2003 YAMAHA YZ250F brake light

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7Engine stop switch
8Kickstarter crank
9Fuel tank
0Radiator
ACoolant drain bolt
BRear brake pedal
CValve joint
DFuel cock
ECold starter knob
FDrive chain
GAir filter
HShift pedal
IDipstick
JFront forkNOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.

2 - 21
SPECCABLE ROUTING DIAGRAM
1Brake master cylinder
2Brake hose holder
3Brake hoseÅInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projection
on the brake caliper.
ıPass the brake hose into the brake hose holders.
ÇIf the brake hose contacts the spring (rear shock
absorber), correct its twist.
ÎInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projection
on the brake master cylinder.

3 - 44
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Hot starter cable endÅUse Yamaha cable lube or equivalent on these
areas.
ıUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÇLubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC

5 - 18
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Copper washer 1
Union bolt 2
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake cali-
per.
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
Brake hose holder 1
Brake caliper 2
Bolt (brake caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
4. Tighten:
Pad pin 4
5. Install:
Pad pin plug 5
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.
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)

5 - 21
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake lever 1
Bolt (brake lever) 2
Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the brake master cylinder piston.
Rear brake master cylinder
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake
master cylinder.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..30 Nm (3.0 m · kg, 22 ft · lb)
2. Install:
Brake master cylinder 1
Bolt (brake master cylinder) 2
3. Install:
Spring 1
Brake pedal 2
O-ring 3
Bolt (brake pedal) 4
Clip 5
NOTE:
Apply the lithium soap base grease on the
bolt, O-ring and brake pedal bracket.
Install the clip with its stopper portion a fac-
ing inward.
T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake
master cylinder.
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Rear brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as shown and lightly
touches the projection b on the brake cali-
per.
T R..30 Nm (3.0 m · kg, 22 ft · lb)