2015 YAMAHA WR 250F Owners Manual

FRONT BRAKE
5-19
3. Install:
• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing
the brake caliper.
• Never force to insert.
EAS2GB2177INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• Front brake caliper bracket
• Front brake caliper
(temporarily)
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
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 3-26.
3. Tighten:
• Brake hose holder nut “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.
EWA
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 refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
Front brake caliper bracket
23 Nm (2.3 m·kgf, 17 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 nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Recommended brake fluid
DOT 4
T R..
T R..
1 2
b
a

FRONT BRAKE
5-20
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-24.
6. Check:
• Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-29.
7. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-25.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-24.
EAS2GB2178REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
• Union bolt
• Copper washers
• Brake hoses
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GB2179CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder “1”
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body)
Obstruction  Blow out with compressed
air.2. Check:
• Brake master cylinder kit
Damage/scratches/wear  Replace.
3. Check:
• Brake master cylinder reservoir cap
4. Check:
• Brake hoses
Cracks/damage/wear  Replace.
EAS2GB2180ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
EWA
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• 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”.
EWA
WARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.Recommended brake fluid
DOT 4
1
2

FRONT BRAKE
5-21
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”
TIP
• Before installation, apply brake fluid to the
brake master cylinder kit.
• Use circlip pliers to install the circlip.
EAS2GB2181INSTALLING 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
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
During installation, bring the brake hose
into contact with the brake master cylinder
projection “a” and make its bent portion “b”
face downward.
1 2
3
1 2
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..
1
New
T R..

FRONT BRAKE
5-22
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.
3. Pour brake fluid to the brake master cylinder
reservoir up to the specified level.
EWA
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 refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-24.
5. Check:
• Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-29.6. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-25.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-24.
Recommended brake fluid
DOT 4
a

REAR BRAKE
5-23
EAS2GB2182
REAR BRAKE
Removing the rear brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-24.
1 Protector 1
2 Union bolt 1
3 Copper washers 2
4 Rear brake hose 1
5 Brake pad pin plug 1
6 Brake pad pin 1
7 Rear brake pad assembly 2
8 Rear brake caliper bracket 1
9 Brake pad springs 2
10 Rear brake disc cover 1
11 Rear brake caliper assembly 1
For installation, reverse the removal proce-
dure.
2
3
4 11
56
79
1
8
9 10
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
17 Nm (1.7 m•kgf, 12 ft•Ibf)T.R.
30 Nm (3.0 m•kgf, 22 ft•Ibf)T.R.
New
S
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)T.R.

REAR BRAKE
5-24
Disassembling the rear brake caliper
Order Part name Q’ty Remarks
1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
For assembly, reverse the disassemble pro-
cedure.
1
2
3
4
S
BF
T R..6 Nm (0.6 m kgf, 4.3 ft Ibf)

REAR BRAKE
5-25
Removing the rear brake master cylinder
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-24.
1 Union bolt 1
2 Copper washers 2
3 Brake hose 1
4 Split pin 1
5Washer 1
6Pin 1
7 Brake master cylinder reservoir cap 1
8 Brake master cylinder reservoir diaphragm plate 1
9 Brake master cylinder reservoir diaphragm 1
10 Rear brake master cylinder 1
For installation, reverse the removal proce-
dure.
1
2
3
4 7
5 8
6 9
T R..
T R..
10
T R..

REAR BRAKE
5-26
Disassembling the rear brake master cylinder
Order Part name Q’ty Remarks
1 Dust boot 1
2 Circlip 1
3 Push rod 1
4 Brake master cylinder kit 1
For assembly, reverse the disassemble pro-
cedure.
4
3
2
1
BF
S
New
New