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YZ250F(E)
Yamaha YZ250F(E) User Manual
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REAR BRAKE
4-22
Disassembling the
rear brake
caliper
Order
Part name
Q’ty
Remarks
1
Brake caliper piston
1
2
Brake calip
er piston dust seal
1
3
Brake calip
er 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)
145
147
Table of Contents
Table of Contents
11
Important Manual Information
6
Safety Information
7
How to Use this Manual
8
General Information
13
Location of Important Labels
15
Description
18
Identification
19
Vehicle Identification Number
19
Engine Serial Number
19
Model Label
19
Features
20
Outline of the Fi System
20
Fi System
21
Included Parts
22
Sidestand
22
Spark Plug Wrench
22
Nipple Wrench
22
Handlebar Protector
22
Fuel Hose Joint Cover
22
Coupler for Connecting Optional Part
22
Important Information
24
Preparation for Removal and Disassembly
24
Replacement Parts
24
Gaskets, Oil Seals and O-Rings
25
Lock Washers/Plates and Cotter Pins
25
Bearings and Oil Seals
25
Circlips
25
Basic Service Information
26
Electrical System
26
Special Tools
29
Control Functions
34
Engine Stop Switch
34
Clutch Lever
34
Shift Pedal
34
Kickstarter Lever
34
Throttle Grip
34
Front Brake Lever
34
Rear Brake Pedal
35
Starter Knob/Idle Screw
35
Fuel Tank Cap
35
Starting and Break-In
36
Fuel
36
Starting a Cold Engine
36
Starting a Warm Engine
37
Break-In Procedures
37
Maintenance after Break-In
38
Major Maintenance
38
Torque-Check Points
39
Cleaning and Storage
41
Cleaning
41
Storage
41
Specifications
43
General Specifications
44
Engine Specifications
45
Chassis Specifications
51
Electrical Specifications
54
Tightening Torques
55
General Tightening Torque Specifications
55
Engine Tightening Torques
56
Chassis Tightening Torques
59
Lubrication Points and Lubricant Types
62
Engine
62
Chassis
64
Lubrication System Chart and Diagrams
66
Lubrication Diagrams
66
Cable Routing Diagram
74
Periodic Checks and Adjustments
85
Maintenance Intervals
87
Pre-Operation Inspection and Maintenance
93
General Inspection and Maintenance
93
Engine
94
Checking the Coolant Level
94
Checking the Cooling System
94
Changing the Coolant
94
Checking the Radiator Cap
95
Checking the Radiator Cap Opening Pressure
95
Checking the Coolant Circulatory System for Leaks
96
Adjusting the Clutch Lever Position
96
Adjusting the Clutch Lever Free Play
96
Adjusting the Throttle Grip Free Play
97
Lubricating the Throttle Cable
98
Cleaning the Air Filter Element
98
Checking the Throttle Body Joint
99
Checking the Breather Hoses
99
Checking the Exhaust System
99
Checking the Fuel Line
100
Checking the Engine Oil Level
100
Changing the Engine Oil
101
Adjusting the Engine Idling Speed
102
Adjusting the Valve Clearance
103
Chassis
107
Bleeding the Brake System
107
Checking the Brake Hose
108
Adjusting the Front Brake
108
Adjusting the Rear Brake
109
Checking the Front Brake Pads
109
Checking the Rear Brake Pads
111
Checking the Rear Brake Pad Insulator
112
Checking the Brake Fluid Level
112
Adjusting the Drive Chain Slack
113
Checking the Front Fork Legs
114
Checking the Front Fork Protector Guide
114
Cleaning the Front Fork Oil Seal and Dust Seal
114
Air Bleeding from Front Fork
114
Adjusting the Front Fork Legs
115
Checking the Swingarm Operation
116
Checking the Rear Suspension
116
Adjusting the Rear Shock Absorber Assembly
116
Checking the Tires
118
Checking and Tightening the Spokes
118
Checking the Wheels
119
Checking the Wheel Bearings
119
Checking and Adjusting the Steering Head
119
Lubricating the Levers
120
Lubricating the Pedal
120
Electrical System
121
Checking the Spark Plug
121
Checking the Ignition Timing
121
Chassis
123
General Chassis
125
Removing the Left Side Cover
126
Removing the Seat
126
Removing the Number Plate
126
Front Wheel
127
Removing the Front Wheel
128
Checking the Front Wheel
128
Disassembling the Front Wheel
129
Assembling the Front Wheel
129
Installing the Front Wheel
130
Rear Wheel
131
Removing the Rear Wheel
132
Checking the Rear Wheel
132
Disassembling the Rear Wheel
132
Checking and Replacing the Rear Wheel Sprocket
132
Assembling the Rear Wheel
133
Installing the Rear Wheel
133
Front Brake
135
Introduction
139
Checking the Front Brake Disc
139
Removing the Front Brake Caliper
139
Disassembling the Front Brake Caliper
139
Checking the Front Brake Caliper
140
Assembling the Front Brake Caliper
140
Installing the Brake Caliper Piston
140
Installing the Front Brake Caliper
141
Removing the Front Brake Master Cylinder
142
Checking the Front Brake Master Cylinder
142
Assembling the Front Brake Master Cylinder
142
Installing the Front Brake Master Cylinder
143
Rear Brake
145
Introduction
149
Checking the Rear Brake Disc
149
Removing the Rear Brake Caliper
150
Disassembling the Rear Brake Caliper
150
Checking the Rear Brake Caliper
150
Assembling the Rear Brake Caliper
150
Installing the Brake Caliper Piston
151
Installing the Rear Brake Caliper
151
Removing the Rear Brake Master Cylinder
152
Checking the Rear Brake Master Cylinder
152
Assembling the Rear Brake Master Cylinder
153
Installing the Rear Brake Master Cylinder
153
Handlebar
157
Removing the Handlebar
157
Checking the Handlebar
157
Installing the Handlebar
157
Front Fork
161
Removing the Front Fork Legs
163
Disassembling the Front Fork Legs
163
Checking the Front Fork Legs
164
Assembling the Front Fork Legs
165
Installing the Front Fork Legs
171
Steering Head
173
Removing the Lower Bracket
174
Checking the Steering Head
174
Installing the Steering Head
174
Rear Shock Absorber Assembly
177
Handling the Rear Shock Absorber
180
Disposing of a Rear Shock Absorber
180
Removing the Rear Shock Absorber Assembly
180
Removing the Bearing
180
Checking the Rear Shock Absorber Assembly
181
Checking the Connecting Arm and Relay Arm
181
Installing the Relay Arm
181
Installing the Rear Shock Absorber Assembly
182
Swingarm
184
Removing the Swingarm
185
Removing the Bearing
185
Checking the Swingarm
185
Installing the Swingarm
186
Chain Drive
187
Removing the Drive Chain
188
Checking the Drive Chain
188
Checking the Drive Sprocket
189
Checking the Rear Wheel Sprocket
189
Installing the Drive Chain
189
Engine
191
Engine Removal
194
Removing the Drive Sprocket
199
Removing the Exhaust Pipe 2
199
Removing the Silencer
199
Changing the Silencer Fiber
200
Checking the Silencer and Exhaust Pipe
200
Removing the Engine
200
Installing the Engine
201
Installing the Brake Pedal
202
Installing the Drive Sprocket
202
Installing the Exhaust Pipe and Muffler
203
Camshaft
204
Removing the Camshaft
206
Checking the Camshaft
207
Checking the Timing Chain and Camshaft Sprocket
208
Checking the Timing Chain Tensioners
208
Checking the Decompression System
209
Installing the Camshafts
209
Cylinder Head
211
Removing the Cylinder Head
213
Checking the Timing Chain Guide (Intake Side)
213
Checking the Cylinder Head
213
Installing the Cylinder Head
214
Valves and Valve Springs
216
Removing the Valves
216
Checking the Valves and Valve Guides
217
Checking the Valve Seats
218
Checking the Valve Springs
220
Checking the Valve Lifters
220
Installing the Valves
221
Cylinder and Piston
224
Removing the Piston
224
Checking the Cylinder and Piston
224
Checking the Piston Rings
225
Checking the Piston Pin
226
Installing the Piston and Cylinder
226
Clutch
229
Removing the Clutch
231
Checking the Friction Plates
231
Checking the Clutch Plates
231
Checking the Clutch Springs
231
Checking the Clutch Housing
232
Checking the Clutch Boss
232
Checking the Pressure Plate
232
Checking the Push Lever Shaft
232
Checking the Clutch Push Rods
232
Checking the Primary Drive Gear
232
Checking the Primary Driven Gear
233
Installing the Oil Seal
233
Installing the Right Crankcase Cover
233
Installing the Clutch
234
Installing the Kickstarter Lever
236
Kickstater
238
Removing the Kick Shaft Assembly
238
Checking the Kick Shaft and Ratchet Wheel
238
Checking the Kick Gear, Kick Idle Gear, and Ratchet Wheel
238
Installing the Kick Shaft Assembly
238
Installing the Kick Idle Gear
239
Shift Shaft
240
Removing the Shift Guide and Shift Lever Assembly
242
Removing the Segment
242
Checking the Shift Shaft
242
Checking the Shift Guide and Shift Lever Assembly
242
Checking the Stopper Lever
242
Installing the Stopper Lever
243
Installing the Segment
243
Installing the Shift Guide and Shift Lever Assembly
243
Installing the Shift Shaft
244
Installing the Shift Pedal
244
Oil Pump and Balancer Gear
246
Removing the Balancer
247
Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
247
Checking the Balancer
247
Checking the Oil Pump
247
Assembling the Oil Pump
248
Installing the Oil Pump and Balancer Gear
248
Ac Magneto
251
Removing the Ac Magneto
252
Checking the Ac Magneto
252
Checking the Woodruff Key
252
Installing the Ac Magneto
252
Crankcase
254
Disassembling the Crankcase
257
Removing the Crankcase Bearing
257
Checking the Timing Chain, Timing Chain Guide
257
Oil Strainer
257
Checking the Crankcase
257
Installing the Oil Seal
258
Assembling the Crankcase
258
Crankshaft Assembly and Balancer Shaft
259
Removing the Crankshaft Assembly
260
Checking the Crankshaft Assembly
260
Installing the Crankshaft Assembly
261
Installing the Balancer Shaft
261
Transmission
262
Removing the Transmission
263
Checking the Shift Forks
263
Checking the Shift Drum Assembly
264
Checking the Transmission
264
Installing the Transmission
264
Cooling System
267
Water Pump
273
Fuel System
275
Fuel Tank
276
Checking the Fuel Pump Body
277
Installing the Fuel Pump
277
Removing the Fuel Pump
277
Removing the Fuel Tank
277
Checking the Fuel Pressure
278
Installing the Fuel Tank
278
Checking and Replacing the Protector
279
Checking the Damper
279
Throttle Body
280
Checking the Injector
283
Checking the Throttle Body
283
Checking the Throttle Body Joint
283
Adjusting the Throttle Position Sensor
284
Electrical System
285
Ignition System
288
Circuit Diagram
288
Troubleshooting
290
Charging System
292
Circuit Diagram
292
Trouble Shooting
294
Fuel Injection System
296
Circuit Diagram
296
Yamaha Diagnostic Tool
298
Troubleshooting Details
299
Fuel Pump System
318
Circuit Diagram
318
Troubleshooting
320
Electrical Components
322
Checking the Switches
324
Checking the Ignition Spark Gap
327
Checking the Spark Plug Cap
327
Checking the Ignition Coil
327
Checking the Crankshaft Position Sensor
328
Checking the Ecu
329
Checking the Stator Coil
329
Checking the Rectifier/Regulator
329
Checking the Coolant Temperature Sensor
330
Checking the Throttle Position Sensor
330
Checking the Throttle Position Sensor Input Voltage
331
Checking the Intake Air Pressure Sensor
332
Checking the Intake Air Temperature Sensor
332
Checking the Neutral Switch
332
Checking the Fuel Injector
333
Electrical Components
335
Trouble Shooting
336
General Information
336
Starting Failures
336
Incorrect Engine Idling Speed
336
Poor Medium-And-High-Speed Performance
337
Faulty Gear Shifting
337
Shift Pedal Does Not Move
337
Jumps out of Gear
337
Faulty Clutch
337
Overheating
337
Overcooling
338
Poor Braking Performance
338
Faulty Front Fork Legs
338
Unstable Handling
338
List of Self-Diagnostic and Fail-Safe Actions
339
Tuning
343
Chassis
344
Drive and Rear Wheel Sprockets Setting Parts
344
Selection of the Secondary Reduction Ratio (Sprocket)
344
Change in Amount and Characteristics of Fork Oil
345
Front Fork Setting
345
Tire Pressure
345
Choosing Set Length
346
Front Fork Setting Parts
346
Rear Suspension Setting
346
Setting of Spring after Replacement
346
Setting of Spring after Replacement
347
Rear Shock Absorber Setting Parts
348
Suspension Setting (Front Fork)
349
Suspension Setting (Rear Shock Absorber)
350
Wiring Diagram
352
5
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Yamaha YZ250F(E) Specifications
General
Brand
Yamaha
Model
YZ250F(E)
Category
Motorcycle
Language
English
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