2009 YAMAHA YZ250F brake fluid

HOW TO READ DESCRIPTIONS
To help identify parts and clarify pro-
cedure steps, there are exploded dia-
grams at the start of each removal
and disassembly section.
1. An easy-to-see exploded diagram
"1" is provided for removal and
disassembly jobs.
2. Numbers "2" are given in the or-der of the jobs in the exploded di-
agram. A number that is enclosed
by a circle indicates a disassem-
bly step.
3. An explanation of jobs and notes
is presented in an easy-to-read
way by the use of symbol marks
"3". The meanings of the symbol
marks are given on the next page.4. A job instruction chart "4" accom-
panies the exploded diagram,
providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more informa-
tion, the step-by-step format sup-
plements "5" are given in addition
to the exploded diagram and job
instruction chart.
ILLUSTRATED SYMBOLS (Refer to
the illustration)Illustrated symbols "1" to "7" are used
to identify the specifications appear-
ing in the text.
1. With engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening
6. Specified value, Service limit
7. Resistance (Ω), Voltage (V),
Electric current (A)
Illustrated symbols "8" to "13" in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Apply brake fluid
11. Apply lightweight lithium-soap
base grease
12. Apply molybdenum disulfide
grease
13. Apply silicone grease
Illustrated symbols "14" to "15" in the
exploded diagrams indicate where to
apply a locking agent and where to in-
stall new parts.14. Apply locking agent (LOC-
TITE
®)
15. Use new one
1
23
45

2-9
MAINTENANCE SPECIFICATIONS
Spring rate, STD K = 52.0 N/mm (5.30 kg/
mm, 296.8 lb/in)←----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04
in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 19 × 1.85/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain: USA, CDN EUROPE, AUS, NZ, ZA
Type/manufacturer DID520DMA2 SDH/
DAIDO←----
Number of links 111 links + joint 113 links + joint ----
Chain slack 50–60 mm (2.0–2.4 in)←----
Chain length (15 links) ----←242.9 mm
(9.563 in)
Front disc brake:
Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height (vertical height above footrest
top)5 mm (0.20 in) ---- Item Standard Limit

3-3
MAINTENANCE INTERVALS
OIL STRAINER
Clean●
ENGINE GUARD
Replace●Breakage
FRAME
Clean and inspect●●
FUEL TANK, COCK
Clean and inspect●●
BRAKES
Adjust lever position and pedal
height●●
Lubricate pivot point●●
Check brake disc surface●●
Check fluid level and leakage●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts●●
Replace pads●
Replace brake fluid●Every one year
FRONT FORKS
Inspect and adjust●●
Replace oil●●Suspension oil "S1"
Replace oil seal●
FRONT FORK OIL SEAL AND
DUST SEAL
Clean and lube●●Lithium base grease
PROTECTOR GUIDE
Replace●
REAR SHOCK ABSORBER
Inspect and adjust●●
Lube●(After
rain
ride)●Molybdenum disulfide grease
Replace spring seat●Every one year
Retighten●●
DRIVE CHAIN GUIDE AND
ROLLERS
Inspect●●
SWINGARM
Inspect, lube and retighten●●Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD
Inspect, lube and retighten●●Molybdenum disulfide grease ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks

3-14
CHASSIS
CHASSIS
BLEEDING THE HYDRAULIC
BRAKE SYSTEM
Bleed the brake system if:
• The system has been disassem-
bled.
• A brake hose has been loosened
or removed.
• The brake fluid is very low.
• The brake operation is faulty.
A dangerous loss of braking per-
formance may occur if the brake
system is not properly bled.
1. Remove:
• Brake master cylinder cap
• Diaphragm
• Reservoir float (front brake)
• Protector (rear brake)
2. Bleed:
• Brake fluid
Air bleeding steps:
a. Add proper brake fluid to the res-
ervoir.
b. Install the diaphragm. Be careful
not to spill any fluid or allow the
reservoir to overflow.
c. Connect the clear plastic tube "2"
tightly to the caliper bleed screw
"1".
A. Front
B. Rear
d. Place the other end of the tube
into a container.
e. Slowly apply the brake lever or
pedal several times.
f. Pull the lever in or push down on
the pedal. Hold the lever or pedal
in position.
g. Loosen the bleed screw and allow
the lever or pedal to travel to-
wards its limit.h. Tighten the bleed screw when the
lever or pedal limit has been
reached; then release the lever or
pedal.
i. Repeat steps (e) to (h) until of the
air bubbles have been removed
from the system.
If bleeding is difficult, it may be nec-
essary to let the brake fluid system
stabilize for a few hours. Repeat the
bleeding procedure when the tiny
bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on
the reservoir.
Check the operation of the brake
after bleeding the brake system.
3. Install:
• Protector (rear brake)
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap
ADJUSTING THE FRONT BRAKE
1. Check:
• Brake lever position "a"
2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
Brake lever position adjustment
steps:
a. Loosen the locknut "1".
b. Turn the adjusting bolt "2" until the
lever position "a" is within speci-
fied position.c. Tighten the locknut.
Be sure to tighten the locknut, as it
will cause poor brake perfor-
mance.
4. Install:
• Brake lever cover
ADJUSTING THE REAR BRAKE
1. Check:
• Brake pedal height "a"
Out of specification→Adjust.
2. Adjust:
• Brake pedal height
Pedal height adjustment steps:
a. Loosen the locknut "1".
b. Turn the adjusting nut "2" until the
pedal height "a" is within specified
height.
c. Tighten the locknut.
• Adjust the pedal height between
the maximum "A" and the mini-
mum "B" as shown. (In this ad-
justment, the bolt "3" end "b"
should protrude out of the
threaded portion "4" but not be
less than 2 mm (0.08 in) "c" away
from the brake pedal "5").
• After the pedal height adjust-
ment, make sure that the rear
brake does not drag.
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
Brake lever position "a":
Standard posi-
tionExtent of ad-
justment
95 mm (3.74 in)86–105 mm
(3.39–4.13 in)
Locknut:
5 Nm (0.5 m •kg, 3.6
ft•lb)
Brake pedal height "a":
5 mm (0.20 in)

3-15
CHASSIS
CHECKING AND REPLACING THE
FRONT BRAKE PADS
1. Inspect:
• Brake pad thickness "a"
Out of specification→Replace as
a set.
2. Replace:
•Brake pad
Brake pad replacement steps:
a. Remove the pad pin plug "1".
b. Loosen the pad pin "2".
c. Remove the brake caliper "3"
from the front fork.
d. Remove the pad pin and brake
pads "4".e. Connect the transparent hose "5"
to the bleed screw "6" 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 pads "7" and pad
pin.
• 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 "8" and
tighten the pad pin "9".j. Install the pad pin plug "10".
3. Inspect:
• Brake fluid level
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check:
• Brake lever operation
A softy or spongy feeling→Bleed
brake system.
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion.
CHECKING AND REPLACING THE
REAR BRAKE PADS
1. Inspect:
• Brake pad thickness "a"
Out of specification→Replace as
a set.
2. Replace:
• Brake pad
Brake pad replacement steps:
a. Remove the protector "1" and pad
pin plug "2". Brake pad thickness:
4.4 mm (0.17 in)
: 1.0 mm (0.04
in)
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
Bolt (brake caliper):
28 Nm (2.8 m•kg, 20
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)
Brake pad thickness:
6.4 mm (0.25 in)
: 1.0 mm (0.04
in)

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

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