2016 YAMAHA YZ250F air bleeding

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ......... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-13
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-22
BLEEDING THE BRAKE SYSTEM .......................................................... 3-22
CHECKING THE BRAKE HOSE .............................................................. 3-23
ADJUSTING THE FRONT BRAKE .......................................................... 3-23
ADJUSTING THE REAR BRAKE ............................................................. 3-24
CHECKING THE FRONT BRAKE PADS ................................................. 3-24
CHECKING THE REAR BRAKE PADS ................................................... 3-26
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-27
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-27
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-28
CHECKING THE FRONT FORK LEGS ................................................... 3-29
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-29
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-29
AIR BLEEDING FROM FRONT FORK .................................................... 3-29
ADJUSTING THE FRONT FORK LEGS .................................................. 3-30
CHECKING THE SWINGARM OPERATION ........................................... 3-31
CHECKING THE REAR SUSPENSION ................................................... 3-31
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-31
CHECKING THE TIRES ........................................................................... 3-33
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-33
CHECKING THE WHEELS ...................................................................... 3-34

CHASSIS
3-22
EAS1SM9087
CHASSIS
EAS1SM9088BLEEDING THE BRAKE SYSTEMEWA13100
WARNING
Bleed the brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected,
or replaced.
• The brake fluid level is very low.
• Brake operation is faulty.
1. Remove:
• Brake master cylinder cap
• Reservoir diaphragm
• Reservoir float (front brake)
• Protector (rear brake)
TIP
• Be careful not to spill any brake fluid or allow
the reservoir to overflow.
• Make sure that there is enough brake fluid be-
fore applying the brake. Ignoring this precau-
tion could allow air to enter the brake system,
considerably lengthening the bleeding proce-
dure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours. Re-
peat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
2. Bleed the brake system.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the reservoir to the proper level with the
recommended brake fluid.
b. Install the reservoir diaphragm.
c. Connect the plastic hose “1” to the bleed
screw “2” securely, and place a container
under the end of the plastic hose.d. Slowly apply the brake several times.
e. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
f. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the
pressure in the brake caliper and cause the
brake lever to contact the throttle grip or the
brake pedal to fully extend.
g. Tighten the bleed screw and then release
the brake lever or brake pedal.
h. Repeat steps (d) to (g) until all of the air bub-
bles have disappeared from the brake fluid
in the plastic hose.
TIP
During the procedure, keep adding brake fluid
to the reservoir.
ECA
NOTICE
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
i. Tighten the bleed screw.
j. Pour brake fluid to the reservoir up to the
specified level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 2
A
A. Front
B. Rear
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
2
1B
T R..

CHASSIS
3-23
EAS1SM9089CHECKING THE BRAKE HOSE
1. Check:
• Brake hose “1”
Cracks/damage/wear  Replace.
2. Check:
• Brake hose clamp
Loose Connection  Tighten the clamp bolt.
3. Stand the vehicle upright and apply the front
brake and the rear brake several times.
4. Check:
• Brake hoses
Brake fluid leaks  Replace the damaged
brake hose.
Refer to “FRONT BRAKE” on page 4-11.
Refer to “REAR BRAKE” on page 4-21.
EAS1SM9090ADJUSTING THE FRONT BRAKE
1. Check:
• Brake lever position “a”2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake lever position is
obtained.
c. Tighten the locknut.
EWA13050
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance.
ECA13490
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Brake lever cover
A. Front
B. Rear
Brake lever position
95 mm (3.74 in)
Extent of adjustment
86–105 mm (3.39–4.13 in)
1
1
Direction “a”
Brake lever position is increased.
Direction “b”
Brake lever position is decreased.
Locknut
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
a
b
T R..

CHASSIS
3-29
EAS1SM9097CHECKING THE FRONT FORK LEGS
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Inner tube
Damage/scratches  Replace.
• Front fork leg (s)
Oil leaks between inner tube and outer tube
 Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 4-37.
EAS1SM9098CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”
Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EAS1SM9099CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver.
2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
EAS1SM9100AIR BLEEDING FROM FRONT FORK
TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
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. Remove the air bleed screw “1” and release
the internal pressure from the front fork.
1
a
1
LS
a
b

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
4-28
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
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 “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
7. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22.
EAS1SM9155REMOVING THE REAR BRAKE MASTER
CYLINDER
TIP
Before removing the rear brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS1SM9156CHECKING THE REAR 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/wear  Replace.
3. Check:
• Master cylinder reservoir cap
Crack/damage  Replace.
• Brake master cylinder reservoir diaphragm
holder
• Brake master cylinder reservoir diaphragm
Crack/damage  Replace.
4. Check:
• Brake hoses
Cracks/damage/wear  Replace.
a
1
2