ECU YAMAHA YZ250F 2003 User Guide

5 - 10
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:1 Brake hose removal2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid.
WARNING
Support the machine securely so there is nodanger of it falling over.
Refer to “REMOVAL POINTS”.
1 Brake hose cover 1
2 Brake hose holder 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Brake caliper 1
9 Brake lever 1
10 Brake master cylinder bracket 1
11 Brake master cylinder 1
2
3
1
3
2

5 - 11
CHAS
EC5A8100
REAR BRAKE
Extent of removal:1 Brake master cylinder removal2 Brake hose removal
3 Brake caliper removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
3
1
321
FRONT BRAKE AND REAR BRAKE

5 - 26
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (upper bracket) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (lower bracket) 2 Only loosening.
6 Front fork 1
1

5 - 45
CHAS
EC560000
STEERING
Extent of removal:1 Lower bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Number plate
Handlebar
Cable guide
Front fenderRefer to “HANDLEBAR” section.
1 Steering stem nut 1
2 Front fork 2 Refer to “FRONT FORK” section.
3 Upper bracket 1
4 Steering ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
5 Lower bracket 1
6 Ball race cover 1
7 Upper bearing 1
8 Lower bearing 1 Refer to “REMOVAL POINTS”.
9Ball race
2Refer to “REMOVAL POINTS”.
2
1
STEERING

5 - 50
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear brake caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

5 - 58
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Seat and fitting band Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
1 Clamp (air filter joint) 1 Only loosening.
2 Rear frame 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Lower spring guide 1
1
2