2010 YAMAHA YZ250F radiator

CONTENTS
CHAPTER 1GENERAL
INFORMATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
INCLUDED PARTS .......... 1-6
IMPORTANT
INFORMATION................. 1-6
CHECKING OF
CONNECTION .................. 1-7
SPECIAL TOOLS ............. 1-8
CONTROL
FUNCTIONS ................... 1-12
STARTING AND
BREAK-IN ...................... 1-13
TORQUE-CHECK
POINTS........................... 1-15
CLEANING AND
STORAGE ...................... 1-16
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-10
LUBRICATION
DIAGRAMS .................... 2-16
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3 REGULAR
INSPECTION AND ADJUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-24
CHAPTER 4 ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-5
CARBURETOR................. 4-7
CAMSHAFTS.................. 4-14
CYLINDER HEAD........... 4-19
VALVES AND VALVE
SPRINGS ........................ 4-21
CYLINDER AND
PISTON ........................... 4-25
CLUTCH ......................... 4-29
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-33
BALANCER .................... 4-38
OIL PUMP ....................... 4-40
KICK SHAFT AND
SHIFT SHAFT ................. 4-44
CDI MAGNETO............... 4-49
ENGINE REMOVAL ....... 4-51
CRANKCASE AND
CRANKSHAFT ............... 4-55
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK................... 4-61
CHAPTER 5CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................5-1
FRONT BRAKE AND
REAR BRAKE ..................5-6
FRONT FORK .................5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-31
REAR SHOCK
ABSORBER ....................5-36
CHAPTER 6
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........6-2
IGNITION SYSTEM...........6-3
THROTTLE POSITION
SENSOR SYSTEM ...........6-6
CHAPTER 7 TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6

1-5
DESCRIPTION
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. Air filter
17. Drive chain
18. Shift pedal
19. Oil level check window
20. Front fork

1-9
SPECIAL TOOLS
Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352These tools are used for checking
the cooling system.
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.
Cap bolt wrench
YM-01500, 90890-01500 This tool is used to loosen or tighten
the base valve.
Cap bolt ring wrench
YM-01501, 90890-01501 This tool is used to loosen or tighten
the damper assembly.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Spoke nipple wrench
YM-01521, 90890-01521 This tool is used to tighten the
spoke.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Tool name/Part number How to use Illustration

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) ←
----

2-10
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque ti ghtening after break-in or before each race.
Item StandardLimit
Ignition system: Advancer type Electrical----
CDI: Magneto-model (stator)/manufacturer 17D-50/YAMAHA----
Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F)
(Green–Brown) ----
Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black–Pink) ----
Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ----
CDI unit-model/manufacturer 17D-50/YAMAHA (For USA and CDN) ----
17D-60/YAMAHA (Except for USA and
CDN) ----
Ignition coil: Model/manufacturer 5UL-20/DENSO----
Minimum spark gap 6 mm (0.24 in)----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11
Cylinder head (bolt) M9 × 1.25 4 38 3.8 27
Cylinder head (nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Balancer weight M6 × 1.0 2 10 1.0 7.2
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Impeller M8 × 1.25 1 14 1.4 10
Radiator hose clamp M6 × 1.0 10 2 0.2 1.4
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Water pump housing M6 × 1.0 4 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
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

2-13
TIGHTENING TORQUES
△Front brake disc M6 × 1.0 6 12 1.2 8.7
△ Rear brake disc M6 × 1.0 6 14 1.4 10
△ Footrest bracket and frame M10 × 1.25 4 55 5.5 40
△ Brake pedal M8 × 1.25 1 26 2.6 19
△ Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△ Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
△ Rear wheel axle and axle nut M22 × 1.5 1 135 13.5 98
△ Nipple (spoke) —72 3 0.3 2.2
△ Rear wheel sprocket M8 × 1.25 6 42 4.2 30
△ Rear brake disc cover M6 × 1.0 2 10 1.0 7.2
△ Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 21 2.1 15
Engine mounting:
△ Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△ Upper engine bracket and frame M8 × 1.25 4 34 3.4 25
△ Front engine bracket and frame M8 × 1.25 4 34 3.4 25
△ Engine and engine bracket (upper) M10 × 1.25 2 55 5.5 40
Lower engine guard M6 × 1.0 3 10 1.0 7.2
CDI unit bracket M6 × 1.0 2 7 0.7 5.1
Cable guide and frame M6 × 1.0 2 7 0.7 5.1
△ Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△ Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△ Connecting rod and frame M14 × 1.5 1 80 8.0 58
△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△ Rear frame (upper) M8 × 1.25 2 32 3.2 23
△ Rear frame (lower) M8 × 1.25 2 32 3.2 23
△ Swingarm and brake hose holder M5 × 0.8 4 3 0.3 2.2
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
△ Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△ Fuel tank M6 × 1.0 1 9 0.9 6.5
△ Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 2 7 0.7 5.1
Side cover set bracket and fuel tank M6 × 1.0 2 7 0.7 5.1
Fitting band set screw and fuel tank M6 × 1.0 1 7 0.7 5.1
△ Air scoop and fuel tank M6 × 1.0 2 7 0.7 5.1
△ Air scoop and radiator guard M6 × 1.0 4 7 0.7 5.1
Air scoop and frame M6 × 1.0 2 7 0.7 5.1
Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-14
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL Radiator mounting boss and frame
M10 × 1.25 2 20 2.0 14
△ Front fender M6 × 1.0 4 10 1.0 7.2
△ Rear fender (front) M6 × 1.0 2 7 0.7 5.1
△ Rear fender (rear) M6 × 1.0 2 16 1.6 11
△ Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
△ Number plate M6 × 1.0 1 7 0.7 5.1
Part to be tightened
Thread size Q'tyTightening torque
Nm m•kg ft•lb
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9

2-18
CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose
2. Radiator hose 1
3. Cylinder head breather hose
4. Radiator hose 3
5. Clutch cable
6. Throttle position sensor lead
7. Hot starter cable
8. Fuel hose
9. Carburetor breather hose10. Carburetor overflow hose
11. Throttle position sensor lead
protector
12. Throttle position sensor cover A. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Aligh the paint mark on the cylin- der head breather hose with the
front end of the hose guide.
A
B
A C
B
C