2003 YAMAHA YZ250F steering

3 - 42
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
EC36U013
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering stem
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play → Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust steering ring
nut.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:
Remove the number plate.
Remove the handlebar and handlebar
upper bracket.
Loosen the steering ring nut 1 using the
steering nut wrench 2.
Steering nut wrench:
YU-33975/90890-01403

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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the steering ring nut 3 using
steering nut wrench 4.
NOTE:
Apply the lithium soap base grease on the
thread of the steering stem.
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench:
YU-33975/90890-01403
T R..
Steering ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
Loosen the steering ring nut one turn.
Retighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Steering ring nut (final tightening):
7 Nm (0.7 m • kg, 5.1 ft • lb)
Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
Install the upper bracket 5, washer, steer-
ing stem nut 6, handlebar 7, handlebar
upper holder 8 and number plate 9.
NOTE:
The upper handlebar holder should be
installed with the punched mark a for-
ward.
Insert the end of fuel breather hose 0 into
the hole of the number plate.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering stem nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar upper holder:
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (upper bracket):
23 Nm (2.3 m • kg, 17 ft • lb)
Number plate:
7 Nm (0.7 m • kg, 5.1 ft • lb)

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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 - 46
CHAS
EC563000
REMOVAL POINTS
Steering ring nut
1. Remove:
Steering ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering stem so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Lower bearing
1. Remove:
Lower bearing 1
Use the floor chisel 2.
ACHTUNG:CAUTION:
Take care not to damage the steering shaft
thread.
EC563400
Ball race
1. Remove:
Ball race 1
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
Steering stem
1. Inspect:
Steering stem 1
Bend/damage → Replace.
STEERING

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CHAS
EC564101
Bearing and ball race
1. Wash the bearings and ball races with a
solvent.
2. Inspect:
Bearing 1
Ball race
Pitting/damage → Replace bearings
and ball races as a set.
Install the bearing in the ball races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the ball races, replace
bearings and ball races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Lower bracket
1. Install:
Lower bearing 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Ball race
Upper bearing 1
Ball race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and ball race cover lip.
3. Install:
Lower bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing, the portion a and thread of the steer-
ing stem.
STEERING

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CHASSTEERING
4. Install:
Steering ring nut 1
Tighten the steering ring nut using the
steering nut wrench 2.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering stem by turning it lock
to lock. If there is any binding, remove
the steering stem assembly and inspect
the steering bearings.
6. Install:
Front fork 1
Upper bracket 2
NOTE:
Temporarily tighten the pinch bolts (lower
bracket).
Do not tighten the pinch bolts (upper bracket)
yet.
7. Install:
Washer 1
Steering stem nut 2
T R..145 Nm (14.5 m · kg, 105 ft · lb)
8. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the steering
ring nut little by little.
9. Adjust:
Front fork top end a
Front fork top end (standard) a:
5 mm (0.20 in)

5 - 49
CHAS
10. Tighten:
Pinch bolt (upper bracket) 1
Pinch bolt (lower bracket) 2
ACHTUNG:CAUTION:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
STEERING