2011 YAMAHA YFM250R service

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WARNING
EWB00410These shock absorber assemblies contain
highly pressurized nitrogen gas. Read and un-
derstand the following information before han-
dling the shock absorber assemblies.
Do not tamper with or attempt to open the
cylinder assemblies.
Do not subject the shock absorber assem-
blies to an open flame or other high heat
source. This may cause the unit to explode
due to excessive gas pressure.
Do not deform or damage the cylinders in
any way. Cylinder damage will result in poor
damping performance.
Do not dispose of a damaged or worn out
shock absorber assembly yourself. Take the
shock absorber assembly to a Yamaha deal-
er for any service.EBU28243Adjusting the rear shock absorber as-
sembly (YFM25RA/YFM250RA)The spring preload can be adjusted to suit the rid-
er’s weight and the riding conditions.
1. Compression damping force adjusting screw (for slow
compression damping)Compression damping setting (for slow com-
pression damping):
Minimum (soft):
16 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned in di-
rection (a)
(b)(a)
1
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4
WARNING
EWB00450This shock absorber assembly contains highly
pressurized nitrogen gas. If the shock absorb-
er assembly is damaged, it could explode
causing injury or property damage. Shock ab-
sorber cylinder damage could also result in
poor handling which could cause an accident.
Do not tamper with or attempt to open the
cylinder assembly.
Do not subject the shock absorber assembly
to an open flame or other high heat.
Do not deform or damage the cylinder in any
way.
Do not dispose of a damaged or worn out
shock absorber assembly yourself. Take the
shock absorber assembly to a Yamaha deal-
er for any service.
EBU29312Adjusting the rear shock absorber as-
sembly (YFM25RSEA/YFM250RSEA)The spring preload, rebound damping and com-
pression damping forces of the rear shock absorb-
er assembly can be adjusted to suit the rider’s
weight and the riding conditions.
WARNING
EWB02500Suspension components become hot during
operation. Never touch the compression
damping force adjusting screw, the rebound
damping force adjusting dial or the oil reser-
voir with your bare hand or skin until suspen-
sion components have cooled.NOTICEECB00090Never turn an adjusting mechanism beyond
the minimum and maximum settings.Spring preload
1. Loosen the locknut. Tightening torque:
Locknut:
42 Nm (4.2 m·kgf, 30 ft·lbf)
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WARNING
EWB00430This shock absorber assembly contains highly
pressurized nitrogen gas. Read and under-
stand the following information before han-
dling the shock absorber assembly.
Do not tamper with or attempt to open the
cylinder assembly.
Do not subject the shock absorber assembly
to an open flame or other high heat source.
This may cause the unit to explode due to ex-
cessive gas pressure.
Do not deform or damage the cylinder in any
way. Cylinder damage will result in poor
damping performance.
Do not dispose of a damaged or worn out
shock absorber assembly yourself. Take the
shock absorber assembly to a Yamaha deal-
er for any service.
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8
EBU28783
PERIODIC MAINTENANCE AND ADJUSTMENT
EBU21672Periodic inspection, adjustment, and lubrication
will keep your vehicle in the safest and most effi-
cient condition possible. Safety is an obligation of
the vehicle owner/operator. The most important
points of vehicle inspection, adjustment, and lubri-
cation are explained on the following pages.
WARNING
EWB01841Failure to properly maintain the vehicle or per-
forming maintenance activities incorrectly may
increase your risk of injury or death during ser-
vice or while using the vehicle. If you are not fa-
miliar with vehicle service, have a Yamaha
dealer perform the service.
WARNING
EWB02561Turn off the engine when performing mainte-
nance unless otherwise specified.
A running engine has moving parts that can
catch on body parts or clothing and electri-
cal parts that can cause shocks or fires.

Running the engine while servicing can lead
to eye injury, burns, fire, or carbon monoxide
poisoning - possibly leading to death. See
page 2-1 for more information about carbon
monoxide.
WARNING
EWB02690Brake discs, calipers, drums, and linings can
become very hot during use. To avoid possible
burns, let brake components cool before
touching them.The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
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EBU29790Owner’s manual and tool kit Be sure to put this owner’s manual in the cover and
always carry it along with the low-pressure tire
gauge and the owner’s tool kit under the seat.
The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIPIf you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
1. Low-pressure tire gauge
2. Owner’s tool kit
3. Owner’s manual
4. Manual cover123
4
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EBU23071TIP
Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
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4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU29601Brakes Replacement of brake components requires pro-
fessional knowledge. Brake service should be per-
formed by a Yamaha dealer.
WARNING
EWB02571Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.EBU24130Checking the front and rear brake pads The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart.EBUM0190Front brake pads
Each brake pad is provided with a wear indicator
groove, which allows you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor groove. If a brake pad has worn to the point that
the wear indicator groove has almost disappeared,
have a Yamaha dealer replace the brake pads as
a set.
1. Rubber cover
2. Throttle cable free play adjusting bolt
3. Locknut
4. Throttle cable free play
4 2 1
3
(a)
(b)
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8
TIPIf the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.6. Tighten the locknut on the brake cable.
7. Slide the rubber cover to its original position.
8. Turn in the adjusting bolt at the rear brake cal-
iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.
NOTICE: When tightening the locknut,hold the adjusting bolt with a wrench so
that it does not turn together with the lock-
nut.
[ECB00521]
WARNING
EWB02090Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.EBU24742Brake light switches The brake light, which is activated by the brake
pedal and brake lever, should come on just before
braking takes effect.
1. Rubber cover
2. Adjusting nut
3. Locknut
2
3
1(a)(b)
Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 12 ft·lbf)
U1BT61E0.book Page 27 Tuesday, April 6, 2010 1:28 PM