2016 YAMAHA YZ250F drain bolt

CHASSIS
3-25
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 plastic hose “5” to the bleed
screw “6” and place a container under the
end of the plastic hose.
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pads “7” and the pad pin.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “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. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
4. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22. Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
3
2
4
6
5
T R..
Bolt (brake caliper)
28 Nm (2.8 m·kgf, 20 ft·lbf)
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
7
a b
T R..
8
9
T R..
10

FRONT BRAKE
4-11
EAS1SM9133
FRONT BRAKE
Removing the front brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
For installation, reverse the removal proce-
dure.
3
9
1
2
8
4
5 7
6
T.R.30 Nm (3.0 mlbf) kgf, 22 ft
T.R.28 Nm (2.8 mlbf) kgf, 20 ft
T.R.17 Nm (1.7 mlbf) kgf, 12 ft
T.R.2.5 Nm (0.25 mlbf) kgf, 1.8 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft

FRONT BRAKE
4-13
Removing the front brake master cylinder
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Brake lever 1
2 Union bolt 1
3 Copper washers 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1
For installation, reverse the removal proce-
dure.
5
6
7
23
48
9
1
T.R.30 Nm (3.0 mlbf) kgf, 22 ft
T.R.1.5 Nm (0.15 mlbf) kgf, 1.1 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft

FRONT BRAKE
4-15
EAS1SM9134INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components
unless absolutely necessary.
• If there is any problem with connections
on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake
components.
• Immediately wipe off the spilled brake fluid
to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to
let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS1SM9135CHECKING THE FRONT BRAKE DISC
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-3.
2. Check:
• Front brake disc
Damage/galling  Replace.
3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.4. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-3.
EAS1SM9136REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
EAS1SM9137DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
Brake disc thickness limit
2.5 mm (0.10 in)
3
2
1

FRONT BRAKE
4-18
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 3-22.
6. Check:
• Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
7. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-23.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22.
EAS1SM9142REMOVING 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.
EAS1SM9143CHECKING 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.
EAS1SM9144ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
EWAWARNING
• 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”.
EWAWARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.Specified brake fluid
DOT 4
1
2
12
3

REAR BRAKE
4-21
EAS1SM9146
REAR BRAKE
Removing the rear brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
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
4-23
Removing the rear brake master cylinder
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
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
4-25
EAS1SM9147INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components
unless absolutely necessary.
• If there is any problem with connections
on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing internal
brake components.
• Use new brake fluid for cleaning the brake
components.
• Immediately wipe off the spilled brake fluid
to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to
let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS1SM9148CHECKING THE REAR BRAKE DISC
1. Remove:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
2. Check:
• Brake disc
Damage/galling  Replace.
3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-15.
4. Measure:
• Brake disc deflection
Out of specification  Correct the brake disc
deflection or replace the brake disc.5. Adjust:
• Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Turn the mounted position of the brake disc
by one bolt hole.
c. Install the brake disc.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
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6. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7. Brake disc thickness limit
3.5 mm (0.14 in)
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)
Brake disc bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
T R..