2007 YAMAHA YZ250F boot

IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
machine to be operated on any public street,
road, or highway. Off-road use on public lands
may also be illegal. Please check local regula-
tions before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its character-
istics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, always
wear an approved helmet with gog-
gles or a face shield. Also wear heavy
boots, gloves, and protective cloth-
ing. Always wear proper fitting cloth-
ing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
SAFETY INFORMATION

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Repair.
Radiator 1
Radiator hose joint 2
Coolant leakage → Repair or replace.
Radiator hose 3
Swelling → Replace.
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Before adjustment, expose the adjuster by
moving the boot 3 and cap 4 away.
Make minute adjustment on the lever side
using the adjuster 5.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknuts 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknuts.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)

3 - 10
INSP
ADJTHROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
3. Install:
Cap 1
Boot 2
NOTE:
Place the tip a of the cap in the boot.
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
2. Adjust:
Throttle grip free play
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
Throttle grip free play adjustment steps:
Slide the adjuster cover.
Loosen the locknut 1.
Turn the adjuster 2 until the specified free
play is obtained.
Tighten the locknut.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
1 2
THROTTLE LUBRICATION
1. Remove:
Cover (throttle cable cap) 1
Cover (grip cap) 2
Throttle grip cap 3

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 Push rod (Front) 1
5 Brake master cylinder boot 1
6 Circlip 1 Use a long nose circlip pliers.
7 Washer 1
8 Push rod (Rear) 1
9 Brake master cylinder kit 1
2
2
2
1
1

5 - 20
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
Brake master cylinder kit 1
Washer 2
Circlip 3
Brake master cylinder boot 4
Push rod 5
To brake master cylinder 6.
[Rear]
Brake master cylinder kit 1
Push rod 2
Circlip 3
Brake master cylinder boot 4
To brake master cylinder 5.
NOTE:
Apply the brake fluid on the brake master cyl-
inder kit.
Apply the lithium soap base grease on the tip
of the push rod.
When installing the circlip, use a long nose
circlip pliers.
È
Front
ÉRear
È
É
Front brake master cylinder
1. 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
face upward.
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)