2009 Yamaha YZ250F(Y) Owner's Service Manual PDF (P/N 5XC-28199-35)

Yamaha's 2009 YZ250F(Y) Owner's Service Manual covers the US, Canadian, European, Australian, New Zealand, and South African competition models across seven technical chapters. This first edition (May 2008) carries cover reference 5XC-28199-35 and English-edition code 5XC-28199-35-E0.

Text search and diagram detail: The main text is searchable, but the valve-pad selection table entries are not. Section bookmarks provide direct links; the main chapter bookmarks return to the contents page. Small wiring and connector labels are readable when enlarged.

• Engine repair: Top-end disassembly, valve-clearance adjustment, camshaft installation, crankcase separation, crankshaft inspection, and balancer service.

• Clutch and transmission: Wet-clutch inspection and reassembly, kick-shaft and shift-shaft service, plus gearbox, shift-cam, and shift-fork repair.

• Carburetor service: KEIHIN FCR-MX37 disassembly, float-height checks, accelerator-pump timing adjustment, and market-specific jetting references.

• Cooling and lubrication: Radiator-cap and cooling-system pressure tests, water-pump repair, oil-pump inspection, and lubrication diagrams.

• Brakes and chassis: Hydraulic brake bleeding, caliper and master-cylinder repair, front-fork overhaul, steering-bearing replacement, and swingarm linkage service.

• Electrical diagnosis: Wiring diagrams, ignition-system test charts, coil checks, and throttle position sensor testing, replacement, and adjustment.

The repair sections assume existing Yamaha motorcycle service knowledge; operating instructions and routine-maintenance guidance are also included for owners.

Engine Repair and Race Maintenance

Pre-operation checklists and maintenance schedules distinguish break-in, race-based service, and periodic replacement items. The engine sections document cylinder and piston inspection, valve-guide and valve-seat work, camshaft clearance checks, and decompression-system inspection, with valve-pad selection tables for clearance adjustment.

Yamaha warns that uneven camshaft-cap tightening can damage the cylinder head, caps, and camshafts.

Bottom-end work: Gear-dog and shift-fork inspections accompany transmission reassembly and operational checks. Exploded assembly views and job instruction charts identify parts and service operations. The special-tool list identifies the crankcase separating tool (YU-1135-A / 90890-01135) and flywheel puller (YM-1189 / 90890-01189) used for crankshaft and CDI magneto work.

FCR-MX37 Carburetor and Tuning

Regional tables distinguish NHKR and NFLR jet needles, with different pilot-jet and needle-clip settings. These distinctions help match replacement and tuning parts to the machine's market specification.

Carburetor setting charts connect acceleration problems and spark-plug condition to throttle opening and related checks. Tuning references explain leak-jet selection and include part numbers for jets and needles.

Cooling and Oil Circulation

Cooling-system checks cover pressure retention, hose condition, and radiator-cap operation. Water-pump inspection extends to the impeller shaft, seals, and bearing. Dry-sump lubrication diagrams show the oil circuit, supported by oil-pressure verification, strainer service, and oil-pump clearance checks.

Fork, Brake, and Suspension Service

Chassis procedures cover wheel alignment, wheel-bearing replacement, and brake piston and seal inspection. Cable routing diagrams show control-cable, sensor-harness, and brake-hose placement.

Fork and shock setup: Suspension setting charts relate handling symptoms to damping, spring choice, and fork-oil quantity. Spring-rate and identification tables distinguish regional fork specifications and optional steel or titanium rear springs. The fork section warns that dropping the damper assembly into the inner tube can damage its internal valve.

Rear-shock coverage includes removal, spring and bearing service, inspection, and adjustment; it does not provide an internal nitrogen-damper rebuild procedure.

Always review the included safety warnings before handling high-pressure suspension components or engine fluids to prevent personal injury.

Ignition and Throttle Position Sensor Tests

The ignition troubleshooting chart addresses a no-spark condition through component and connection checks. Electrical references distinguish the 5XC-R0 CDI unit for US/Canadian models from the 5XC-S0 unit for other markets.

Throttle position sensor diagnosis includes resistance, input-voltage, and output-voltage checks, with connector illustrations and adjustment instructions after replacement. Specification tables supply electrical test values alongside component torque, capacity, clearance, and wear-limit data.

English PDF and Included Pages

Supplied as one printable, 190-page PDF with English technical content. The total includes 178 numbered chapter pages and 12 cover, introductory, contents, and end-matter pages, including one blank page; these are already counted in the 190 pages.