2009 YAMAHA WR 250F brake

6-12
FRONT BRAKE AND REAR BRAKE
INSTALLING THE FRONT BRAKE
CALIPER
1. Install:• Pad support "1"
• Brake pad "2"
• Pad pin "3"
• Install the brake pads with their pro-jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at this point.
2. Install:
• Brake caliper "1"
• Bolt (brake caliper) "2"
3. Tighten: • Pad pin "3"
4. Install: • Pad pin plug "4"
INSTALLING THE REAR BRAKE
CALIPER
1. Install: • Pad support "1"
• Brake pad "2"
• Pad pin "3"
• Install the brake pads with their pro-jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at this point.
2. Install:• Brake disc cover "1"
• Bolt (brake disc cover) "2"
3. Install: • Brake caliper "1"
• Rear wheel "2"
Refer to "FRONT WHEEL AND
REAR WHEEL" section.
4. Tighten: • Pad pin "3"
5. Install: • Pad pin plug "4"
INSTALLING THE BRAKE
MASTER CYLINDER KIT
1. Clean: • Brake master cylinder
• Brake master cylinder kitClean them with brake fluid.
2. Install: • Brake master cylinder cup (prima-ry) "1"
• Brake master cylinder cup (sec- ondary) "2"
To brake master cylinder piston
"3".
Apply the brake fluid on the brake
master cylinder cup.
After installing, cylinder cup
should be installed as shown di-
rection. Wrong installation cause
improper brake performance.
A. Front
B. Rear
3. Install: • Spring "1"
To brake master cylinder piston
"2".
Install the spring at the smaller dia.
side.
A. Front
B. Rear
4. Install:
• Brake master cylinder kit "1"
• Washer (front brake) "2"
• Push rod (rear brake) "2"
•Circlip "3"
• Brake master cylinder boot "4"To brake master cylinder.
• Apply the brake fluid on the brake
master cylinder kit.
• Apply the silicone grease on the tip of the push rod.
• When installing the circlip, use a long nose circlip pliers.
Bolt (brake caliper): 23 Nm (2.3 m•kg, 17
ft•lb)
Pad pin: 18 Nm (1.8 m•kg, 13
ft•lb)
Pad pin plug: 3 Nm (0.3 m•kg, 2.2
ft•lb)
Bolt (brake disc cover):10 Nm (1.0 m•kg, 7.2
ft•lb)
Pad pin: 18 Nm (1.8 m•kg, 13
ft•lb)
Pad pin plug: 3 Nm (0.3 m•kg, 2.2
ft•lb)

6-13
FRONT BRAKE AND REAR BRAKE
A. Front
B. Rear
INSTALLING THE FRONT BRAKE
MASTER CYLINDER
1. Install: • Brake master cylinder "1"
• Brake master cylinder bracket "2"
• Bolt (brake master cylinder brack-et) "3"
• 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.
2. Install:
• Brake lever "1"
• Bolt (brake lever) "2" • Nut (brake lever) "3"
Apply the silicone grease on the
brake lever sliding surface, bolt and
contacting surface of the brake mas-
ter cylinder piston.
INSTALLING THE REAR BRAKE
MASTER CYLINDER
1. Install:
• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake master cylinder.
2. Install:
• Brake master cylinder "1"
• Bolt (brake master cylinder) "2"
3. Install: • Spring "1"
• Brake pedal "2"
• O-ring "3"
• Bolt (brake pedal) "4"
•Clip "5"
Apply the lithium soap base grease
on the bolt, O-ring and brake pedal
bracket.
4. Install:•Pin "1"
• Washer "2"
• Cotter pin "3"
After installing, check the brake pedal
height. Refer to "ADJUSTING THE
REAR BRAKE" section in the CHAP-
TER 3.
Bolt (brake master cylin-
der bracket): 9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (brake lever): 6 Nm (0.6 m•kg, 4.3
ft•lb)
Nut (brake lever):
6 Nm (0.6 m•kg, 4.3
ft•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Bolt (brake master cylin-
der):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (brake pedal): 26 Nm (2.6 m•kg, 19
ft•lb)

6-14
FRONT BRAKE AND REAR BRAKE
INSTALLING THE FRONT BRAKE
HOSE
1. Install:• Copper washer "1"
•Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:
• Brake hose holder "1"
• Bolt (brake hose holder) "2"
3. Install: • Brake hose holder "1"
• Nut (brake hose holder) "2"
Align the top "a" of the brake hose
holder with the paint "b" of the brake
hose.
4. Pass the brake hose through the front brake hose guides "1".
5. Install: • Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that it
contacts the brake master cylinder
projection "a" and that its bent
portion "b" faces downward.
INSTALLING THE REAR BRAKE
HOSE
1. Install:• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:• Brake hose holder "1"
• Screw (brake hose holder) "2"
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.
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Bolt (brake hose holder): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Nut (brake hose holder): 7 Nm (0.7 m•kg, 5.1 ft
•lb)
Union bolt:30 Nm (3.0 m•kg, 22
ft•lb)
Union bolt: 30 Nm (3.0 m•kg, 22
ft•lb)
Screw (brake hose hold-
er):3 Nm (0.3 m•kg, 2.2
ft•lb)

6-15
FRONT BRAKE AND REAR BRAKE
FILLING THE BRAKE FLUID
1. Fill:• Brake fluidUntil the fluid level reaches
"LOWER" level line "a".
• Use only the designated quality
brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a
harmful chemical reaction and
lead to poor performance.
• Be careful that water does not enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the flu-
id and may result in vapor lock.
Brake fluid may erode painted sur-
faces or plastic parts. Always
clean up spilled fluid immediately.
A. Front
B. Rear
2. Air bleed:
• Brake systemRefer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion in the CHAPTER 3.
3. Inspect: • Brake fluid level
Fluid at lower level →Fill up.
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section in
the CHAPTER 3. 4. Install:
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap "1"
• Screw (bolt) {brake master cylin-der cap} "2"
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.
A. Front
B. Rear
5. Install: (rear brake only) •Protector "1"
• Bolt (protector) "2"
Recommended brake flu-
id:
DOT #4
Screw (bolt) {brake mas-
ter cylinder cap}:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (protector): 7 Nm (0.7 m•kg, 5.1
ft•lb)

6-16
FRONT FORK
FRONT FORK
REMOVING THE FRONT FORKOrder Part name Q'ty Remarks Hold the machine by placing the suitable stand
under the engine. Refer to "HANDLING NOTE".
Front wheel Refer to "FRONT WHEEL AND REAR
WHEEL" section.
Front brake caliper Refer to "FRONT BRAKE AND REAR
BRAKE" section.
Headlight
Handlebar Refer to "HANDLEBAR" section.
1Protector 1
2 Pinch bolt (upper bracket) 2 Only loosening.
3 Cap bolt 1 Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 2 Only loosening.
5 Front fork 1

6-23
HANDLEBAR
HANDLEBAR
REMOVING THE HANDLEBAROrder Part name Q'ty Remarks Headlight
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 Disconnect the clutch switch lead.
5 Engine stop switch 1 Disconnect the engine stop switch lead.
6 Brake master cylinder 1 Refer to removal section.
7 Start switch 1 Disconnect the start switch lead.
8 Throttle cable cap 1
9 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Right grip 1 Refer to removal section.
12 Tube guide 1
13 Left grip 1 Refer to removal section.
14 Handlebar upper holder 2
15 Handlebar 1
16 Handlebar lower holder 2

6-24
HANDLEBAR
REMOVING THE BRAKE MASTER
CYLINDER
1. Remove:• Brake master cylinder bracket "1"
• Brake master cylinder "2"
• Do not let the brake master cylin-
der hang on the brake hose.
• Keep the brake master cylinder
cap side horizontal to prevent air
from coming in.
REMOVING THE GRIP
1. Remove:•Grip "1"
Blow in air between the handlebar or
tube guide and the grip. Then remove
the grip which has become loose.
CHECKING THE HANDLEBAR
1. Inspect:• Handlebar "1"
Bends/cracks/damage →Re-
place.
Do not attempt to straighten a bent
handlebar as this may dangerous-
ly weaken the handlebar.
INSTALLING THE HANDLEBAR
1. Install: • Handlebar lower holder "1"
•Washer "2"
• Nut (handlebar lower holder) "3"
• Install the handlebar lower holder with its side having the greater dis-
tance "a" from the mounting bolt
center facing forward.
• Apply the lithium soap base grease on the thread of the handlebar low-
er holder.
• Installing the handlebar lower hold- er in the reverse direction allows the
front-to-rear offset amount of the
handlebar position to be changed.
• Do not tighten the nut yet.
2. Install:
• Handlebar "1"
• Handlebar upper holder "2"
• Bolt (handlebar upper holder) "3"
• The handlebar upper holder should be installed with the punched mark
"a" forward.
• Install the handlebar so that the marks "b" are in place on both
sides.
• Install the handlebar so that the pro- jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• First tighten the bolts on the front side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
3. Tighten:
• Nut (handlebar lower holder) "1"
4. Install: • Left grip "1"Apply the adhesive to the handle-
bar "2".
• Before applying the adhesive, wipe off grease or oil on the handlebar
surface "a" with a lacquer thinner.
• Install the left grip to the handlebar
so that the line "b" between the two
arrow marks faces straight upward.
Bolt (handlebar upper
holder): 28 Nm (2.8 m•kg, 20
ft•lb)
Nut (handlebar lower
holder):
34 Nm (3.4 m•kg, 24
ft•lb)

6-25
HANDLEBAR
5. Install:•Right grip "1"
•Collar "2"Apply the adhesive on the tube
guide "3".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark "b" and
tube guide slot "c" form the angle as
shown.
6. Install:• Grip cap cover "1"
• Throttle grip "2"
Apply the lithium soap base grease
on the throttle grip sliding surface.
7. Install:
• Throttle cables "1"To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
8. Install:• Throttle cable cap "1"
• Screw (throttle cable cap) "2"
After tightening the screws, check
that the throttle grip "3" moves
smoothly. If it does not, retighten
the bolts for adjustment.
9. Install:• Grip cap cover "1"
• Cover (throttle cable cap) "2" 10. Install:
• Start switch "1"
• Brake master cylinder "2"
• Brake master cylinder bracket "3"
• Bolt (brake master cylinder brack-et) "4"
•Clamp "5"
• The start switch and brake master cylinder bracket should be installed
according to the dimensions
shown.
• 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.
11. Install:• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
•Clamp "6"
Screw (throttle cable
cap): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (clutch lever holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (hot starter lever
holder): 4 Nm (0.4 m•kg, 2.9
ft•lb)