2016 YAMAHA YZ250F engine

TIGHTENING TORQUES
2-12
EAS1SM9055ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt
M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug
M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug
M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder head bolts
M9 4 33 Nm (3.3 m·kgf, 24 ft·lbf)
Cylinder head nuts
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)
Balancer nut M10 1 38 Nm (3.8 m·kgf, 27 ft·lbf)
Timing chain guide stopper plate
(exhaust side)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw
M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing cover bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt
M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw
M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp bolt
M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp bolt
M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter guide holder screw
M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
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TIGHTENING TORQUES
2-13
Air filter case cap screw
M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw
M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut
M6 1 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf)
Clutch cable locknut (engine side)
M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut
M8 2 See TIP.
Exhaust pipe protector screw
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt
M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt
M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer body bolt
M5 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Oil nozzle bolt
M5 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Engine oil drain bolt
M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt
M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw
M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw
M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screwM6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft)M8 4 22 Nm (2.2 m·kgf, 16 ft·lbf)
Oil passage squeeze nozzle
M8 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Clutch cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt
M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt
M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kick starter lever bolt
M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
Kick starter lever boss screw
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Primary drive gear nut
M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Clutch spring bolt
M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer. ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
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TIGHTENING TORQUES
2-15
EAS1SM9056CHASSIS TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Outer tube and upper bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem nut M24 1 145 Nm (14.5 m·kgf, 105 ft·lbf)
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nut M28 1 See TIP.
Outer tube and damper assembly M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjuster M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Damper assembly and base valve M42 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Damper assembly adjuster M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
valveM5 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork protector bolt M6 6 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front fork protector and brake hose
holder boltM6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Throttle grip cap screw M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder bolt M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch lever position locknut M5 1
4.8 Nm (0.48 m·kgf, 3.5 ft·lbf)
Front brake master cylinder holder
boltM6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder reser-
voir cap screwM4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknut M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and lower
bracket boltM6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M8 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Front brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nut M18 1 115 Nm (11.5 m·kgf, 83 ft·lbf)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
LT

TIGHTENING TORQUES
2-16
Front brake disc bolt M6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf)
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reservoir
cap boltM4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 135 Nm (13.5 m·kgf, 98 ft·lbf)
Drive chain puller adjust bolt and
locknutM8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Rear wheel sprocket nut M8 6 42 Nm (4.2 m·kgf, 30 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side)M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M10 1 55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine mounting bolt (lower side) M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 38 Nm (3.8 m·kgf, 27 ft·lbf)
Engine guard bolt (right side) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly up-
per boltM10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
Rear shock absorber assembly low-
er boltM10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
screwM5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Drive chain tensioner bolt (upper
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES RemarksLT
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LUBRICATION POINTS AND LUBRICANT TYPES
2-18
EAS1SM9057
LUBRICATION POINTS AND LUBRICANT TYPES
EAS1SM9058ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Balancer shaft journal (left)
Balancer nut threads (left)
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft
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CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (pull)
3. Throttle cable (return)
4. Cable holder
5. Engine stop switch lead
6. Frame
7. Coupler for connecting optional part
8. Bracket
9. Engine stop switch coupler
10. Rectifier/regulator coupler
11. Starter knob/idle screw
12. Neutral switch lead
13. Crankcase cover
14. AC magneto lead
15. Front engine bracket
16. Radiator hose
17. Coupler cover
18. Tension arm
19. Rectifier/regulator lead
20. Main harness
21. Tank rail
22. Radiator
23. Cylinder head breather hose
24. Radiator breather hose
25. Down tube
26. Crankcase
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Pass the engine stop switch lead between the
coupler for connecting optional part and the
frame, where the main harness should face the
outside of the vehicle.
C. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
D. Insert and fix the engine stop switch coupler to
the bracket.
E. Insert and fix the rectifier/regulator coupler to the
bracket.
F. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
G. 70 mm (2.76 in)
H. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
I. Bring the AC magneto lead into line with the
clutch cable with no sag allowed.
J. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
K. Clamp the clutch cable and the AC magneto lead
by the plastic locking tie. Regardless of the orien-
tation of the lock on the plastic locking tie, cut the
end.
L. Pass the clutch cable with no downward sag al-
lowed.
M. Bring the grommet of the clutch cable into contact
with the radiator hose, and pass it to the outside
of the neutral switch lead and the AC magneto
lead (the outside of the vehicle).
N. 40 mm (1.57 in)
O. Clamp the clutch cable, the AC magneto lead,
and the neutral switch lead by the plastic locking
tie. Make sure that they are clamped at the posi-
tioning tape in the clutch cable. Make the lock on
the plastic locking tie face the front of the vehicle,
and cut the end.
P. After connecting the neutral switch coupler, at-
tach the coupler cover.
Q. After connecting the AC magneto coupler, attach
the coupler cover.R. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
S. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
T. Pass the engine stop switch lead between the
coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
U. Pass the radiator breather hose between the
down tubes.
V. Clamp the radiator breather hose, above the en-
gine bracket (front). Clamp the lock on the plastic
tie with it located outside the vehicle, and face the
end toward the front of the vehicle.
W. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
X. Make the lock on the plastic locking tie face the
front of the vehicle, and insert the projection into
the hole in the frame. Cut the end of the plastic
locking tie.

CABLE ROUTING DIAGRAM
2-34
1. Bracket
2. Condenser
3. Coolant temperature sensor
4. Coupler cover
5. Intake air temperature sensor coupler
6. Intake air temperature sensor coupler
7. Radiator hoses
8. Radiator breather hose
9. Joint coupler
10. Plate
11. Tension arm
12. Throttle position sensor lead
13. Ground lead
14. Throttle position sensor coupler
15. Radiator breather hose
16. Cylinder head breather hose
17. Engine guard
18. Crankcase
19. Fuel pump coupler
20. Fuel hose
21. Condenser lead
22. Fuel pump lead
23. Condenser coupler
24. Ground lead terminal
25. Fuel tank
26. Damper
27. Rear frame
28. Main harness
A. Insert the condenser into the bracket as far as it
will go.
B. Attach the coupler cover to the coolant tempera-
ture sensor coupler.
C. Pass the radiator breather hose to the inside of
the radiator hose (the side of the vehicle).
D. Insert and fix the joint coupler to the plate. After
fixing it, attach the cover.
E. Pass the throttle position sensor lead to the out-
side of the tension arm (the outside of the vehi-
cle).
F. After connecting the throttle position sensor cou-
pler, attach the cover.
G. Pass the radiator breather hose to the outside of
the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the inside
of the radiator hose (the side of the vehicle).
H. Pass the protector of the cylinder head breather
hose until it touches the holder.
I. Pass the cylinder head breather hose between
the engine guard and the crankcase.
J. Install the end of the cylinder head breather hose
with it facing downward.
K. After connecting the fuel pump coupler, attach
the coupler cover.
L. 55 mm (2.17 in) (seat load receiver)
M. Clamp the fuel hose and the fuel pump lead by
the holder. Make sure that the painted part on the
fuel hose is clamped, and face the lock on the
clamp toward the rear top of the vehicle.
N. Do not install the plastic locking tie to the seat
load receiver.
O. Make the lock on the plastic locking tie face the
front of the vehicle, and make the end face the
bottom of the vehicle. Do not cut the end.
P. Install the ground lead terminal between the plate
and the bolt.
Q. Detent
R. Fix the ground lead terminal to the detent in the
plate. For the ground lead terminal, either side
will do.S. Insert the projection on the plastic locking tie into
the hole in the rear frame.
T. Clamp the painted part on the fuel hose by the
plastic clamp. Make the lock on the plastic clamp
face the bottom of the vehicle, and cut the end.

CABLE ROUTING DIAGRAM
2-36
1. Throttle cable
2. Clutch cable
3. Engine stop switch lead
4. Cable guide
5. Head pipe
6. Front brake hose
7. Brake hose guide
8. Number plate
A. Number plate band
B. Pass the clutch cable to the rear of the number
plate band.
C. Clamp the engine stop switch lead to the handle-
bar by the plastic band. Do not cut the end of the
plastic band.
D. Pass the engine stop switch lead between the
head pipe and the cable guide.
E. Pass the front brake hose to the front of the num-
ber plate.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han-
dlebar.
I. Pass the clutch cable to the guide in the number
plate.