2005 YAMAHA YZ250F height adjustment

3 - 26
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification → Adjust.
Brake pedal height
a:
5 mm (0.20 in)
2. Adjust:
Brake pedal height
Pedal height adjustment steps:
Loosen the locknut 1.
Turn the adjusting nut 2 until the pedal
height a is within specified height.
Tighten the locknut.
WARNING
Adjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment, the bolt
3
end
b should protrude out of the
threaded portion
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).
After the pedal height adjustment, make
sure that the rear brake does not drag.
È
É
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
Brake pad thickness a
Out of specification → Replace as a set.
Brake pad thickness:
4.4 mm (0.17 in)
: 1.0 mm (0.04 in)
2. Replace:
Brake pad
Brake pad replacement steps:
Remove the pad pin plug 1.

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ENGCARBURETOR
Float height
1. Measure:
Float height a
Out of specification → Adjust.
Float height:
8.0 mm (0.31 in)
Measurement and adjustment steps:
Hold the carburetor in an upside down
position.
NOTE:
Slowly tilt the carburetor in the opposite
direction, then take the measurement
when the needle valve aligns with the float
arm.
If the carburetor is level, the weight of the
float will push in the needle valve, resulting
in an incorrect measurement.
Measure the distance between the mating
surface of the float chamber and top of the
float using a vernier calipers.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressing the needle
valve.
If the float height is not within specification,
inspect the valve seat and needle valve.
If either is worn, replace them both.
If both are fine, adjust the float height by
bending the float tab b on the float.
Recheck the float height.
EC464600
Float
1. Inspect:
Float 1
Damage → Replace.

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ENGCARBURETOR
15. Install:
Jet needle 1
Collar 2
Spring 3
Needle holder 4
Throttle valve plate 5
To throttle valve 6.5
6
1
2
3
4
16. Install:
Throttle valve assembly 1
Screw (throttle shaft) 2
NOTE:
Install the valve lever rollers 3 into the slits a
of the throttle valve.
17. Install:
O-ring 1
Valve lever housing cover 2
Bolt (valve lever housing cover) 3
18. Install:
Carburetor breather hose 1
NOTE:
Install the carburetor breather hoses to the
carburetor so that the hoses do not bend near
where they are installed.
Accelerator pump timing adjustment
Adjustment steps:
NOTE:
In order for the throttle valve height a to
achieve the specified value, tuck under the
throttle valve plate 1 the rod 2 etc. with the
same outer diameter as the specified value.
Throttle valve height:
0.9 mm (0.035 in)

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Pin 1
Washer 2
Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
Front brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
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)
2. Install:
Brake hose holder 1
Bolt (brake hose holder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Brake hose holder 1
Nut (brake hose holder) 2
NOTE:
Align the top a of the brake hose holder with
the paint b of the brake hose.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)