2016 YAMAHA YZ250F ABS

REAR SHOCK ABSORBER ASSEMBLY
4-54
13 O-ring 2
14 Dust seal 2
15 Stopper ring 1
16 Bearing 1
For installation, reverse the removal proce-
dure.
Removing the rear shock absorber assembly
Order Part name Q’ty Remarks
2
12
1615
1413
12
14
4
5
7
6
83
9
9 10
10 11
1
New
New
13New
LS
LS
M
M
M
M
M

REAR SHOCK ABSORBER ASSEMBLY
4-55
Disassembling the relay arm
Order Part name Q’ty Remarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
5
6
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf) kgf, 58 ft
M
M
M
M
M MM

REAR SHOCK ABSORBER ASSEMBLY
4-56
EAS1SM9174HANDLING THE REAR SHOCK ABSORBEREWAWARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS1SM9175DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out
rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS1SM9176REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS1SM9177REMOVING THE BEARING
1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

REAR SHOCK ABSORBER ASSEMBLY
4-57
2. Remove:
• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS1SM9178CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace.
• Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts
Bends/damage/wear  Replace.
EAS1SM9179CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check:
• Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check:
• Oil seals
Damage/pitting  Replace.
EAS1SM9180INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install:
• Bearing “1”
• Washer “2”
• Oil seals “3”
(to relay arm “4”)
3. Install:
• Bearing “1”
• Oil seals “2”
(to connecting arm “3”)
1
Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0 mm (0 in)
Installed depth “a”
0 mm (0 in)
New
3 3
43
2 2
22
a
1
11
New

REAR SHOCK ABSORBER ASSEMBLY
4-58
EAS1SM9181INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:
• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA1DX1012
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:
• O-ring
3. Install:
• Bearing
• Stopper ring
(to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper
ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring.
4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”
(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt
(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt
6. Install:
• Rear shock absorber assembly
TIP
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
• Install the rear shock absorber assembly up-
per bolt, and connecting arm bolt (frame side)
from the right.
• Install the rear shock absorber assembly low-
er bolts, connecting arm bolt (relay arm side),
and relay arm bolt (swingarm side) from the
left.
7. Tighten:
• Rear shock absorber assembly upper bolt
• Connecting arm bolt (frame side) Recommended lubricant
Molybdenum disulfide grease
Recommended lubricant
Molybdenum disulfide grease
3
a 1
12
a
2
New
Installed depth “a”
4.25 mm (0.17 in)
Recommended lubricant
Molybdenum disulfide grease
Rear shock absorber assembly
upper bolt
56 Nm (5.6 m·kgf, 41 ft·lbf)
Connecting arm bolt (frame side)
80 Nm (8.0 m·kgf, 58 ft·lbf)
T R..
T R..

REAR SHOCK ABSORBER ASSEMBLY
4-59
• Connecting arm bolt (relay arm side)
• Relay arm bolt (swingarm side)
• Rear shock absorber assembly lower boltConnecting arm bolt (relay arm
side)
80 Nm (8.0 m·kgf, 58 ft·lbf)
Relay arm bolt (swingarm side)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear shock absorber assembly
lower bolt
53 Nm (5.3 m·kgf, 38 ft·lbf)
T R..
T R..
T R..

ENGINE REMOVAL
5-1
EAS1SM9193
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS1SM9194
ENGINE REMOVAL
Removing the exhaust pipe
Order Part name Q’ty Remarks
*Refer to “INSTALLING THE EXHAUST
PIPE AND MUFFLER” on page 5-10.
Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1.
Rear shock absorber assembly lower boltRefer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
Connecting arm bolt (frame side)Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-53.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
4 Exhaust pipe 2 1
10
5
9
2 6
1
66
3
84 7 (8)
(6)
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
New
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
20 Nm (2.0 m kgf, 14 ft Ibf)T.R.
New
20 Nm (2.0 m kgf, 14 ft lbf) 13 Nm (1.3 m kgf, 9.4 ft lbf)T.R.
LT
LT
LT
*
*

ENGINE REMOVAL
5-6
EAS1SM9195REMOVING THE SILENCER
1. Remove:
• Rear shock absorber assembly lower bolt
“1”
• Connecting arm bolt (frame side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS1SM9196REMOVING THE EXHAUST PIPE 2
1. Remove:
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS1SM9197REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:
• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3