brake pads YAMAHA YZ250F 2007 Owners Manual

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear
ROTOR NUT
Retighten
EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten
Clean
Replace * Whichever comes first
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1. Retighten
AIR FILTER
Clean and lubricate
Use foam air-filter oil or
equivalent oil
Replace
OIL FILTER
Replace
OIL STRAINER
Clean
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, caliper
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 sealItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks


3

3 - 26
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
Loosen the pad pin 2.
Remove the brake caliper 3 from the front
fork.
Remove the pad pin and brake pads 4.
Connect the transparent hose 5 to the
bleed screw 6 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m  kg, 4.3 ft  lb)
Install the brake pads 7 and pad pin.
NOTE:
Install the brake pads with their projections
a into the brake caliper recesses b.
Temporarily tighten the pad pin at this
point.
Install the brake caliper 8 and tighten the
pad pin 9.
T R..
Bolt (brake caliper):
23 Nm (2.3 m  kg, 17 ft  lb)
Pad pin:
18 Nm (1.8 m  kg, 13 ft  lb)

3 - 28
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
Remove the pad pin 6 and brake pads 7.
Connect the transparent hose 8 to the
bleed screw 9 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m  kg, 4.3 ft  lb)
Install the brake pad 0 and pad pin A.
NOTE:
Install the brake pads with their projections
a into the brake caliper recesses b.
Temporarily tighten the pad pin at this
point.
Install the brake caliper B and rear wheel
C.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.
Tighten the pad pin D.
T R..
Pad pin:
18 Nm (1.8 m  kg, 13 ft  lb)
Install the pad pin plug E and protector
F.
T R..
Pad pin plug:
3 Nm (0.3 m  kg, 2.2 ft  lb)
Bolt (protector):
7 Nm (0.7 m  kg, 5.1 ft  lb)

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
Bearing (left) 1
Spacer 2
Bearing (right) 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Install the collars with their projections a
facing the wheel.
4. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.

5 - 8
CHAS
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
FRONT WHEEL AND REAR WHEEL
5. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
6. Install:
Drive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
7. Install:
Left drive chain puller 1
Wheel axle 2
NOTE:
Install the left drive chain puller, and insert
the wheel axle from left side.
Apply the lithium soap base grease on the
wheel axle.
8. Install:
Right drive chain puller 1
Washer 2
Nut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.

5 - 17
CHAS
Brake caliper piston
1. Clean:
Brake caliper
Piston seal
Dust seal
Brake caliper piston
Clean them with brake fluid.
2. Install:
Piston seal 1
Dust seal 2
WARNING
Always use new piston seals and dust
seals.
NOTE:
Fit the piston seals and dust seals onto the slot
on brake caliper correctly.
È
Front
ÉRear
È
É
3. Install:
Brake caliper piston 1
NOTE:
Apply the brake fluid on the piston wall.
CAUTION:
Install the piston with its shallow
depressed side a facing the brake cali-
per.
Never force to insert.
È
Front
ÉRear
Front brake caliper
1. Install:
Pad support 1
Brake pad 2
Pad pin 3
NOTE:
Install the brake pads with their projections
a into the brake caliper recesses b.
Temporarily tighten the pad pin at this point.
È
É
FRONT BRAKE AND REAR BRAKE

5 - 18
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake caliper 1
Bolt (brake caliper) 2
3. Tighten:
Pad pin 3
4. Install:
Pad pin plug 4
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
Rear brake caliper
1. Install:
Pad support 1
Brake pad 2
Pad pin 3
NOTE:
Install the brake pads with their projections
a into the brake caliper recesses b.
Temporarily tighten the pad pin at this point.
2. Install:
Brake disc cover 1
Bolt (brake disc cover) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)