2005 YAMAHA YZ250F brake

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 - 6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
Wheel axle 1
NOTE:
Apply the lithium soap base grease on the
wheel axle.
6. Install:
Nut (wheel axle) 1
T R..105 Nm (10.5 m · kg, 75 ft · lb)
7. Tighten:
Bolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork sev-
eral times with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
Rear wheel
1. Install:
Bearing (right) 1
Circlip 2
Spacer 3
Bearing (left) 4
Oil seal 5
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Install the bearing with seal facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Right 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..14 Nm (1.4 m · kg, 10 ft · lb)
3. Install:
Rear wheel sprocket 1
Bolt (rear wheel sprocket) 2
Washer (rear wheel sprocket) 3
Nut (rear wheel sprocket) 4
NOTE:
Tighten the nuts in stage, using a crisscross
pattern.
T R..42 Nm (4.2 m · kg, 30 ft · lb)

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 - 10
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:
1 Brake hose removal
2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
FRONT BRAKE REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake hose holder (protector) 2
2 Brake hose holder (brake caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6 Pad pin 1 Loosen when disassembling the brake
caliper.
7 Brake caliper 1
8Brake lever 1
9 Brake master cylinder bracket 1
10 Brake master cylinder 1
3
3
2
2
1

5 - 11
CHAS
EC5A8100
REAR BRAKE
Extent of removal:
1 Brake master cylinder removal
2 Brake hose removal
3 Brake caliper removal
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the brake
caliper.
8 Brake caliper 1
3
32
1
1
FRONT BRAKE AND REAR BRAKE

5 - 12
CHAS
BRAKE CALIPER DISASSEMBLY
ÈFront
ÉRear
Extent of removal:
1 Front brake caliper disassembly
2 Rear brake caliper disassembly
Extent of removal Order Part name Q’ty Remarks
BRAKE CALIPER DISASSEM-
BLYAB
1 Pad pin 1 1
2 Brake pad 2 2
3 Pad support 1 1
4 Brake caliper piston 2 1
Refer to “REMOVAL POINTS”.
5 Dust seal 2 1
6 Piston seal 2 1
21
FRONT BRAKE AND REAR BRAKE

5 - 13
CHASFRONT BRAKE AND REAR BRAKE
BRAKE MASTER CYLINDER DISASSEMBLY
ÈFront
ÉRear
Extent of removal:
1 Front brake master cylinder disassembly
2 Rear brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
BRAKE MASTER CYLINDER
DISASSEMBLY
1 Brake master cylinder cap 1
2 Diaphragm 1
3 Reservoir float 1
4 Brake master cylinder boot 1
5 Circlip 1 Use a long nose circlip pliers.
6 Washer 1
7 Push rod 1
8 Brake master cylinder kit 1
2
2
2
1
1