2016 YAMAHA YZ250F torque

MAINTENANCE INTERVALS
3-4
FUEL TANK, FUEL
PUMP
Inspect
FUEL HOSE
Inspect
Replace Every four years
FRONT FORK LEG
(S)
Clean Dust seal
Inspect and adjust
Replace oil
Replace oil seal
Clean and grease
oil seals and dust
sealsLithium-soap-based grease
PROTECTOR
GUIDE
Replace
REAR SHOCK AB-
SORBER
Inspect and adjust
Lubricate(After
rain
ride)Grease pillow balls and bear-
ings.
Retighten Check for tightening torques.
BRAKE(S)
Adjust lever posi-
tion and pedal
height
Lubricate pivot
point
Check brake disc
surface
Check fluid level
and leakage
Retighten brake
disc bolts, caliper
bolts, master cylin-
der bolts and union
boltsCheck for tightening torques.
Replace padsITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

MAINTENANCE INTERVALS
3-5
Replace brake flu-
idEvery one year
SWINGARM
Inspect, lube and
retightenMolybdenum disulfide grease
RELAY ARM, CON-
NECTING ROD
Inspect, lube and
retightenMolybdenum disulfide grease
STEERING HEAD
Inspect free play
and retightenCheck for tightening torques.
Clean and lube After rain ride
Replace bearings
TIRE, WHEELS
Inspect air pres-
sure, wheel run-
out, tire wear and
spoke looseness
Retighten sprocket
bolt
Check the bearing
Replace bearings
Lubricate Lithium-soap-based grease
DRIVE CHAIN Use chain oil.
Clean, lubricate,
slack, alignment
Replace
DRIVE CHAIN
GUIDE
Inspect Inspect wear.
DRIVE CHAIN
GUIDE AND DRIVE
CHAIN SUPPORT
Replace
CABLES
Routing (Connec-
tion)
Check and grease
Check and clean
throttle cableCheck throttle cables on the
throttle body for dirt and wear. ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

MAINTENANCE INTERVALS
3-6
LEVERS
Adjust clutch lever
free play
KICKSTARTER LE-
VER, BRAKE PED-
AL, FOOTREST
Lubricate
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “TORQUE-CHECK
POINTS” on page 1-23. ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

ENGINE
3-13
4. Check:
• Air filter element
Damage  Replace.
5. Foam-air-filter oil or equivalent oil to the ele-
ment
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:
• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”
7. Install:
• Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”.
8. Install:
• Fuel tank cap cover
EAS1SM9079CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body joint
Refer to “CHECKING THE THROTTLE
BODY JOINT” on page 7-8.
EAS1SM9080CHECKING THE BREATHER HOSES
1. Check:
• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA14920
NOTICE
Make sure the cylinder head breather hose
is routed correctly.
EAS1SM9081CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check:
• Exhaust pipe 1
• Exhaust pipe 2
• Silencer
Crack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 5-1.
• Exhaust gas
Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 5-1.
3. Check:
• Tightening torques Oil application quantify
50 g
Air filter mounting bolt
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T R..
31
2
a
b 1
Exhaust pipe bolt 1 and nut “1”
20 Nm (2.0 m·kgf, 14 ft·lbf)
Exhaust pipe 1 and exhaust pipe
2 bolt “2”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe 2 and silencer bolt
“3”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4”
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
T R..

CHASSIS
3-34
2. Tighten:
• Spokes
Use a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180 °) or more for one
tightening.
• Make sure that tightening after a break-in is
done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
EAS1SM9107CHECKING THE WHEELS
1. Check:
• Wheel(s)
Damage/out-of-round  Replace.
EWA
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EAS1SM9108CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4 and “CHECKING THE REAR
WHEEL” on page 4-8.
EAS1SM9109
CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Use a suitable stand to raise the front wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove:
• Handlebar
Refer to “HANDLEBAR” on page 4-31.
• Upper bracket
Refer to “STEERING HEAD” on page 4-49.
4. Adjust:
• Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the washer “1”.
b. After loosening the ring nut “2” with a steer-
ing nut wrench “3”, tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly. Spoke nipple wrench (6–7)
90890-01521
YM-01521
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..
1
3
2

CHASSIS
3-35
c. Turn the front fork to the right and left a few
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-49.
d. Loosen the ring nut fully turn and then tight-
en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-49.
f. Install the washer “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Upper bracket
Refer to “STEERING HEAD” on page 4-49.
• Handlebar
Refer to “HANDLEBAR” on page 4-31.
EAS1SM9110LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS1SM9111LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal. Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Ring nut (initial tightening torque)
38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
T R..
1
Recommended lubricant
Silicone grease
Recommended lubricant
Lithium-soap-based grease
Recommended lubricant
Lithium-soap-based grease

FRONT FORK
4-48
3. Adjust:
• Front fork top end “a”
4. Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA33DD044
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
• Protector “1”
• Bolt (protector) “2”6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
7. Adjust:
• Compression damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position. Front fork top end (standard) “a”
5 mm (0.20 in)
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Bolt (protector)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
a
T R..
T R..
21
T R..
1
2
1
1

STEERING HEAD
4-52
8. Install:
• Steering stem nut “1”
TIP
Apply the lithium soap base grease to the con-
tact surface of the steering stem nut when in-
stalling.
9. After tightening the nut, check the steering
for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”11.Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA33DD049
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction. Steering stem nut
145 Nm (14.5 m·kgf, 105 ft·lbf)
Front fork top end (standard) “a”
5 mm (0.20 in)T R..
a
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
T R..
21