2009 YAMAHA YZ250F brake

3-16
CHASSIS
b. Loosen the pad pin "3".
c. Remove the rear wheel "4" and
brake caliper "5".
Refer to "FRONT WHEEL AND
REAR WHEEL" section in the
CHAPTER 5.
d. Remove the pad pin "6" and brake
pads "7".
e. Connect the transparent hose "8"
to the bleed screw "9" and place
the suitable container under its
end.
f. Loosen the bleed screw and push
the brake caliper piston in.
Do not reuse the drained brake flu-
id.
g. Tighten the bleed screw.
h. Install the brake pad "10" and pad
pin "11".
• Install the brake pads with their pro-
jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at
this point.
i. Install the brake caliper "12" and
rear wheel "13".
Refer to "FRONT WHEEL AND
REAR WHEEL" section in the
CHAPTER 5.
j. Tighten the pad pin "14".
k. Install the pad pin plug "15" and
protector "16".
3. Inspect:
• Brake fluid level
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check:
• Brake pedal operation
A softy or spongy feeling→Bleed
brake system.
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion.CHECKING THE REAR BRAKE
PAD INSULATOR
1. Remove:
• Brake pad
Refer to "CHECKING AND RE-
PLACING THE REAR BRAKE
PADS" section.
2. Inspect:
• Rear brake pad insulator "1"
Damage→Replace.
CHECKING THE BRAKE FLUID
LEVEL
1. Place the brake master cylinder
so that its top is in a horizontal po-
sition.
2. Inspect:
• Brake fluid level
Fluid at lower level→Fill up.
• Use only designated quality
brake fluid to avoid poor brake
performance.
• Refill with same type and brand
of brake fluid; mixing fluids
could result in poor brake perfor-
mance.
• Be sure that water or other con-
taminants do not enter master
cylinder when refilling.
• Clean up spilled fluid immediate-
ly to avoid erosion of painted
surfaces or plastic parts.
a. Lower level
A. Front
B. Rear
CHECKING THE SPROCKET
1. Inspect:
• Sprocket teeth "a"
Excessive wear→Replace. Bleed screw:
6 Nm (0.6 m•kg, 4.3
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 (protector):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Recommended brake flu-
id:
DOT #4

3-18
CHASSIS
A. Right
B. Left
Turn the adjuster so that the drive
chain is in line with the sprocket, as
viewed from the rear.
d. Tighten the axle nut while pushing
down the drive chain.
e. Tighten the locknuts.
CHECKING THE FRONT FORK
1. Inspect:
• Front fork smooth action
Operate the front brake and
stroke the front fork.
Unsmooth action/oil leakage→
Repair or replace.
CLEANING THE FRONT FORK OIL
SEAL AND DUST SEAL
1. Remove:
•Protector
• Dust seal "1"
Use a thin screw driver, and be care-
ful not to damage the inner fork tube
and dust seal.
2. Clean:
• Dust seal "a"
•Oil seal "b"
• Clean the dust seal and oil seal af-
ter every run.
• Apply the lithium soap base grease
on the inner tube.
RELIEVING THE FRONT FORK
INTERNAL PRESSURE
If the front fork initial movement feels
stiff during a run, relieve the front fork
internal pressure.
1. Elevate the front wheel by placing
a suitable stand under the engine.
2. Remove the air bleed screw "1"
and release the internal pressure
from the front fork.
3. Install:
• Air bleed screw
ADJUSTING THE FRONT FORK
REBOUND DAMPING FORCE
1. Adjust:
• Rebound damping force
By turning the adjuster "1".• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
ADJUSTING THE FRONT FORK
COMPRESSION DAMPING FORCE
1. Adjust:
• Compression damping force
By turning the adjuster "1". Axle nut:
135 Nm (13.5 m•kg, 98
ft•lb)
Locknut:
19 Nm (1.9 m•kg, 13
ft•lb)
Air bleed screw:
1 Nm (0.1 m•kg, 0.7
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
10 clicks out
* 9 clicks out
* Except for USA and CDN
Stiffer "a" →Increase the com-
pression damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the com-
pression damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)

3-23
CHASSIS
LUBRICATION
To ensure smooth operation of all
components, lubricate your machine
during setup, after break-in, and after
every race.
1. All control cable
2. Clutch lever pivot
3. Shift pedal pivot
4. Footrest pivot
5. Throttle-to-handlebar contact
6. Drive chain
7. Tube guide cable winding por-
tion
8. Throttle cable end
9. Clutch cable end
10. Hot starter cable end
A. Use Yamaha cable lube or
equivalent on these areas.B. Use SAE 10W-30 motor oil or
suitable chain lubricants.
C. Lubricate the following areas
with high quality, lightweight lith-
ium-soap base grease.
Wipe off any excess grease, and
avoid getting grease on the brake
discs.

4-29
CLUTCH
CLUTCH
REMOVING THE CLUTCH
Order Part name Q'ty Remarks
Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Clutch spring 5
3 Pressure plate 1
4 Push rod 1 1
5 Circlip 1
6 Washer 1
7 Bearing 1
8Ball 1
9 Push rod 2 1
10 Friction plate 9
11 Clutch plate 8
12 Nut (clutch boss) 1 Refer to removal section.
13 Lock washer 1 Refer to removal section.

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.

4-50
ENGINE REMOVAL
1 Lower engine guard 1
2 Neutral switch 1
3 Drive chain sprocket cover 1
4 Nut (drive sprocket) 1 Refer to removal section.
5 Lock washer 1 Refer to removal section.
6 Drive sprocket 1 Refer to removal section.
7 Clip 1
8 Bolt (brake pedal) 1
9 Brake pedal 1
10 Upper engine bracket 2
11 Lower engine bracket 2
12 Engine mounting bolt 3
13 Pivot shaft 1 Refer to removal section.
14 Engine 1 Refer to removal section. Order Part name Q'ty Remarks

4-51
ENGINE REMOVAL
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE DRIVE
SPROCKET
1. Remove:
• Nut (drive sprocket) "1"
• Lock washer "2"
• Straighten the lock washer tab.
• Loosen the nut while applying the
rear brake.
2. Remove:
• Drive sprocket "1"
• Drive chain "2"
Remove the drive sprocket together
with the drive chain.
REMOVING THE ENGINE
1. Remove:
• Pivot shaft "1"
If the pivot shaft is pulled all the way
out, the swingarm will come loose. If
possible, insert a shaft of similar di-
ameter into the other side of the swin-
garm to support it.
2. Remove:
• Engine "1"
From right side.
Make sure that the couplers, hoses
and cables are disconnected.
INSTALLING THE ENGINE
1. Install:
•Engine "1"
Install the engine from right side.
• Pivot shaft "2"
• Engine mounting bolt (lower) "3"
• Lower engine bracket "4"
• Bolt (lower engine bracket) "5"
•Patch "6"
• Engine mounting bolt (front) "7"
• Upper engine bracket "8"
• Bolt (upper engine bracket) "9"
• Engine mounting bolt (upper) "10"
• Lower engine guard "11"
• Bolt (lower engine guard) "12"
• Apply the molybdenum disulfide
grease on the pivot shaft.
• Install the patch with the claw "a"
facing outside the chassis.
INSTALLING THE BRAKE PEDAL
1. 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-rings and brake pedal
bracket.
INSTALLING THE DRIVE
SPROCKET
1. Install:
• Drive sprocket "1"
• Drive chain "2"
Install the drive sprocket together
with the drive chain.
Pivot shaft:
85 Nm (8.5 m•kg, 61
ft•lb)
Engine mounting bolt
(lower):
53Nm (5.3 m•kg, 38
ft•lb)
Bolt (lower engine brack-
et):
34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(front):
53 Nm (5.3 m•kg, 38
ft•lb)
Bolt (upper engine brack-
et):
34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(upper):
55 Nm (5.5 m•kg, 40
ft•lb)
Bolt (lower engine
guard):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (brake pedal):
26 Nm (2.6 m•kg, 19
ft•lb)

4-52
ENGINE REMOVAL
2. Install:
• Lock washer "1"
• Nut (drive sprocket) "2"
Tighten the nut while applying the
rear brake.
3. Bend the lock washer tab to lock
the nut.
4. Install:
• Drive chain sprocket guide "1"
• Drive chain sprocket cover "2"
• Screw (drive chain sprocket cov-
er) "3"
INSTALLING THE NEUTRAL
SWITCH
1. Install:
• Spring "1"
•Pin "2"
• O-ring "3"
• Neutral switch "4"
• Screw (neutral switch) "5"
Apply the lithium soap base grease
on the O-ring.
2. Install:
• Hose guide (cylinder head breath-
er hose) "1"
• Bolt (hose guide) "2"
Nut (drive sprocket):
75 Nm (7.5 m•kg, 54
ft•lb)
Screw (drive chain
sprocket cover):
8 Nm (0.8 m•kg, 5.8
ft•lb)
Screw (neutral switch):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (hose guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)