Yamaha YZ250F(Z) 2010 Owner's Service Manual (P/N 17D-28199-30-E0)

Yamaha's Owner's Service Manual for the 17D-series 2010 YZ250F(Z) covers operation, maintenance, tuning, and repair for closed-course competition use. P/N 17D-28199-30-E0, first edition May 2009.

Searchable Text, Section Bookmarks, and Diagram Detail

Search and navigation: The main chapters have searchable text, although some warning-label artwork does not. Section bookmarks jump directly to individual topics; chapter entries lead to the contents page. Small wiring color codes and connector labels are readable with zoom.

One printable, 196-page PDF with English service text: 184 numbered manual pages, 10 opening pages (including covers, multilingual notices, and a blank page), one blank closing page, and the back cover.

Engine Rebuilds, Carburetor Tuning, and Chassis Service

These selected service topics are part of the manual's coverage, alongside starting and break-in guidance and silencer-fiber replacement.

• Engine and transmission: Step-by-step engine removal, crankcase separation, cylinder and piston inspection, camshaft installation, clutch service, and transmission, shift-cam, and shift-fork inspection.

• Carburetor service and tuning: Keihin FCR-MX37 disassembly, float-height checks, accelerator-pump timing, and jet and needle settings for throttle response.

• Cooling and lubrication: Radiator and cap pressure tests, water-pump seal and bearing replacement, oil-pump clearance checks, and oil-strainer service.

• Brakes and running gear: Front and rear caliper and master-cylinder repair, hydraulic bleeding, wheel-bearing replacement, steering service, and drive-chain adjustment.

• Suspension: Front-fork damper and seal service, swingarm and linkage bearings, rear-shock spring replacement, and compression and rebound adjustment.

• Electrical diagnosis: Wiring and connector views, no-spark inspection charts, CDI magneto tests, and throttle-position-sensor testing and adjustment.

The repair sections are intended for mechanics with Yamaha servicing knowledge; the front-fork section recommends dealer maintenance.

Race Maintenance and Internal Engine Repair

Workshop reference: Race-hour maintenance schedules, component-specific torque tables, lubrication diagrams, and job instruction charts bring inspection requirements and assembly data together for routine workshop planning.

Top-end inspection: Cylinder-head warpage, valve-seat width, and camshaft runout are covered, along with valve-pad selection tables and decompression-system checks. Cylinder-head installation includes a tightening diagram and staged-tightening requirements.

Uneven camshaft-cap tightening can damage the cylinder head, caps, and camshafts. The titanium-valve instructions require new replacement valves after seat lapping rather than reusing the valves used for that operation.

Crankshaft inspection: Runout, connecting-rod clearance, and crank-width measurements support internal condition checks. The special-tool list identifies the crankcase separating tool as YU-1135-A / 90890-01135.

Regional Carburetor Settings and Electrical Fault Tracing

Regional tables distinguish carburetor identification marks, jet needles, and leak jets for North American and other market versions. The “Examples of Carburetor Setting Depending on Symptom” chart relates rich or lean running and throttle response to possible fuel-system checks.

Ignition diagnosis covers the stop and neutral switches, pickup and charging coils, and primary and secondary ignition-coil resistance. The throttle-position-sensor section adds resistance sweeps, input and output voltage checks, and replacement setup.

Fork, Linkage, and Brake Service

Front-fork exploded views distinguish the base valve, damper assembly, bushings, and seals. The “Suspension Setting (Front Fork)” and “Suspension Setting (Rear Shock Absorber)” charts connect handling symptoms with adjustment and inspection points; spring-option tables include identification marks and part numbers.

Rear-shock limits: The link-type Monocross suspension coverage includes relay-arm and connecting-rod bearings. Rear-shock work covers removal, inspection, spring replacement, and mounting bearings; the manual prohibits dismantling the pressurized damper cylinder or nitrogen tank.

The rear-shock section warns of explosion risk from mishandling high-pressure nitrogen. Its dealer-only nitrogen-release instructions concern shock disposal.

Brake assembly drawings show seal and piston orientation, while inspection data cover disc thickness, rear-disc deflection, pad wear, and hydraulic leak checks.

Selected Valve, Spark-Plug, and Oil Specifications

Cold valve-clearance specifications are 0.12–0.17 mm for intake and 0.17–0.22 mm for exhaust. The NGK CR8E spark plug has a specified gap of 0.7–0.8 mm.

For the dry-sump lubrication system, an oil change with filter replacement calls for 1.05 L. The front-fork specification table lists 541 cm³ per leg for USA and Canada and 528 cm³ for Europe, Australia, New Zealand, and South Africa; the repair section separately identifies damper filling and outer-tube oil quantities.