2010 YAMAHA YZ250F brake pads

3-3
MAINTENANCE INTERVALS
COOLING SYSTEMCheck coolant level and leakage ●●
Check radiator cap operation ●
Replace coolant ●Every two years
Inspect hoses ●
OUTSIDE NUTS AND BOLTS Retighten ●● Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER Clean and lubricate ●● Use foam air-filter oil or equivalent oil.
Replace ●
OIL FILTER Replace ●●
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 ●
Item
After
break- in Every
race
(about 2.5
hours)
Every third
(about 7.5
hours) Every
fifth
(about 12.5
hours)
As re-
quired Remarks

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 levelRefer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check: • Brake lever operationA 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.
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
2. Replace:• Brake pad
Brake pad replacement steps:
a. Remove the protector "1" and pad pin plug "2".
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 levelRefer to "CHECKING THE
BRAKE FLUID LEVEL" section. 4. Check:
• Brake pedal operationA 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 padRefer 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
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

5-4
FRONT WHEEL AND REAR WHEEL
2. Install:• Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:•Collar "1"
• Apply the lithium soap base grease on the oil seal lip.
• Install the collars with their projec-
tions "a" facing the wheel.
4. Install:• Wheel
Install the brake disc "1" between the
brake pads "2" correctly.
5. Install:• Wheel axle "1"
Apply the lithium soap base grease
on the wheel axle.
6. Install:• Nut (wheel axle) "1"
7. Tighten: • Bolt (axle holder) "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok-
ing the front fork several times with
the front brake applied.
INSTALLING THE REAR WHEEL
1. Install:• Bearing (right) "1"
• Circlip "2"
• Spacer "3"
• Bearing (left) "4"
• Oil seal "5"
• Apply the lithium soap base grease on the bearing and oil seal lip when
installing.
• Install the bearing with seal facing outward.
• Use a socket that matches the out- side diameter of the race of the
bearing.
• Right side of bearing shall be in- stalled first.
• Install the oil seal with its manufac- ture's marks or numbers facing out-
ward.
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
2. Install:
• Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:
• Rear wheel sprocket "1"
• Bolt (rear wheel sprocket) "2"
• Washer (rear wheel sprocket) "3"
• Nut (rear wheel sprocket) "4"
Tighten the nuts in stage, using a
crisscross pattern.
Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7
ft•lb)
Nut (wheel axle):105 Nm (10.5 m•kg, 75
ft•lb)
Bolt (axle holder): 21 Nm (2.1 m•kg, 15
ft•lb)
Bolt (brake disc): 14 Nm (1.4 m•kg, 10
ft•lb)
Nut (rear wheel sprock-
et): 42 Nm (4.2 m•kg, 30
ft•lb)

5-5
FRONT WHEEL AND REAR WHEEL
4. Install:•Collar "1"
Apply the lithium soap base grease
on the oil seal lip.
5. Install:• Wheel
Install the brake disc "1" between the
brake pads "2" correctly.
6. Install:• Drive chain "1"
Push the wheel "2" forward and install
the drive chain.
7. Install:• Left drive chain puller "1"
• Wheel axle "2"
• Install the left drive chain puller, and
insert the wheel axle from left side.
• Apply the lithium soap base grease on the wheel axle.
8. Install:
• Right drive chain puller "1"
• Washer "2"
• Nut (wheel axle) "3"
Temporarily tighten the nut (wheel
axle) at this point.
9. Adjust:• Drive chain slack "a"
Refer to "ADJUSTING THE
DRIVE CHAIN SLACK" section in
the CHAPTER 3.
10. Tighten: • Nut (wheel axle) "1"
• Locknut "2"
Drive chain slack: 50–60 mm (2.0–2.4 in)
Nut (wheel axle): 135 Nm (13.5 m•kg, 98
ft•lb)
Locknut: 21 Nm (2.1 m•kg, 15
ft•lb)

5-11
FRONT BRAKE AND REAR BRAKE
3. Inspect: (front brake only)• Reservoir float "1"Damage →Replace.
4. Inspect: • Brake master cylinder piston "1"
• Brake master cylinder cup "2"Wear/damage/score marks →Re-
place brake master cylinder kit.
CHECKING THE BRAKE CALIPER
1. Inspect: • Brake caliper cylinder inner sur-
face "a"
Wear/score marks →Replace
brake caliper assembly.
A. Front
B. Rear
2. Inspect: • Brake caliper piston "1"
Wear/score marks →Replace
brake caliper piston assembly.
Replace the brake caliper piston
seals and brake caliper piston dust
seals "2" whenever a caliper is dis-
assembled.
CHECKING THE BRAKE HOSE
1. Inspect: • Brake hose "1"Crack/damage →Replace.
HANDLING NOTE
• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricat- ed with brake fluid when in-
stalled.
• Replace the brake caliper piston seals and brake caliper piston
dust seals whenever a caliper is
disassembled.
INSTALLING THE BRAKE
CALIPER PISTON
1. Clean:• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper piston
Clean them with brake fluid.
2. Install: • Brake caliper piston seal "1"
• Brake caliper piston dust seal "2"
Always use new brake caliper pis-
ton seals and brake caliper piston
dust seals.
• Apply the brake fluid on the brake
caliper piston seal.
• Apply the silicone grease on the brake caliper piston dust seal.
• Fit the brake caliper piston seals and brake caliper piston dust seals
onto the slot on brake caliper cor-
rectly.
A. Front
B. Rear
3. Install: • Brake caliper piston "1"
Apply the brake fluid on the piston
wall.
• Install the piston with its shallow depressed side "a" facing the
brake caliper.
• Never force to insert.
A. Front
B. Rear
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.

5-12
FRONT BRAKE AND REAR BRAKE
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.
3. Install:• Spring "1"
To brake master cylinder piston
"2".
Install the spring at the smaller dia.
side.
4. Install:• Brake master cylinder kit "1"
• Washer (front brake) "2"
• Push rod (rear brake) "2"
• Circlip "3"
• Brake master cylinder boot "4"
• Push rod (front brake) "5"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.
A. Front
B. Rear
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)
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)