2011 YAMAHA YZ250F Owners Manual

4-15
CAMSHAFTS
REMOVING THE CAMSHAFTS
Order Part name Q'ty Remarks
1 Timing mark accessing screw1 Refer to removal section.
2 Crankshaft end accessing screw 1 Refer to removal section.
3 Timing chain tensioner cap bolt 1 Refer to removal section.
4 Timing chain tensioner 1 Refer to removal section.
5 Camshaft cap 2 Refer to removal section.
6 Clip 2 Refer to removal section.
7 Exhaust camshaft 1 Refer to removal section.
8 Intake camshaft 1 Refer to removal section.

4-16
CAMSHAFTS
REMOVING THE CAMSHAFT
1. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
2. Align:
• T.D.C. mark
With align mark.
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.
3. Remove:
• Timing chain tensioner cap bolt
"1"
• Timing chain tensioner "2"
• Gasket4. Remove:
• Bolt (camshaft cap) "1"
• Camshaft cap "2"
• Clip
Remove the bolts (camshaft cap) in a
crisscross pattern, working from the
outside in.
The bolts (camshaft cap) must be
removed evenly to prevent dam-
age to the cylinder head, cam-
shafts or camshaft caps.
5. Remove:
• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to
prevent it from falling into the crank-
case.
CHECKING THE CAMSHAFT
1. Inspect:
• Cam lobe
Pitting/scratches/blue discolor-
ation→Replace.
2. Measure:
• Cam lobe length "a" and "b"
Out of specification→Replace.3. Measure:
• Runout (camshaft)
Out of specification→Replace.
Cam lobes length:
Intake "a":
30.330–30.430 mm
(1.1941–1.1980 in)
:
30.230 mm (1.1902 in)
Intake "b":
22.45–22.55 mm
(0.8839–0.8878 in)
:
22.35 mm (0.8799 in)
Exhaust "a":
30.399–30.499 mm
(1.1968–1.2007 in)
:
30.299 mm (1.1929 in)
Exhaust "b":
22.45–22.55 mm
(0.8839–0.8878 in)
:
22.35 mm (0.8799 in)
Runout (camshaft):
Less than 0.03 mm
(0.0012 in)

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
Plastigauge
®.
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" proj-
ects 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. 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)

4-18
CAMSHAFTS
c. Fit the timing chain "3" onto both
camshaft sprockets and install the
camshafts on the cylinder head.
The camshafts should be installed
onto the cylinder head so that the
punch mark "c" on the exhaust cam-
shaft and the punch mark "d" on the
intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
Do not turn the crankshaft during
the camshaft installation. Damage
or improper valve timing will re-
sult.
d. Install the clips, camshaft caps "4"
and bolts (camshaft cap) "5".
• Before installing the clips, cover the
cylinder head with a clean rag to
prevent the clips from into the cylin-
der head cavity.
• Apply the molybdenum disulfide oil
on the thread of the bolts (camshaft
cap).
• Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
The bolts (camshaft cap) must be
tightened evenly, or damage to the
cylinder head, camshaft caps, and
camshaft will result.
2. Install:
• Timing chain tensioner
Installation steps:
a. While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver and wind the tension-
er rod up fully clockwise.
b. With the rod fully wound and the
chain tensioner UP mark "a" fac-
ing upward, install the gasket "1"
and the timing chain tensioner "2",
and tighten the bolt "3" to the
specified torque.
c. Release the screwdriver, check
the tensioner rod to come out and
tighten the gasket "4" and the cap
bolt "5" to the specified torque.
3. Turn:
• Crankshaft
Counterclockwise several turns.4. Check:
• Rotor T.D.C. mark
Align with the crankcase align
mark.
• Camshaft match marks
Align with the cylinder head sur-
face.
Out of alignment→Adjust.
5. Install:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
6. Install:
• Timing chain guide (top side) "1"
• Cylinder head cover gasket "2"
• Cylinder head cover "3"
• Bolt (cylinder head cover) "4"
Apply the sealant on the cylinder
head cover gasket.
7. Install:
• Cylinder head breather hose
• Spark plug Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain ten-
sioner):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Tensioner cap bolt:
7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (cylinder head cov-
er):
10 Nm (1.0 m•kg, 7.2
ft•lb)
YAMAHA Bond No. 1215
(ThreeBond
® No. 1215):
90890-85505
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)

4-19
CYLINDER HEAD
CYLINDER HEAD
REMOVING THE CYLINDER HEAD
Order Part name Q'ty Remarks
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Exhaust pipe and silencerRefer to "EXHAUST PIPE AND SILENCER"
section.
Radiator hose 1 Disconnect at cylinder head side.
Carburetor Refer to "CARBURETOR" section.
Camshaft Refer to "CAMSHAFTS" section.
Upper engine bracket Refer to "ENGINE REMOVAL" section.
1 Radiator pipe 1
2 Oil delivery pipe 1
3Nut 2
4 Bolt [L = 135 mm (5.31 in)] 2
5 Bolt [L = 145 mm (5.71 in)] 2
6 Cylinder head 1
7 Timing chain guard (exhaust side) 1

4-20
CYLINDER HEAD
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Carbon deposits (from the com-
bustion chambers)
Use a rounded scraper.
Do not use a sharp instrument to
avoid damaging or scratching:
• Spark plug threads
• Valve seats
2. Inspect:
• Cylinder head
Scratches/damage→Replace.
Replace the titanium valves with the
cylinder head.
Refer to "CHECKING THE
VALVE".
3. Measure:
• Cylinder head warpage
Out of specification→Resurface.
Warpage measurement and resur-
facing steps:
a. Place a straightedge and a feeler
gauge across the cylinder head.
b. Use a feeler gauge to measure
the warpage.
c. If the warpage is out of specifica-
tion, resurface the cylinder head.
d. Place a 400–600 grit wet sandpa-
per on the surface plate, and re-
surface the head using a figure-
eight sanding pattern.
To ensure an even surface rotate the
cylinder head several times.
INSTALLING THE CYLINDER
HEAD
1. Install:
• Dowel pin "1"
• Cylinder head gasket "2"
• Timing chain guide (exhaust side)
"3"
• Cylinder head "4"
While pulling up the timing chain, in-
stall the timing chain guide (exhaust
side) and cylinder head.
2. Install:
• Washer "1"
• Cable guide "2"
• Bolts [L = 145 mm (5.71 in)] "3"
• Bolts [L = 135 mm (5.31 in)] "4"
•Nuts "5"
• Apply the molybdenum disulfide
grease on the thread and contact
surface of the bolts.
• Follow the numerical order shown
in the illustration. Tighten the bolts
and nuts in two stages.
3. Install:
• Copper washer "1"
• Oil delivery pipe "2"
• Union bolt (M8) "3"
• Union bolt (M10) "4"
First tighten the union bolts temporar-
ily. Then retighten them with the width
"a" across flats of the oil delivery pipe
held tight with a spanner.
4. Install:
• Radiator pipe "1"
• Bolt (radiator pipe) "2" Cylinder head warpage:
Less than 0.05 mm
(0.002 in)
Bolts [L = 145 mm (5.71
in)]:
38 Nm (3.8 m•kg, 27
ft•lb)
Bolts [L = 135 mm (5.31
in)]:
38 Nm (3.8 m•kg, 27
ft•lb)
Nuts:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Union bolt (M8):
18 Nm (1.8 m•kg, 13
ft•lb)
Union bolt (M10):
20 Nm (2.0 m•kg, 14
ft•lb)
Bolt (radiator pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-21
VALVES AND VALVE SPRINGS
VALVES AND VALVE SPRINGS
REMOVING THE VALVES AND VALVE SPRINGS
Order Part name Q'ty Remarks
Cylinder head Refer to "CYLINDER HEAD" section.
1 Valve lifter 5 Refer to removal section.
2 Adjusting pad 5 Refer to removal section.
3 Valve cotter 10 Refer to removal section.
4 Valve spring retainer 5
5 Valve spring 5
6 Valve stem seal 5
7 Valve spring seat 5
8 Exhaust valve 2
9 Intake valve 3

4-22
VALVES AND VALVE SPRINGS
REMOVING THE VALVE LIFTER
AND VALVE COTTER
1. Remove:• Valve lifter "1"
• Pad "2"
Identify each lifter "1" and pad "2" po-
sition very carefully so that they can
be reinstalled in their original place.
2. Check:• Valve sealingLeakage at the valve seat →In-
spect the valve face, valve seat
and valve seat width.
Checking steps:
a. Pour a clean solvent "1" into the intake and exhaust ports.
b. Check that the valve seals prop- erly.
There should be no leakage at the
valve seat "2".
3. Remove:• Valve cotter
Attach a valve spring compressor "1"
between the valve spring retainer and
the cylinder head to remove the valve
cotters.
CHECKING THE VALVE
1. Measure:
• Stem-to-guide clearance
Out of specification →Replace the
valve guide.
2. Replace: • Valve guide
Replacement steps:
To ease guide removal, installation
and to maintain correct fit heat the
cylinder head in an over to 100 °C
(212 °F).
a. Remove the valve guide using a valve guide remover "1". b. Install the new valve guide using a
valve guide remover "1" and valve
guide installer "2".
c. After installing the valve guide, bore the valve guide using a valve
guide reamer "3" to obtain proper
stem-to-guide clearance.
After replacing the valve guide reface
the valve seat.
Valve spring compres-
sor:
YM-4019/90890-04019
Stem-to-guide clearance = valve guide inside diameter "a" -
valve stem diameter "b"
Clearance (stem to
guide):Intake:0.010–0.037 mm
(0.0004–0.0015 in)
:0.08 mm
(0.003 in)
Exhaust:
0.025–0.052 mm
(0.0010–0.0020 in)
:0.10 mm
(0.004 in)Valve guide installation
height "a": Intake:11.8–12.2 mm
(0.46–0.48 in)
Exhaust: 11.3–11.7 mm
(0.44–0.46 in)
Valve guide remover: Intake:4.0 mm (0.16 in)YM-4111/90890-04111
Exhaust:4.5 mm (0.18
in) YM-4116/90890-04116
Valve guide installer: Intake:4.0 mm (0.16 in)YM-4112/90890-04112
Exhaust:4.5 mm (0.18
in) YM-4117/90890-04117
Valve guide reamer: Intake:4.0 mm (0.16 in)YM-4113/90890-04113
Exhaust:4.5 mm (0.18
in) YM-4118/90890-04118