1
Y
B
L
Tester (+) lead
→Yellow lead "1"
Tester (-) lead →Black lead "2"
Throttle position sensor coil vari- able resistance Tes-
ter se-
lector posi- tion
Full
closed Full
opened
kΩ×1
Zero –3
kΩat
20°C
(68 °F) 4–6
k Ωat
20 °C
(68 °F)
Y
B
L
Tester (+) lead
→Yellow lead "3"
Tester (-) lead →Black lead "4"

6-8
THROTTLE POSITION SENSOR SYSTEM
8. Start the engine.
9. Adjust:• Throttle position sensor output voltage
Adjustment steps:
a. Adjust the installation angle of the throttle position sensor "1" to ob-
tain the specified output voltage.
Measure the output voltage accurate-
ly with a digital electronic voltmeter
that gives an easy reading of a small
voltage.
10. Put the aligning marks "a" on the throttle position sensor and car-
buretor.
11. Stop the engine.
12. Remove the carburetor.
13. Tighten: • Screw (throttle position sensor) "1"
Tighten the screw (throttle position
sensor) using the T25 bit.
14. Install the carburetor. CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Start the engine.
3. Inspect:
• Throttle position sensor input volt-age
Out of specification →Replace the
CDI unit.
Throttle po- sition sen-
sor output voltage Tester se-
lector posi- tion
0.58–0.78 V DCV
Tester (+) lead →Blue lead "1"
Tester (-) lead →Black/Blue lead
"2"
Throttle po-sition sen- sor input voltage Tester se-
lector posi-
tion
4–6 V DCV-20
LY
B/L

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 al low 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 jet CONSTRUCTION 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. #182
2. #178
3. #180
Air
tem p. Hu-
midi- ty Air
pres- sure
(alti-
tude) Mix-
ture Set-
ting
High High Low
(high) Rich-
er Lean-
er
Low Low High
(low) Lean-
er Rich-
er
Standard main jet #180
7

7-4
ENGINE
SPECIFICATIONS OF JET NEEDLE
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM For USA and CDN
Diameter of straight portion
Rich Lean
NPQRS TU
Rich 1 richer NDJN-5 NDJP-5 NDJQ-5 NDJR-5 NDJS-5 NDJT-5 NDJU-5 0.5 richer NCVN-4 NCVP-4 NCVQ-4 NCVR-4 NCVS-4 NCVT-4 NCVU-4STD NDJN-4 NDJP-4 NDJQ-4 NDJR-4 NDJS-4 NDJT-4 NDJU-4
0.5 leaner NCVN-3 NCVP-3 NCVQ-3 NCVR-3 NCVS-3 NCVT-3 NCVU-3
Lean 1 leaner NDJN-3 NDJP-3 NDJQ-3 NDJR-3 NDJS-3 NDJT-3 NDJU-3
Except for USA and CDN Diameter of straight portion
Rich Lean
NPQRS TU
Rich 1 richer NFLN-7 NFLP-7 NFLQ-7 NHKR-5 NFLS-7 NFLT-7 NFLU-7 0.5 richer NFPN-6 NFPP-6 NFPQ-6 NFPR-6 NFPS-6 NFPT-6 NFPU-6STD NFLN-6 NFLP-6 NFLQ-6 NHKR-4 NFLS-6 NFLT-6 NFLU-6
0.5 leaner NFPN-5 NFPP-5 NFPQ-5 NFPR-5 NFPS-5 NFPT-5 NFPU-5
Lean 1 leaner NFLN-5 NFLP-5 NFLQ-5 NHKR-3 NFLS-5 NFLT-5 NFLU-5
Symptom Setting Checking
At full throttle Hard breathing
Shearing noise
Whitish spark plug ↓
Lean mixture Increase main jet calibration no. (Gradual-
ly)
Discoloration of spark plug
→If tan color, it
is in good condition.
If cannot be corrected: Clogged float valve seat
Clogged fuel hose
Clogged fuel cock
Check that the accelerator pump operates
smoothly.
At full throttle Speed pick-up stops
Slow speed pick-up
Slow response
Sooty spark plug
↓
Rich mixture Decrease main jet calibration no. (Gradual-
ly)
Discoloration of spark plug
→If tan color, it
is in good condition.
If cannot be corrected: Clogged air filter
Fuel overflow from carburetor
Lean mixture Lower jet needle clip position. (1 groove
down)
The clip position is the jet needle groove on
which the clip is installed.
The positions are numbered from the top.
Check that the accelerator pump operates
smoothly. (except for rich mixture symp-
tom).
Rich mixture
Raise jet needle clip position. (1 groove up)
1/4–3/4 throttle Hard breathing
Lack of speed Lower jet needle clip position. (1 groove
down)
1/4–1/2 throttle Slow speed pick-up
Poor acceleration Raise jet needle clip position. (1 groove up)
Jet needleClip
Groove 7 Groove 6
Groove 5
Groove 4
Groove 3
Groove 2
Groove 1
Leaner
(Standard) Richer

7-5
ENGINE
This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions
of the engine.
Closed to 1/4 throttle Hard breathing
Speed down Use jet needle with a smaller diam
eter. Slow-speed-circuit passage
Clogged→Clean.
Overflow from carburetor
Closed to 1/4 throttle Poor acceleration Use jet needle with a larger diameter.
Raise jet needle clip position. (1 groove up)
Poor response in the low to in-
termediate speeds Raise jet needle clip position.
If this has no effect, lower the jet needle clip
position.
Poor response when throttle is
opened quickly Check overall settings.
Use main jet with a lower calibration no.
Raise jet needle clip position. (1 groove up)
If these have no effect, use a main jet with
a higher calibration no. and lower the jet
needle clip position. Check air filter for fouling.
Check that the accelerator pump operates
smoothly.
Symptom
Setting Checking