2012 YAMAHA YZ250F Owners Manual

2-23
CABLE ROUTING DIAGRAM
1. Brake master cylinder
2. Brake hose holder
3. Brake hoseA. Install the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the brake caliper.
B. Pass the brake hose into the
brake hose holders.C. If the brake hose contacts the
spring (rear shock absorber),
correct its twist.
D. Install the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the brake master cylin-
der.

2-24
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Hot starter cable
4. Clutch cable
5. Engine stop switch lead
6. Cable guide
7. Brake hose
8. Hose guideA. Fasten the engine stop switch
lead to the handlebar.
B. Pass the clutch cable and hot
starter cable through the cable
guide.
C. Pass the engine stop switch
lead behind the CDI unit.D. Pass the brake hose in front of
the number plate.
E. Pass the throttle cables through
the cable guide.
F. Pass the clutch cable and hot
starter cable through the cable
guide on the number plate.
G. Pass the engine stop switch
lead over the number plate
mounting location.
A
CB
C
B
A

3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to maintenance 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 maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine 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.
ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
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 SYSTEM
Check 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● ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks

3-4
MAINTENANCE INTERVALS
REAR SHOCK ABSORBER
Inspect 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● ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks

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 Routine Page
CoolantCheck that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage.P.3-6 – 7
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and oil line
for leakage.P.3-9 – 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-7
Throttle grip/HousingCheck 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 effect of front and rear brake. P.3-14 – 16
Drive chainCheck drive chain slack and alignment. Check that the drive chain
is lubricated properly.P.3-17 – 18
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-20 – 21
SteeringCheck that the handlebar can be turned smoothly and have no ex-
cessive play.P.3-21 – 22
Front forks and rear shock
absorberCheck that they operate smoothly 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 – 6
Rear wheel sprocket Check that the rear wheel 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 connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-7
SettingsIs 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

3-6
ENGINE
ENGINE
CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level
place, and hold it in an upright po-
sition.
2. Remove:
• Radiator cap
3. Check:
• Coolant level "a"
Coolant level low→Add coolant.
1. Radiator
CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en-
gine.
2. Remove:
• Coolant drain bolt "1"
3. Remove:
• Radiator cap
Drain the coolant completely.
4. Clean:
• Cooling system
Thoroughly flush the cooling sys-
tem with clean tap water.
5. Install:
• Copper washer
• Coolant drain bolt
6. Fill:
• Radiator
•Engine
To specified level.
• Do not mix more than one type of
ethylene glycol antifreeze con-
taining corrosion inhibitors for
aluminum engine.
• Do not use water containing im-
purities or oil.
Handling notes of coolant:
The coolant is harmful so it should be
handled with special care.
• When coolant splashes to your
eye.
Thoroughly wash your eye with
water and see your doctor.
• When coolant splashes to your
clothes.
Quickly wash it away with water
and then with soap.
• When coolant is swallowed.
Quickly make him vomit and take
him to a doctor.
7. Install:
• Radiator cap
Start the engine and warm it up
for a several minutes.
8. Check:
• Coolant level
Coolant level low→Add coolant.
CHECKING THE RADIATOR CAP
1. Inspect:
• Seal (radiator cap) "1"
• Valve and valve seat "2"
Crack/damage→Replace.
Exist fur deposits "3" →Clean or
replace.
CHECKING THE RADIATOR CAP
OPENING PRESSURE
1. Attach:
• Radiator cap tester "1" and adapt-
er "2"
Apply water on the radiator cap seal.
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant:
High quality ethylene
glycol anti-freeze con-
taining anti-corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio:
50%/50%
Coolant capacity:
1.00 L (0.88 Imp qt, 1.06
US qt)
Radiator cap tester:
YU-24460-01/90890-
01325
Radiator cap tester
adapter:
YU-33984/90890-01352