2008 YAMAHA YFM250R service

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PRE-OPERATION CHECKS
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Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
WARNING

EWB00480
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s
Manual. Failure to inspect increases the possibility of an accident or equipment damage.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic
maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-7, 5-3
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-10
Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.

Check hydraulic system for leakage. Correct if necessary.5-3, 8-22, 8-23, 8-26

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
WARNING

EWB01840
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.
EBU21730
Owner’s manual and tool kit
Be sure to put this owner’s manual in the plastic
bag and always carry it on the bottom of the seat
as shown. Put the owner’s tool kit and low-pres-
sure tire gauge under the seat.
1. Low-pressure tire gauge
2. Owner’s tool kit
3. Owner’s manual1 23

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The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
NOTE:

If you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
WARNING

EWB01850
Never modify this ATV through improper in-
stallation or use of accessories, as it may
cause changes in handling, which in some sit-
uations could lead to an accident. All parts and
accessories added to this ATV should be gen-
uine Yamaha or equivalent components de-
signed for use on this ATV and should be
installed and used according to instructions. If
you have questions, consult an authorized
Yamaha ATV dealer.

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NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.

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Checking the front brake lever free play
The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system.
WARNING

EWB02070
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
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Checking the brake pedal position
The brake pedal position must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The top of the brake pedal should be positioned
40.0 mm (1.57 in) above the top of the frame as
shown. If the brake pedal is not positioned as spec-
ified, have a Yamaha dealer adjust it.
1. Brake lever free play
1

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WARNING

EWB02110
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the brake pedal position is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
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Adjusting the parking brake free play
The parking brake free play must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Cable length “A” should measure 64–68 mm
(2.52–2.60 in). Adjust the parking brake free play
as follows.
1. Release the parking brake by moving the
1. Brake pedal position
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1. Adjusting bolt
2. Cable length “A”
3. Locknut
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parking brake lever to the right.
2. Fully loosen the locknut and the adjusting bolt
at the rear brake caliper.
3. Loosen the locknut on the brake cable.
4. Turn the adjusting nut on the brake cable in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
NOTE:

If the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.
5. Tighten the locknut on the brake cable.
6. Turn in the adjusting bolt at the rear brake cal-iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.CAUTION:
ECB00520
When tightening the locknut, hold the adjust-
ing bolt with a wrench so that it does not turn
together with the locknut.WARNING
EWB02090
Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.
1. Locknut
2. Adjusting nut
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(a)(b)

Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 11.6 ft·lbf)

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gine as well as other vital parts of the ATV and
can lead to drive chain slippage or breakage.
To prevent this from occurring, keep the drive
chain slack within the specified limits.
5. Pull the rod out, and then tighten the rear axle
pinch bolts to the specified torque in the order
shown.
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Lubricating the drive chain
The drive chain must be cleaned and lubricated at
the intervals specified in the periodic maintenanceand lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or wet areas.
Service the drive chain as follows.CAUTION:

ECB00560
The drive chain must be lubricated after wash-
ing the ATV or riding in the rain.
1. Clean the drive chain with kerosene and a
small soft brush.
CAUTION:

ECB00570
To prevent damaging the O-rings, do not clean
Tightening torque:
Rear axle pinch bolt:
21 Nm (2.1 m·kgf, 15.2 ft·lbf)
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1. O-rings
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