2006 YAMAHA YZ250F brake

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
4. Pass the brake hose through the cable
guide 1.
5. 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
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.
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)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake hose holder 1
Screw (brake hose holder) 2
CAUTION:
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
Brake fluid
1. Fill:
Brake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
È
Front
ÉRear
Recommended brake fluid:
DOT #4
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
È
É

5 - 25
CHASFRONT BRAKE AND REAR BRAKE
2. Air bleed:
Brake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
3. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
4. Install:
[Front]
Reservoir float
Diaphragm
Brake master cylinder cap 1
Screw (brake master cylinder cap) 2
[Rear]
Diaphragm
Brake master cylinder cap 1
Bolt (brake master cylinder cap) 2
CAUTION:
After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.
È
Front
ÉRear
5. Install: (rear brake only)
Protector 1
Bolt (protector) 2
È
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
É
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

5 - 26
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
1 Protector 1
2 Pinch bolt (upper bracket) 2 Only loosening.
3 Damper assembly 1 Loosen when disassembling the front
fork.
Use special tool.
Refer to “REMOVAL POINTS”.
4 Pinch bolt (lower bracket) 2 Only loosening.
5 Front fork 1
1

5 - 43
CHASHANDLEBAR
EC5B0000
HANDLEBAR
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
HANDLEBAR REMOVAL
Number plate Remove the band only.
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1
5 Engine stop switch 1
6 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
7 Throttle cable cap 1
8 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
9 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
10 Right grip 1 Refer to “REMOVAL POINTS”.
11 Tube guide 1
12 Collar 1
13 Left grip 1 Refer to “REMOVAL POINTS”.
14 Handlebar upper holder 2
15 Handlebar 1
16 Handlebar lower holder 2
1

5 - 44
CHAS
EC5B3000
REMOVAL POINTS
Brake master cylinder
1. Remove:
Brake master cylinder bracket 1
Brake master cylinder 2
CAUTION:
Do not let the brake master cylinder hang
on the brake hose.
Keep the brake master cylinder cap side
horizontal to prevent air from coming in.
EC5B3200
Grip
1. Remove:
Grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:
Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
EC5B5000
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
Handlebar lower holder 1
Washer 2
Nut (handlebar lower holder) 3
NOTE:
Install the handlebar lower holder with its
side having the greater distance a from the
mounting bolt center facing forward.
Apply the lithium soap base grease on the
thread of the handlebar lower holder.
Installing the handlebar lower holder in the
reverse direction allows the front-to-rear off-
set amount of the handlebar position to be
changed.
Do not tighten the nut yet.
HANDLEBAR

5 - 47
CHASHANDLEBAR
7. Install:
•Throttle cables 1
To tube guide 2.
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
8. Install:
•Throttle cable cap 1
•Screw (throttle cable cap) 2
WARNING
After tightening the screws, check that the
throttle grip
3 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
9. Install:
•Grip cap cover 1
•Cover (throttle cable cap) 2
10. Install:
•Brake master cylinder 1
•Brake master cylinder bracket 2
•Bolt (brake master cylinder bracket) 3
NOTE:
•Install the bracket so that the arrow mark a
faces upward.
•First tighten the bolt on the upper side of the
brake master cylinder bracket, and then
tighten the bolt on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)

5 - 54
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM 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.
Brake hose holder Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward. Rear brake caliper
Bolt (brake pedal)
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1