brake YAMAHA YZ250F 2016 Owner's Guide

CHASSIS
3-35
c. Turn the front fork to the right and left a few
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-49.
d. Loosen the ring nut fully turn and then tight-
en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-49.
f. Install the washer “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Upper bracket
Refer to “STEERING HEAD” on page 4-49.
• Handlebar
Refer to “HANDLEBAR” on page 4-31.
EAS1SM9110LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS1SM9111LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal. Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Ring nut (initial tightening torque)
38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
T R..
1
Recommended lubricant
Silicone grease
Recommended lubricant
Lithium-soap-based grease
Recommended lubricant
Lithium-soap-based grease

4
CHASSIS
GENERAL CHASSIS........................................................................................ 4-1
REMOVING THE LEFT SIDE COVER ....................................................... 4-2
REMOVING THE SEAT ............................................................................. 4-2
REMOVING THE NUMBER PLATE ........................................................... 4-2
FRONT WHEEL................................................................................................ 4-3
REMOVING THE FRONT WHEEL............................................................. 4-4
CHECKING THE FRONT WHEEL ............................................................. 4-4
DISASSEMBLING THE FRONT WHEEL ................................................... 4-5
ASSEMBLING THE FRONT WHEEL ......................................................... 4-5
INSTALLING THE FRONT WHEEL ........................................................... 4-6
REAR WHEEL.................................................................................................. 4-7
REMOVING THE REAR WHEEL ............................................................... 4-8
CHECKING THE REAR WHEEL................................................................ 4-8
DISASSEMBLING THE REAR WHEEL ..................................................... 4-8
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ............ 4-8
ASSEMBLING THE REAR WHEEL ........................................................... 4-9
INSTALLING THE REAR WHEEL.............................................................. 4-9
FRONT BRAKE.............................................................................................. 4-11
INTRODUCTION ...................................................................................... 4-15
CHECKING THE FRONT BRAKE DISC .................................................. 4-15
REMOVING THE FRONT BRAKE CALIPER ........................................... 4-15
DISASSEMBLING THE FRONT BRAKE CALIPER................................. 4-15
CHECKING THE FRONT BRAKE CALIPER ........................................... 4-16
ASSEMBLING THE FRONT BRAKE CALIPER ....................................... 4-16
INSTALLING THE BRAKE CALIPER PISTON ........................................ 4-16
INSTALLING THE FRONT BRAKE CALIPER ......................................... 4-17
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................ 4-18
CHECKING THE FRONT BRAKE MASTER CYLINDER......................... 4-18
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER .................... 4-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER....................... 4-19
REAR BRAKE................................................................................................ 4-21
INTRODUCTION ...................................................................................... 4-25
CHECKING THE REAR BRAKE DISC..................................................... 4-25
REMOVING THE REAR BRAKE CALIPER ............................................. 4-26
DISASSEMBLING THE REAR BRAKE CALIPER ................................... 4-26
CHECKING THE REAR BRAKE CALIPER .............................................. 4-26
ASSEMBLING THE REAR BRAKE CALIPER ......................................... 4-26
INSTALLING THE BRAKE CALIPER PISTON ........................................ 4-27
INSTALLING THE REAR BRAKE CALIPER ............................................ 4-27
REMOVING THE REAR BRAKE MASTER CYLINDER .......................... 4-28
CHECKING THE REAR BRAKE MASTER CYLINDER ........................... 4-28
ASSEMBLING THE REAR BRAKE MASTER CYLINDER....................... 4-29
INSTALLING THE REAR BRAKE MASTER CYLINDER ......................... 4-29

FRONT WHEEL
4-3
EAS1SM9120
FRONT WHEEL
Removing the front wheel
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5Collars 2
6Oil seals 2
7 Bearing 2
8 Brake disc 1
For installation, reverse the removal proce-
dure.
12 Nm (1.2 mkgf, 8.7 ftIbf)T.R
.
New
New
LT
LS
LS
LS
5
76
5 6 7
(6)
8
12
1 3
21 Nm (2.1 mkgf, 15 ftIbf)T.R.
21 Nm (2.1 mkgf, 15 ftIbf)T.R.
4
115 Nm (11.5 mkgf, 83 ftlbf)T.R.

FRONT WHEEL
4-5
EAS1SM9123DISASSEMBLING THE FRONT WHEEL
1. Remove:
• Oil seals
• Bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel sur-
face.
c. Remove the bearings with a bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM9124ASSEMBLING THE FRONT WHEEL
1. Install:
• Bearing (left side) “1”
• Spacer “2”
• Bearing (right side) “3”
• Oil seals “4”
TIP
• Apply the lithium-soap-based grease to the
bearing and the oil seal lip when installing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.
2. Install:
• Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
12
New
Brake disc bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
LOCTITE®
4
3
2
1
4
New
New
1
T R..

FRONT WHEEL
4-6
3. Install:
• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
EAS1SM9125INSTALLING THE FRONT WHEEL
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the
front wheel axle.3. Tighten:
• Front wheel axle nut “1”
ECA
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”
1
LS
Front wheel axle nut
115 Nm (11.5 m·kgf, 83 ft·lbf)
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..
1 1

REAR WHEEL
4-7
EAS1SM9126
REAR WHEEL
Removing the rear wheel
Order Part name Q’ty Remarks
Use a suitable stand to raise the rear wheel
off the ground.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1
5Collars 2
6 Rear wheel sprocket 1
7Oil seals 2
8 Circlip 1
9 Bearing 3
10 Brake disc 1
For installation, reverse the removal proce-
dure.
(6)
21 Nm (2.1 m•kgf, 15 ft•Ibf)T.R.
2 5
7 9
LS
LS(6)
46
1
(6) 3
LS
8
9 10
7 5
LT
14 Nm (1.4 m•kgf, 10 ft•Ibf)T.R.
3
21 Nm (2.1 m•kgf, 15 ft•Ibf)T.R.
42 Nm (4.2 m•kgf, 30 ft•Ibf)T.R.
135 Nm (13.5 m•kgf, 98 ft•lbf)T.R.

REAR WHEEL
4-8
EAS1SM9127REMOVING THE REAR WHEEL
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten:
• Adjusting bolt “3”
5. Remove:
• Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAS1SM9128CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
2. Check:
•Tire(s)
• Rear wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-33 and “CHECKING THE WHEELS” on
page 3-34.
3. Check:
• Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.4. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
EAS1SM9129DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-5.
EAS1SM9130CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth  Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace:
• Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
12
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut
42 Nm (4.2 m·kgf, 30 ft·lbf)
T R..

REAR WHEEL
4-9
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SM9131ASSEMBLING THE REAR WHEEL
1. Install:
• Bearing (right side) “1”
• Circlip “2”
• Spacer “3”
• Bearing (left side) “4”
• Oil seals “5”
TIP
• Apply the lithium-soap-based grease to the
bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.2. Install:
• Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
3. Install:
• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
EAS1SM9132INSTALLING THE REAR WHEEL
1. Install:
• Rear wheel
New
New
5
43 1
25
LSLS
Brake disc bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
1
T R..
1
LS

REAR WHEEL
4-10
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:
• Drive chain “1”
TIP
Push the rear wheel “2” forward and install the
drive chain.
3. Install:
• Left drive chain puller “1”
• Rear wheel axle “2”
TIP
• Install the left drive chain puller, and insert the
rear wheel axle from the left side.
• Apply the lithium-soap-based grease to the
rear wheel axle.
4. Install:
• Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the nut (rear wheel axle) at
this point.
5. Adjust:
• Drive chain slack “a”
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-28.
6. Tighten:
• Rear wheel axle nut “1”
• Locknut “2”
1 2
LS
Drive chain slack
50–60 mm (1.97–2.36 in)
Wheel axle nut
135 Nm (13.5 m·kgf, 98 ft·lbf)
Locknut
21 Nm (2.1 m·kgf, 15 ft·lbf)
2
1
3
a
T R..
T R..
1
2

FRONT BRAKE
4-11
EAS1SM9133
FRONT BRAKE
Removing the front brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
For installation, reverse the removal proce-
dure.
3
9
1
2
8
4
5 7
6
T.R.30 Nm (3.0 mlbf) kgf, 22 ft
T.R.28 Nm (2.8 mlbf) kgf, 20 ft
T.R.17 Nm (1.7 mlbf) kgf, 12 ft
T.R.2.5 Nm (0.25 mlbf) kgf, 1.8 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft