2014 YAMAHA YZ250F Owners Manual

REAR BRAKE
4-29
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA13520
WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for
cleaning and lubricating.
• Never use solvents on internal brake com-
ponents.
1. Wash the brake master cylinder and the
brake master cylinder kit with brake fluid.
2. Install:
• Primary cylinder cup “1”
• Secondary cylinder cup “2”
Install to the brake master cylinder piston
“3”.
EWA13520
WARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.
3. Install:
• Spring “1”
Install to the brake master cylinder piston
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston.4. Install:
• Master cylinder kit “1”
• Push rod “2”
• Circlip “3”
• Dust boot “4”
TIP
• Before installation, apply brake fluid to the
brake master cylinder kit.
• Before installation, apply silicone grease to
the push rod end.
• Use circlip pliers to install the circlip.
EAS1SM1160INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• Copper washers
• Brake hose
• Union bolt
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CA-
BLE ROUTING DIAGRAM” on page 2-31.
ECA1DX1008
NOTICE
Make sure that the pipe portion of the brake
hose touches the projection “a” on the
brake caliper. Recommended brake fluid
DOT 4
New
New
2
3
1
2
3
1Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
12
New
New
13
4
2NewNew
New
T R..

REAR BRAKE
4-30
2. Pour brake fluid to the brake fluid reservoir
up to the specified level.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When pouring the brake fluid, be careful
that water does not enter the reservoir.
Water will significantly lower the boiling
point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21.
4. Check:
• Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-26.5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21. Recommended brake fluid
DOT 4
a
a

HANDLEBAR
4-31
EAS1SM1161
HANDLEBAR
Removing the handlebar
OrderPart name Q’tyRemarks
Number plate Remove the band only.
1 Clutch cable 1 Disconnect.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Brake master cylinder 1
5 Throttle cable cap 1
6 Throttle cable (pull) 1 Disconnect.
7 Throttle cable (return) 1 Disconnect.
8 Right grip 1
9 Tube guide 1
10 Collars 1
11 Left grip 1
12 Handlebar upper holder 2
13 Handlebar 1

HANDLEBAR
4-32
14 Handlebar lower holder2
15 Damper 4
For installation, reverse the removal proce-
dure.
Removing the handlebar
Order Part name Q’tyRemarks

HANDLEBAR
4-33
EAS1SM1162REMOVING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Grip “1”
TIP
Blow in compressed air between the handlebar
or tube guide and the grip. Then remove the
grip which has become loose.
EAS1SM1163CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage  Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS1SM1164INSTALLING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Damper “1”
• Lower handlebar holders “2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handlebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that
right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d”
of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA14250
NOTICE
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
Upper handlebar holder bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..
2
1
1
a

HANDLEBAR
4-34
3. Tighten:
• Lower handlebar holder nut4. Install:
• Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly coat the handlebar left end with a
rubber adhesive.
b. Install the handlebar grip on the handlebar
by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean
cloth.
EWA13120
WARNING
Do not touch and move the handlebar grip
until its adhesive dries completely.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and
the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder. Lower handlebar holder nut
40 Nm (4.0 m·kgf, 29 ft·lbf)
3
4
T R..
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T R..

HANDLEBAR
4-35
6. Install:
• Right grip “1”
• Collar “2”
Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the
grip match mark “b” and tube guide slot “c”
form the angle as shown.
7. Install:
• Collar “1”
• Rubber cover “2”
• Throttle grip “3”
TIP
Apply the lithium soap base grease on the
throttle grip sliding surface.8. Install:
• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA1DX5001
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
1b
c
3
Screw (throttle cable housings)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..

HANDLEBAR
4-36
10.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install:
• Front brake master cylinder assembly “1”
• Front brake master cylinder holder “2”
• Bolt (brake master cylinder holder) “3”
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.12.Install:
• Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-10.
14.Adjust:
• Throttle grip free play
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-11.
Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
1LS