Checking The Brake Caliper; Checking The Brake Hose; Installing The Brake Caliper Piston; Installing The Front Brake Caliper - Yamaha YZ250F 2008 Owner's Service Manual

CHECKING THE BRAKE CALIPER

1. Inspect:
• Brake caliper cylinder inner sur-
face "a"
→
Wear/score marks
brake caliper assembly.
A. Front
B. Rear
2. Inspect:
• Brake caliper piston "1"
→
Wear/score marks
brake caliper piston assembly.
Replace the brake caliper piston
seals and brake caliper piston dust
seals "2" whenever a caliper is dis-
assembled.

CHECKING THE BRAKE HOSE

1. Inspect:
• Brake hose "1"
→
Crack/damage Replace.
HANDLING NOTE
• All internal parts should be
cleaned in new brake fluid only.
• Internal parts should be lubricat-
ed with brake fluid when in-
stalled.
• Replace the brake caliper piston
seals and brake caliper piston
dust seals whenever a caliper is
disassembled.
INSTALLING THE BRAKE
CALIPER PISTON
1. Clean:
• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper piston
Clean them with brake fluid.
2. Install:
Replace
• Brake caliper piston seal "1"
• Brake caliper piston dust seal "2"
Always use new brake caliper pis-
ton seals and brake caliper piston
dust seals.
• Apply the brake fluid on the brake
caliper piston seal.
• Apply the silicone grease on the
Replace
brake caliper piston dust seal.
• Fit the brake caliper piston seals
and brake caliper piston dust seals
onto the slot on brake caliper cor-
rectly.
A. Front
B. Rear
3. Install:
• Brake caliper piston "1"
Apply the brake fluid on the piston
wall.
• Install the piston with its shallow
depressed side "a" facing the
brake caliper.
• Never force to insert.
FRONT BRAKE AND REAR BRAKE
5-11
A. Front
B. Rear
INSTALLING THE FRONT BRAKE
CALIPER
1. Install:
• Pad support "1"
• Brake pad "2"
• Pad pin "3"
• Install the brake pads with their pro-
jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at
this point.
2. Install:
• Brake caliper "1"
• Bolt (brake caliper) "2"
Bolt (brake caliper):
28 Nm (2.8 m•kg, 20
ft•lb)
3. Tighten:
• Pad pin "3"
Pad pin:
18 Nm (1.8 m•kg, 13
ft•lb)
4. Install:
• Pad pin plug "4"
Pad pin plug:
3 Nm (0.3 m•kg, 2.2
ft•lb)