2012 YAMAHA YZ250F clutch

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 level
The 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 foreign 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 strainer
Clogged→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 type
SAE10W-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

3-23
CHASSIS
LUBRICATION
To ensure smooth operation of all
components, lubricate your machine
during setup, after break-in, and after
every race.
1. All control cable
2. Clutch lever pivot
3. Shift pedal pivot
4. Footrest pivot
5. Throttle-to-handlebar contact
6. Drive chain
7. Tube guide cable winding por-
tion
8. Throttle cable end
9. Clutch cable end
10. Hot starter cable endA. Use Yamaha cable lube or
equivalent on these areas.
B. Use SAE 10W-40 motor oil or
suitable chain lubricants.
C. Lubricate the following areas
with high quality, lightweight lith-
ium-soap base grease.
Wipe off any excess grease, and
avoid getting grease on the brake
discs.

4-2
SEAT, FUEL TANK AND SIDE COVERS
REMOVING THE SIDE COVER
1. Remove:• Bolt (side cover)
• Left side cover "1"
• Right side cover "2"
Draw the side cover downward to re-
move it because its claws "a" are in-
serted in the air filter case.
REMOVING THE NUMBER PLATE
1. Remove:• Bolt (number plate)
• Number plate "1"
• The projection "a" is inserted into the band of the number plate. Pull
the band off the projection before
removal.
• Remove the hot starter cable "2" and clutch cable "3" from the cable
guide "b" on the number plate.
• The projection "c" on the lower bracket is inserted into the number
plate. Remove the number plate by
pulling it off the projection.

4-7
RADIATOR
RADIATOR
REMOVING THE RADIATOR
Order Part name Q'ty Remarks
Drain the coolant.Refer to "CHANGING THE COOLANT" sec-
tion in the CHAPTER 3.
Seat and fuel tankRefer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
1 Radiator guard 2
2 Radiator hose clamp 10 Only loosening.
3 Clutch cable holder 1
4 Radiator hose 1 1
5 Left radiator 1
6 Radiator hose 4 1
7Pipe 1
8 Radiator hose 5 1
9 Right radiator 1
10 Radiator hose 2 1
11 Radiator hose 3 1
12 Radiator breather hose 1
13 Radiator pipe 1 1
2
4
2
3 13
2
2
2
2
211
7
8 22
69
210 12
1
5
1
T R..20 Nm (2.0 m 
kg, 14 ft  Ib)

4-31
CLUTCH
CLUTCH
REMOVING THE CLUTCH
Order Part name Q'ty Remarks
Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8Ball 1
9 Push rod 2 1
10 Friction plate 9
11 Clutch plate 8
12 Nut (clutch boss) 1 Refer to removal section.
13 Lock washer 1 Refer to removal section.

4-32
CLUTCH
14 Clutch boss 1 Refer to removal section.
15 Thrust washer 1
16 Primary driven gear 1
17 Spacer 1
18 Washer 1
19 Push lever shaft 1 Order Part name Q'ty Remarks

4-33
CLUTCH
REMOVING THE CLUTCH BOSS
1. Remove:
•Nut "1"
• Lock washer "2"
• Clutch boss "3"
Straighten the lock washer tab and
use the clutch holding tool "4" to hold
the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
CHECKING THE CLUTCH
HOUSING AND BOSS
1. Inspect:
• Clutch housing "1"
Cracks/wear/damage→Replace.
• Clutch boss "2"
Scoring/wear/damage→Replace.
CHECKING THE PRIMARY DRIVEN
GEAR
1. Check:
• Circumferential play
Free play exists→Replace.
• Gear teeth "a"
Wear/damage→Replace.CHECKING THE CLUTCH
SPRINGS
1. Measure:
• Clutch spring free length "a"
Out of specification→Replace
springs as a set.
CHECKING THE FRICTION
PLATES
1. Measure:
• Friction plate thickness
Out of specification→Replace
friction plate as a set.
Measure at all four points.
CHECKING THE CLUTCH PLATES
1. Measure:
• Clutch plate warpage
Out of specification→Replace
clutch plate as a set.
Use a surface plate "1" and thick-
ness gauge "2".CHECKING THE PUSH LEVER
SHAFT
1. Inspect:
• Push lever shaft "1"
Wear/damage→Replace.
CHECKING THE PUSH ROD
1. Inspect:
• Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
•Ball "5"
Wear/damage/bend→Replace.
INSTALLING THE PUSH LEVER
SHAFT
1. Install:
• Push lever shaft "1"
• Bolt (push lever shaft) "2"
• Apply the lithium soap base grease
on the oil seal lip.
• Apply the engine oil on the push le-
ver shaft.
• Fit the seat plate "3" in the groove
"a" of the push lever shaft and tight-
en the bolt (seat plate).
Clutch holding tool:
YM-91042/90890-04086
Clutch spring free
length:
35.7 mm (1.41 in)
: 34.7 mm (1.37
in)
Friction plate thickness:
2.9–3.1 mm
(0.114–0.122 in)
: 2.8 mm (0.110
in)
Warp limit:
0.1 mm (0.004 in)
Bolt (push lever shaft):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-34
CLUTCH
INSTALLING THE CLUTCH
1. Install:
• Washer "1"
• Spacer "2"
• Primary driven gear "3"
• Thrust washer "4"
• Clutch boss "5"
Apply the engine oil on the primary
driven gear inner circumference.
2. Install:
• Lock washer "1"
• Nut (clutch boss) "2"
Use the clutch holding tool "3" to hold
the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
3. Bend the lock washer "1" tab.4. Install:
• Friction plate "1"
• Clutch plate 1 "2"
• Install the clutch plates and friction
plates alternately on the clutch
boss, starting with a friction plate
and ending with a friction plate.
• Apply the engine oil on the friction
plates and clutch plates.
5. Install:
•Bearing "1"
• Washer "2"
• Circlip "3"
To push rod 1 "4".
Apply the engine oil on the bearing
and washer.
6. Install:
• Push rod 2 "1"
• Ball "2"
• Push rod 1 "3"
Apply the engine oil on the push rod
1, 2 and ball.
7. Install:
• Pressure plate "1"8. Install:
• Clutch spring "1"
• Bolt (clutch spring) "2"
Tighten the bolts in stage, using a
crisscross pattern.
9. Install:
• Dowel pin "1"
• Gasket (clutch cover) "2"
10. Install:
• Clutch cover "1"
• Bolt (clutch cover)
Tighten the bolts in stage, using a
crisscross pattern.
Nut (clutch boss):
75 Nm (7.5 m•kg, 54
ft•lb)
Clutch holding tool:
YM-91042/90890-04086
Bolt (clutch spring):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (clutch cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)