suspension YAMAHA YZ250F 2015 Owners Manual

MAINTENANCE AFTER BREAK-IN
1-24
EAS1SM5047
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-7.
EAS1SM5048MAJOR MAINTENANCE
1. For the engine
• Leaks around the engine
Check for pressure leaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the
cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be-
tween the cylinder and the piston are cor-
rect.
• Engine oil change
Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s)
Check the wheel for runout. Check the
spoke for looseness.
• Brake(s)
Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.• Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket
Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.
JCA1SL1001
NOTICE
After a break-in or before each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-25.)
• Greasing and oiling
Always grease or oil the specified points.

TORQUE-CHECK POINTS
1-25
EAS1SM5049
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Frame to engine protector
Combined seat and fuel tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel (s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handle-
bar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Shift pedal Shift pedal to shift shaft
Fuel system Fuel pump to fuel tank

CHASSIS SPECIFICATIONS
2-9
Brake disc thickness limit 2.5 mm (0.10 in)
Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter 22.65 mm  2 (0.89 in  2)
Recommended brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter  thickness 245  4.0 mm (9.6  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm  1 (1.00 in  1)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 497.0 mm (19.57 in)
Limit 492.0 mm (19.37 in)
Installed length 497.0 mm (19.57 in)
Spring rate K1 4.70 N/mm (0.48 kgf/mm, 26.84 lbf/in) (USA)
(CAN)
4.60 N/mm (0.47 kgf/mm, 26.27 lbf/in) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48 mm (1.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Suspension oil S1
Standard oil amount 531.0 cm
3 (17.95 US oz, 18.73 Imp.oz) (USA)
(CAN)
551.0 cm
3 (18.63 US oz, 19.43 Imp.oz) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 12 click (s) out* (USA) (CAN)
8 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum (hard) Fully turned in

CHASSIS SPECIFICATIONS
2-10
Compression damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 10 click (s) out* (USA) (CAN)
6 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum (hard) Fully turned in
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 132.0 mm (5.20 in)
Spring free length 275.0 mm (10.83 in)
Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) (USA)
(CAN)
54.00 N/mm (5.51 kgf/mm, 30834 lbf/in) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm
2, 139.4 psi)
Spring installed length
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 10 mm
(0.39 in) from its free length.
Maximum Position in which the spring is turned in 18 mm
(0.71 in) from its free length.
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 30 click (s) out*
Standard 14 click (s) out*
Maximum Fully turned in
Compression damping adjusting positions
(for fast compression damping)
* Position in which the adjuster is turned in finger tight
Minimum 2 turn (s) out*
Standard 1-1/3 turn (s) out* (USA) (CAN)
1-1/8 turn (s) out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
Maximum Fully turned in
Compression damping adjusting positions
(for slow compression damping)
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 10 click (s) out*
Maximum Fully turned in
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chain
Type/manufacturer 520DMA2-SDH/DAIDO
Number of links 114
Drive chain slack 50–60 mm (1.97–2.36 in)
15-link length limit 242.9 mm (9.56 in)

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP OPENING PRESSURE ...................... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-13
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-21
BLEEDING THE BRAKE SYSTEM .......................................................... 3-21
CHECKING THE BRAKE HOSE .............................................................. 3-22
ADJUSTING THE FRONT BRAKE .......................................................... 3-22
ADJUSTING THE REAR BRAKE ............................................................. 3-23
CHECKING THE FRONT BRAKE PADS ................................................. 3-23
CHECKING THE REAR BRAKE PADS ................................................... 3-25
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-26
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-26
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-27
CHECKING THE FRONT FORK LEGS ................................................... 3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-28
AIR BLEEDING FROM FRONT FORK .................................................... 3-28
ADJUSTING THE FRONT FORK LEGS .................................................. 3-29
CHECKING THE SWINGARM OPERATION ........................................... 3-30
CHECKING THE REAR SUSPENSION ................................................... 3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-30
CHECKING THE TIRES ........................................................................... 3-32
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-32
CHECKING THE WHEELS ...................................................................... 3-33

CHASSIS
3-29
3. Tighten:
• Air bleed screw
EAS1SM5104ADJUSTING THE FRONT FORK LEGSEWA32D1006
WARNING
• Always adjust the left and right front forks
evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Rebound damping force
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping forceECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Compression damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Air bleed screw
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Direction “a”
Rebound damping force is increased
(suspension is harder).
Direction “b”
Rebound damping force is decreased
(suspension is softer).
Rebound damping force
Maximum
Turn it in finger-tight.
STD
Turn it out by 12 clicks.*
(USA) (CAN)
Turn it out by 8 clicks.*
(EUR) (JPN) (AUS) (NZL) (ZAF)
Minimum
Turn it out by 20 clicks.*
* With the adjuster fully turned in
T R..
1
Direction “a”
Compression damping force is in-
creased (suspension is harder).
Direction “b”
Compression damping force is de-
creased (suspension is softer).
Compression damping force
Maximum
Turn it in finger-tight.
STD
Turn it out by 10 clicks.*
(USA) (CAN)
Turn it out by 6 clicks.*
(EUR) (JPN) (AUS) (NZL) (ZAF)
Minimum
Turn it out by 20 clicks.*
* With the adjuster fully turned in
1
a
b
a b
1

CHASSIS
3-30
EAS1SM5105CHECKING THE SWINGARM OPERATION
1. Check:
• Swingarm smooth action
• Swingarm free play
Refer to “SWINGARM” on page 4-60.
EAS1SM5106CHECKING THE REAR SUSPENSION
1. Stand the vehicle upright on a level surface.
EWA@
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
3. Check:
• Rear shock absorber assembly smooth ac-
tion
• Rear suspension link smooth action
Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
EAS1SM5107ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
Use a suitable stand to raise the rear wheel off
the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.1. Remove:
• Rear frame
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
2. Adjust:
• Spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Loosen the adjuster “2” until there is some
clearance between the spring and the ad-
juster.
c. Measure the spring free length “a”.
d. Turn the adjuster in the direction of “b” or “c”
to make an adjustment.
TIP
• Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjusting ring.
Direction “b”
Spring preload is increased (suspen-
sion is harder).
Direction “c”
Spring preload is decreased (suspen-
sion is softer).
Spring installed length “d”
Minimum
Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
STD
Position in which the spring is
turned in 10 mm (0.39 in) from its
free length.
Maximum
Position in which the spring is
turned in 18 mm (0.71 in) from its
free length.

CHASSIS
3-31
e. Tighten the locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Rear frame
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
Rebound damping force
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
High compression dampingECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• High compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment. Locknut
30 Nm (3.0 m·kgf, 22 ft·lbf)
Direction “a”
Rebound damping force is increased
(suspension is harder).
Direction “b”
Rebound damping force is decreased
(suspension is softer).
c
b
d
T R..
Rebound damping force
Maximum
Turn it in finger-tight.
STD
Turn it out by 14 clicks.*
Minimum
Turn it out by 30 clicks.*
* With the adjuster fully turned
Direction “a”
High compression damping force is in-
creased (suspension is harder).
Direction “b”
High compression damping force is de-
creased (suspension is softer).
High compression damping
Maximum
Turn it in finger-tight.
STD
Turn it out by 1 1/3 turns.*
(USA)(CAN)
Turn it out by 1 1/8 turns.*
(EUR)(JPN)(AUS)(NZL)(ZAF)
Minimum
Turn it out by two turns.*
* With the adjuster fully turned
a
b
1

CHASSIS
3-32
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Low compression dampingECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Low compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM5108
CHECKING THE TIRES
1. Measure:
• Tire pressure
Out of specification  Regulate.
TIP
• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
is low.
• If the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position.
EAS1SM5109CHECKING AND TIGHTENING THE
SPOKES
1. Check:
• Spokes
Bend/damage  Replace.
Loose  Tighten.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat. Direction “a”
Low compression damping force is in-
creased (suspension is harder).
Direction “b”
Low compression damping force is de-
creased (suspension is softer).
Low compression damping
Maximum
Turn it in finger-tight.
STD
Turn it out by 10 clicks.*
Minimum
Turn it out by 20 clicks.*
* With the adjuster fully turned in
1
a b
1ba
Tire pressure
100 kPa (1.0 kgf/cm2,15 psi)

FRONT FORK
4-41
5. Check:
• Base valve “1”
Wear/damage  Replace.
Contamination  Clean.
• O-rings “2”
Wear/damage  Replace.
• Base valve bushing “3”
Wear/damage  Replace.
• Spring “4”
Damage/fatigue  Replace the base valve.
• Air bleed screw “5”
Wear/damage  Replace.
6. Check:
• Contacting surface “a”
Wear/damage  Replace.
7. Check:
• Adjuster “1”
• O-rings “2”
Wear/damage  Replace.EAS1SM5170ASSEMBLING THE FRONT FORK LEGSEWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
• Inner tube bushing
• Outer tube bushing
• Oil seals
• Copper washers
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill:
• Damper assembly
ECA14210
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
front fork leg, take care not to allow any
foreign material to enter the front fork.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper
assembly of air.
TIP
Avoid excessive full stroke. A stroke of 200 mm
(7.9 in) or more will cause air to enter. In this
case, repeat the steps 1 to 3.
21
New
New
New
2
21 543
a
New
Recommended oil
Suspension oil S1
Standard oil amount
204 cm
3 (6.90 US oz, 7.20
Imp.oz)
New
1
2