2009 YAMAHA YZ250F drain bolt

4-12
CARBURETOR
9. Install:
• Push rod "1"
While holding down the lever 1 "2", in-
sert the push rod farthest into the car-
buretor.
10. Install:
• Starter jet "1"
• Pilot jet "2"
• Spacer "3"
• Needle jet "4"
•Main jet "5"
11. Install:
• Needle valve "1"
•Float "2"
• Float pin "3"
• After installing the needle valve to
the float, install them to the carbure-
tor.
• Check the float for smooth move-
ment.
12. Install:
• Pilot screw "1"
• Spring "2"
•Washer "3"
• O-ring "4"
Note the following installation
points:
a. Turn in the pilot screw until it is
lightly seated.
b. Turn out the pilot screw by the
number of turns recorded before
removing.
13. Install:
• O-ring
•Leak jet "1"
• Float chamber "2"
• Bolt (float chamber) "3"
• Cable holder (throttle stop screw
cable) "4"
• Hose holder (carburetor breather
hose) "5"
14. Install:
• Diaphragm (accelerator pump)
"1"
• Spring "2"
• O-ring "3"• Accelerator pump cover "4"
• Hose holder (drain hose) "5"
• Screw (accelerator pump cover)
"6"
Install the diaphragm (accelerator
pump) with its mark "a" facing the
spring.
15. Install:
•Jet needle "1"
•Collar "2"
• Spring "3"
• Needle holder "4"
• Throttle valve plate "5"
To throttle valve "6".
16. Install:
• Throttle valve assembly "1"
• Screw (throttle shaft) "2"
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"
Pilot screw (example):
2 turns out

4-33
OIL FILTER ELEMENT AND WATER PUMP
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE OIL FILTER ELEMENT AND WATER PUMP
Order Part name Q'ty Remarks
Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING THE COOLANT" sec-
tion in the CHAPTER 3.
Radiator hose 3 Disconnect at water pump side.
Exhaust pipe Refer to "EXHAUST PIPE AND SILENCER"
section.
Brake pedal Refer to "ENGINE REMOVAL" section.
Right engine guard
1 Oil filter element cover 1
2 Oil filter element 1
3 Water pump housing 1
4 Oil delivery pipe 1
5 Bolt (oil hose) 1
6 Kickstarter crank 1
7 Right crankcase cover 1
8 Impeller 1 Refer to removal section.

5-6
FRONT BRAKE AND REAR BRAKE
FRONT BRAKE AND REAR BRAKE
REMOVING THE FRONT BRAKE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Drain the brake fluid. Refer to removal section.
1 Brake hose holder (protector) 2
2 Union bolt 2
3Brake hose 1
4 Pad pin plug 1 Remove when loosening the pad pin.
5 Pad pin 1Loosen when disassembling the brake cali-
per.
6 Brake caliper 1
7Brake lever 1
8 Brake master cylinder bracket 1
9 Brake master cylinder 1

5-7
FRONT BRAKE AND REAR BRAKE
REMOVING THE REAR BRAKE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Rear wheel Refer to "FRONT WHEEL AND REAR
WHEEL" section.
Drain the brake fluid. Refer to removal section.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1Loosen when disassembling the brake cali-
per.
8 Brake caliper 1

5-18
FRONT FORK
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
The front fork requires careful atten-
tion. So it is recommended that the
front fork be maintained at the deal-
ers.
To prevent an accidental explosion
of air, the following instructions
should be observed:
• The front fork with a built-in pis-
ton rod has a very sophisticated
internal construction and is par-
ticularly sensitive to foreign ma-
terial. Use enough care not to
allow any foreign material to
come in when the oil is replaced
or when the front fork is disas-
sembled and reassembled.
• Before removing the base valves
or front forks, be sure to extract
the air from the air chamber com-
pletely.
REMOVING THE DAMPER
ASSEMBLY
1. Loosen:
• Damper assembly "1"
Before removing the front fork from
the machine, loosen the damper as-
sembly with the cap bolt ring wrench
"2".
REMOVING THE ADJUSTER
1. Drain the outer tube of its front
fork oil at its top.
2. Loosen:
•Adjuster "1"3. Remove:
• Adjuster "1"
• While compressing the inner tube
"2", set the cap bolt ring wrench "4"
between the inner tube and locknut
"3".
• Hold the locknut and remove the
adjuster.
Do not remove the locknut as the
damper rod may go into the damp-
er assembly and not be taken out.
REMOVING THE INNER TUBE
1. Remove:
• Dust seal "1"
• Stopper ring "2"
Using slotted-head screwdriver.
Take care not to scratch the inner
tube.
2. Remove:
• Inner tube "1"
Oil seal removal steps:
a. Push in slowly "a" the inner tube
just before it bottoms out and then
pull it back quickly "b".
b. Repeat this step until the inner
tube can be pulled out from the
outer tube.
REMOVING THE BASE VALVE
1. Remove:
• Base valve "1"
From damper assembly "2".
Hold the damper assembly with the
cap bolt ring wrench "3" and use the
cap bolt wrench "4" to remove the
base valve.
CHECKING THE DAMPER
ASSEMBLY
1. Inspect:
• Damper assembly "1"
Bend/damage → Replace.
• O-ring "2"
Wear/damage → Replace.
The front fork with a built-in piston
rod has a very sophisticated inter-
nal construction and is particularly
sensitive to foreign material.
Use enough care not to allow any
foreign material to come in when
the oil is replaced or when the
front fork is disassembled and re-
assembled.Cap bolt ring wrench:
YM-01501/90890-01501
Cap bolt ring wrench:
YM-01501/90890-01501
Cap bolt wrench:
YM-01500/90890-01500
Cap bolt ring wrench:
YM-01501/90890-01501