2014 YAMAHA YZ250F diagram

CABLE ROUTING DIAGRAM
2-37

CABLE ROUTING DIAGRAM
2-38
1. Main harness
2. Radiator
3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor lead
6. Intake air pressure sensor lead
7. Frame
8. Fuel hose
9. High tension cord
10. Spark plug cap
11. Cylinder head cover
12. Sub-wire harness
13. Injector coupler
14. Injector lead
15. Throttle body
16. Air filter case
17. ECU
18. Sub-wire harness coupler
A. Fix the main harness by the plastic clamp, and in-
sert the projection of the plastic clamp into the
hole in the sheet metal of the radiator.
B. Insert the projection of the main harness into the
hole in the frame.
C. To the sub-wire harness
D. Pass the high tension cord above the fuel hose.
E. ±10°
F. Install the spark plug cap with this facing the right
of the vehicle.
G. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
H. Pass the injector lead to the top of the vehicle be-
yond the fuel hose.
I. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
J. Pass the sub-wire harness between the ECU and
the air filter case.

CABLE ROUTING DIAGRAM
2-39

CABLE ROUTING DIAGRAM
2-40
1. Brake master cylinder
2. Brake hose holder
3. Brake hoses
A. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake caliper.
B. Pass the brake hose into the brake hose holders.
C. If the brake hose interferes with the rear shock
absorber, correct its twist.
D. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake master cylinder.

CABLE ROUTING DIAGRAM
2-41

FRONT BRAKE
4-17
3. Install:
• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston wall.
ECA33DD047
NOTICE
• Install the piston with its side “a” facing
the brake caliper.
• Never force to insert.
EAS1SM1143INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• Front brake caliper bracket
• Front brake caliper
(temporarily)
• 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.
ECA14170
NOTICE
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on
the brake caliper.2. Install:
• Front brake caliper
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-23.
3. Tighten:
• Brake hose holder mounting bolt “1”
TIP
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
paint “b” on the brake hose.
4. Pour brake fluid to the brake master cylinder
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. Front brake caliper bracket
28 Nm (2.8 m·kgf, 20 ft·lbf)
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
a
1
New
T R..
a
b
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake hose holder mounting bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Recommended brake fluid
DOT 4
T R..
T R..
2
1 b
a

FRONT BRAKE
4-19
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:
• Brake master cylinder kit “1”
• Washer “2”
• Circlip “3”
• Dust boot “4”
• Push rod “5”
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.
EAS1SM1147INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder “1”
TIP
• Install the front brake master cylinder holder
with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower
bolt.
2. 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.
ECA1DX1007
NOTICE
During installation, bring the brake hose
into contact with the brake master cylinder
projection “a” and make its bent portion “b”
face downward.
TIP
Turn the handlebar toward right and left to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Adjust if necessary.
2 1
3
New
New
Brake master cylinder holder bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T R..
New
T R..

REAR BRAKE
4-27
EAS1SM1155INSTALLING THE BRAKE CALIPER PISTON
1. Clean:
• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper piston
Use brake fluid for cleaning.
2. Install:
• Brake caliper piston seals “1”
• Brake caliper piston dust seal “2”
EWA33DD033
WARNING
Always use new brake caliper piston seal
and brake caliper piston dust seal.
TIP
• Apply the brake fluid on the brake caliper pis-
ton 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 correctly.
3. Install:
• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston wall.
ECA33DD047
NOTICE
• Install the piston with its side “a” facing
the brake caliper.
• Never force to insert.
EAS1SM1156INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Rear brake caliper
• Rear brake caliper bracket
2. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
• 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.
ECA14170
NOTICE
Make sure that a bend in its pipe portion “a”
is directed as shown and the brake hose
touches the projection “b” on the brake cal-
iper.
3. Install:
• Brake pad springs
• Brake pads
• Brake pad pin
• Brake pad pin plug
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-25.
4. Pour brake fluid to the brake fluid reservoir
up to the specified level.
New
New
2
1
1
a1
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Recommended brake fluid
DOT 4
New
T R..
b
b
a
T R..