Yamaha BR250F Service Manual Download

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Summary of Contents for BR250F

Page 1: ...o YAMAHA SNOWMOBILE SERVICE MANUAl LI1 12618 00 41 884 28197 10 ...

Page 2: ...notice Information regarding changes is forwarded to all Authorized Yamaha Dealers assoon asavailable YAMAHA MOTOR CO LTD SERVICE DEPARTMENT BR250F SERVICE MANUAL 1981 by Yamaha Motor Corporation U S A 1st edition June 1981 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 12618 00 41...

Page 3: ...TABLE OF CONTENTS GENERAL ENGINE CARBURETION POWER TRAIN CHASSIS ELECTRICAL APPENDIX ...

Page 4: ...2 MACHINE IDENTIFICATION 1 2 1 3 TERMS 1 2 1 4 STORAGE 1 2 1 5 PRE SEASON PREPARATION 1 2 1 6 MAINTENANCE 1 3 A Periodic Maintenance 1 3 B Lubrication Intervals 1 4 C Sealing the Carburetor 1 5 1 7 HIGH ALTITUDE TUNING 1 5 1 8 SPECIAL TOOLS 1 6 ...

Page 5: ...1 1 EXTERNAL VIEW GENERAL 1 1 ...

Page 6: ...ne from the carbure tor 2 With the engine running at idle squirt oil into the carburetor until the engine dies This will distribute oil evenly throughout the engine and protect it against rust 3 Disassemble the suspension clean and grease all parts and reassemble the suspension 4 Lightly coat all shafts and axles with grease 5 Oil all fittings and wire controls with a Iightly oiled cloth 6 Loosen ...

Page 7: ...ry pipe 0 Recoil starter Carburetor Operation of starter jet 0 Mixing adjuster pilot screw 0 Idle speed adjustment 0 Operation and adjustment of oil pump Ignition timing 0 Cylinder compression 0 Cylinder exhaust pipe decarbonize 0 Spark plug condition gap and cleaning 0 Tighten the cylinder 0 DRIVE Tightness of bolts and nuts Wear on slide runners 0 Primary drive system 0 V belt Secondary drive sy...

Page 8: ...ck point 20 hrs or 40 hrs or 80 hrs or When Seasonallv Oil Grease 400 km 800 km 1 600 km necessary Brand name 250 mil 500 mil 1 000 mil ENGINE Starter case 0 Oil pump control box 0 Aeroshell grease 7A or Pump drive cover 0 Esso Beacon 325 grease Oil in the oil tank 0 YAMALUBE 2 cycle oil DRIVE Primary sheave weights 0 and roller pins Molybedenum disulfide Secondary shaft and 0 snowmobile grease sl...

Page 9: ... the snowmobile as out lined below Confirm STD settings Carburetor Page3 3 Ignition timing Page6 2 Spark plug Page6 5 Adjust main jet size according to the chart Page3 3 Test main jet size performance plug colour Not OK Adjust main jet size Page3 6 I I I Not OK Not OK OK I OK Check to see if gearing is too high or low NotOK OK Adjust gearing as required Page4 12 OK Not OK Not OK OK Check engagemen...

Page 10: ...er Body 90890 Q1848 00 4 f 3 Way Puller Attachment 90890 Q1873 00 5 Rotor Holding Tool 90890 Q1235 Q0 608 Primary Sheave Puller M18 TLS 90018 59 02 U S A_ 90890 01898 Q0 6 b Primary Sheave Puller Attachment 90890 01899 Q0 7 Primary SheaveSubassembly Tool TLS 9091 0 60 00 90890 01858 00 8 Bushing Tool 90890 Q1883 Q0 9 SheaveGauge TLS 9091 0 47 02 U S A 90890 01702 Q0 10 Pocket Tester 90890 Q3112 00...

Page 11: ...CTION 2 2 A Recoil Starter 2 2 B Flywheel Magneto 2 3 C Oil Pump 2 4 D Top End 2 6 E Bottom End 2 10 2 3 ASSEMBLY AND ADJUSTMENT 2 12 A Bottom End 2 12 B Top End 2 13 C Flywheel Magneto 2 14 D Recoil Starter 2 15 E Oil Pump Gear Case 2 17 2 4 ENGINE INSTALLATION 2 19 ...

Page 12: ... 1 Muffler 2 Drive guard V belt and primary sheave Refer 4 3 A Removal 3 Carburetor Refer to 3 1 A Removal 4 D handle from the starter rope Knot the rope so it will not be pulled into the starter case 5 Spark plug wire 6 Pulse pipe from the fuel pump 7 Oil line that feeds the autolube pump Disconnect the joint in the middle of the line Do not let air enter the line 8 Four flywheel magneto leads 9 ...

Page 13: ... the sheave drum Rotate the sheave drum five times clock wise to release the preload on the starter spring 3 Remove the securing nut and carefully disassemble the starter Note the relative position of each piece You will have to reassemble the starter as shown in the illustration above Be careful when removing the drive plate and the sheave drum There is a preloaded spring behind each of these ite...

Page 14: ...e the fan 3 Using the 3 way puller remove the magneto 2 3 3 Way Puller Ass y TLU 90901 05 20 U S A 1 3 Way Puller 90890 01848 2 3 Way Puller Attachment 90890 01803 3 3 Way Puller Attachment 90890 01804 4 3 Way Puller Screw 90890 01906 5 Drive handle 90890 01817 4 Remove the woodruff key from the crankshaft Remove the two securing screws and remove the coil plate 5 For inspection refer to 6 1 G Pul...

Page 15: ...Rotate the oil pump drive shaft until the securing pin is opposite the slot in the gear case Remove the pin and remove the pump from the gear case Oil Pump Drive Shaft 5 Remove the drive shaft from the oil pump Inspect the bearing surfaces of the shaft and the gear teeth If any part of the shaft is worn or pitted the shaft must be replaced The oil pump should not be disas sembled unless the pump s...

Page 16: ...ger is at its maximum distance from the pump body c Using a feeler gauge measure the gap between the adjusting plate and the raised bosson the adjusting pulley Maximum pump stroke 1 65 1 87 mm 0 065 0 074 in 1 Oil pump gear 2 Plunger 3 Maximum pump stroke 2 5 9 If either the maximum pump stroke or the minimum pump stroke does not equal specification remove the adjusting plate and add or remove adj...

Page 17: ... Cylinder Disassembly 1 Loosen the spark plug and remove the cyl inder from the crankcase 2 Cover the crankcase with a clean rag so nothing will accidently drop into the crankcase 3 Remove a piston pin cIip from the piston and remove the pin with the universal piston pin puller Universal piston pin puller YU 01304 MS623 BR250F Service Manual Revised 1 82 2 6 Cvlinder Bolt Piston Pin CIip 4 Remove ...

Page 18: ...ng surfaces Install them in the connecting rod small end to inspect for wear Check for play There should be no noticeable vertical play If play exists check the connecting rod small end for wear Replace pin connecting rod and or bearing as required 2 7 e The piston pin should have no noticeable free play in the piston If the piston pin is loose replace the pin and or piston 2 Piston a Remove the p...

Page 19: ...nce Minimum 0 045 mm 0 0018 in Maximum 0 050 mm 0 0020 in Piston oversize 70 25 mm 2 766 in 70 50 mm 2 776 in 1 10 mm 0 39 in 2 8 3 Piston rings a Check the rings for scoring If any severe scratches are noticed replace the rings as a set b Measure the ring end gap in the un installed rings If it is beyond tolerance replace the rings as a set Ring end gap free Approx 6 5 mm 0 26 in c Push the ring ...

Page 20: ... limit Cylinder bore 70 00 70 02 mm 70 05 mm 2 756 2 757 in 2 776 in Cylinder taper 0 05mm 0 002 in Cylinder out of 0 01 mm round 0 004 in _ Boring If the cylinder requires boring follow the standard boring procedures but use an offset bit as shown below This bit is standard equipment with some boring bars Be sure that the depth adjustment is precisely set so the combustion chamber is not damaged ...

Page 21: ...gine Mounting Bracket ae o Right Crankshaft aearing i Disassembly 1 Remove the engine mounting bracket from the crankcase 2 Remove the four crankcase bolts Note the position of the wire bracket You will have to reinstall it on the same bolt ...

Page 22: ...with their manufacturer s marks also facing outward d Always thoroughly lubricate bearings and oil seals with the specified lubricant before installing them on the crankshaft 4 Crankshaft a Check the connecting rod axial play at the small end This will indicate the condition of the big end bearing and crankpin If the rod axial play exceeds specification disassemble the crankshaft and check the con...

Page 23: ...he engine bracket onto the crankcase Torque the four bolts to specification R H Right side 0 02 mm 0 0008 in 80 mm 3 1 in Deflection tolerance Left side 100 mm 3 9 in 0 02 mm 0 0008 in LlH c Check the crankshaft assembly runout with a dial gauge If the runout is not within specification the crankshaft parts are not properly aligned To correct this misalignment tap the flywheel with a brass hammer ...

Page 24: ...B Top End Cylinder Small End Bearing 1 Install the piston rings as shown in the illustration Piston crown JUJ J J __ 1 0 l 7 7 77 7 7 7 7 2 13 rCYlinder Bolt Top Piston ring 2nd ...

Page 25: ...n crown must point to the front of the engine 6 Oil the piston pin and install it in the piston Be sure the piston pin clip is correctly seated in the groove C Flywheel Magneto 7 Oil the piston and install the cylinder onto the crankcase Use a new cylinder gasket Torque the four cylinder bolts to specification You will need a 12 mm crowfoot wrench Tightening torque First 2 0 m kg 14 5 ft lb Final ...

Page 26: ... magneto must align with the key in the crankshaft Rap the magneto with a plastic mallet to seat it on the crankshaft 4 Install the fan on the magneto The arrow on the fan must point to the key way in the magneto Torque the six bolts to specification Tightening torque 0 7 m kg 5 ft lb 2 15 5 Install the flywheel pulley The two cut outs on the edge of the pulley must be opposite the holes in the fa...

Page 27: ...Hook the spring around the first post on the sheave drum as shown in the photograph 2 16 5 Install the drive plate spring spring collar and the drive plate Be sure the cutout in the drive plate fits over the post on the drive pawl Install the thrust washer and torque the nut Grease the pivot point of the drive pawl Tightening torque 1 3 m kg 9 4 ft Ib 6 Pull about four inches of starter rope from ...

Page 28: ...k washer with the screw that secures the air shroud to the starter case Apply a thread locking compound to the two bolts that thread into the engine Torque the bolts to specification E Oil Pump Gear Case Tightening torque 0 65 m kg 4 7 ft lb 2 17 ...

Page 29: ...7 Install the oil pump gear box onto the engine Be sure the drive gear correctly engages the oil pump drive gear on the crankshaft Torque the four securing bolts to specification Tightening torque 0 68 m kg 4 9 ft lb Bleeding the Oil Pump The oil pump must be bled whenever Any portion of the oil system has been disconnected The machine has been turned on its side Whenever the oil tank has been run...

Page 30: ...or connect the following compo nents in the order given below Primary Sheave V belt and drive guard Refer to 4 4 D Assembly Carburetor Refer to 3 1 A III nstal lation Pulse Pipe Oil line that feeds the oil pump Four magneto leads D handle to the starter rope Spark plug and spark plug wire Spark Plug Tightening Torque 2 5 3 0 m kg 18 22 ft lb Muffler and hood limiter bracket 2 19 ...

Page 31: ... 2 D Assembly 3 2 E Installation 3 3 3 2 TUNING AND ADJUSTMENT 3 3 A Carburetor Tuning Data 3 3 B Starter Cable Adjustment 3 4 C Throttle Cable Adjustment 3 5 D Oil Pump Cable Adjustment 3 5 E Low Speed Tuning 3 5 F Mid range and High Speed Tuning 3 6 G Troubleshooting 3 7 3 3 INTAKE 3 9 ...

Page 32: ... the pulse pipe oil pump cable oil delivery pipe throttle cable and the starter cable Be careful not to lose the rubber cap or coil spring from the starter cable 3 1 Starter Jet 2 Loosen the clamp on the carburetor boot and remove the carburetor Do not lose a spring from the air box boot ...

Page 33: ...ew for carbon deposits check the threads for wear Clean and replace the jet as required D Assembly Use new O rings when assembling the carbure tor Thoroughly grease the contact surfaces of the throttle shaft Be sure all moving parts in the carbu retor operate smoothly 1 Install the throttle stop screw with its spring For adjustment Refer to 3 2 E Low Speed Tuning 2 Install the main jet and the slo...

Page 34: ...o the Cable Routing Diagram in the appendix 2 High altitude tuning 3 2 Tuning and Adjustment The carburetor is set at the factory to run at temperatures of 32 F to _4 F 0 to 20 C at seal level If the machine has to be operated under conditions other than specified above the carburetor must be reset as required Special care should be taken in carburetor setting so that the piston will not be damage...

Page 35: ...flow t B Starter Cable Adjustment PuII the starter cable outer tube upward and adjust the free play between the outer tube end and adjuster to specification by turning the adjuster After the adjustment tighten the lock nut and replace the rubber cap to keep the lock nut free from dust and water NOTE _ Starter cable free play must be adjusted after the cable is correctly routed Refer to Cable Routi...

Page 36: ...op screw Always install air silencer before making tuning adjustment High performance tuning cannot be done without the silencer Engine damage may result from attempting to tune without the silencer installed Play 25 1 mm 1 00 0 04 in NOTE _ Always adjust the throttle cable BEFOR E adjusting the oil pump cable 2 Start the engine and fully warm up the engine 3 Adjust the throttle stop screw until t...

Page 37: ...the spark plug The main jet should be adjusted on the basis of the following table Refer to spark plug color samples Standard main jet 108 Spark plug color No 1 Good Carburetor is turned properly No 2 Bad Mixture is too rich l Replace main jet with one step small one No 3 Bad Mixture is too lean Replace main jet with one step larger one Bad Due to too lean a mixture piston is damaged or seized No ...

Page 38: ...in float chamber clean Also check for ice l Overflow Correct Poor idling Improper idling speed Tighten slow adjuster lightly and adjustment check throttle opening If incorrect Relative troubles Slow adjuster Adjust idling speed back it out specification Start the Poor performance at low engine and turn slow adjuster in speeds and out 1 4 turn each time When Poor acceleration the engine runs faster...

Page 39: ...mp performance Repair pump or replace Clogged fuel filter Replace Clogged intake Check for ice and remove Abnormal combustion Lean mix tu res Clean carburetor and adjust Mainly backfire Dirty carburetor Clean carburetor Dirty or clogged fuel pipe Clean or replace fuel pipe Overflow Clogged air vent Clean Relative troubles Clogged float valve Disassemble and clean Clean while taking care not to Pow...

Page 40: ...o see that fuel moves from the fuel tank to the fuel pump then to the carburetor If fuel leaks replace the components as required 2 Inspect the air box boot and the carbure tor boot Replace as necessary Replace the air box boot springs if either is fatigued 3 9 ...

Page 41: ...pection 4 5 D Assembly 4 6 4 5 SECONDARY SHEAVE 4 8 A Removal 4 8 B Inspection 4 9 C Assembly 4 9 4 6 CHAIN CASE 4 10 A Disassembly 4 11 B Inspection 4 11 C Gearing 4 12 D Assembly 4 12 4 7 BRAKE 4 14 A Disassembly 4 14 B Inspection 4 15 C Assembly 4 15 D Brake Adjustment 4 15 4 8 SLIDE RAIL SUSPENSION 4 16 A Removal 4 16 B Inspection 4 17 C Installation 4 18 4 9 DRIVE 4 19 A Removal 4 19 B Inspec...

Page 42: ... to center 266 2 mm 10 47 0 08 in Sheave offset 11 3 mm 0 43 0 12 in 4 2 CLUTCH TUNING The clutch may require tuning depending upon the area of operation and the desired handling characteristics The clutch can be tuned by changing engagement shifting rpm Clutch engagement rpm is defined as the engine speed where the machine first begins to move from a complete stop Shifting rpm is the engine speed...

Page 43: ...constant Color None Q ty 8 p c s unit Roller shim PartsNo 90201 06727 Twist angle 160 0 Secondary spring Color None NOTE _ High altitude specifications apply to operation at an altitude of more than 1506 meters 4500 tt Since the clutch weights are secured in place by the sheave cap bolts the centrifugal force that can alter clutch characteristics comes from the weight of the lever on the spider To...

Page 44: ... in Part No 820 17641 00 3 Measure the length of the V belt It should be within specification if not replace the belt Wear limit 26 mm 1 02 in 4 3 V BELT A Removal 1 Turn the secondary sliding sheave clock wise and push it towards the chain case 2 While holding the sliding sheave in this compressed position remove the V belt from the secondary sheave then from the primary B Inspection 1 Visually i...

Page 45: ...uard and remove the V belt 2 Hold the fixed sheave with the primary sheave holder and remove the clutch bolt Drive the primary sheave off the crankshaft with the primary sheave puller Primary sheave holder T L5 90018 80 00 U S A 9089Q 01701 Primary sheave pu lIer 90890 01898 1 Sheave holder 2 Sheave puller 4 4 ...

Page 46: ...d the primary fixed sheave for scartches If either is severely scratched replace it If scratches are minor burnish the component with emery cloth 2 Check the primary sheave cap bushing and the sliding sheave bushing for wear If worn beyond tolerance replace the bushing Use the bushing tool if a bushing is diffi cult to remove Bushing tool 90890 01883 1 Bushing tool 4 5 r Bushing clearance limit Sm...

Page 47: ...e and inspect the rollers replace worn parts as necessary Torque the nut to specification during reassemb ly Tightening torque 1 0 m kq 7 ft lb 4 6 7 Disassemble and inspect the spider levers replace any worn parts Reassem ble the levers with new cotter pins 8 Inspect the cams for wear replace as necessary 9 Check the spring Replace it if it is fatigued or damaged D Assembly 1 During assembly grea...

Page 48: ...mbly tool 90890 01858 Tightening torque 1 0 m kq 7 ft Ib 7 Check the movement of the sliding sheave If it is not smooth disassemble the primary sheave and reassemble it correctly 4 7 8 Clean the tapered portions of crankshaft and fixed sheave 9 Fit the fixed sheave to the tapered por tion of crankshaft 10 Apply engine oil to the threaded portion of primary sheave bolt and its contact surface with ...

Page 49: ...1fir 7 Fixed Sheave A Removal 1 Lock the brake and install the second ary sheave holder Fit the tool behind the spring seat so it will hold the sliding sheave in place when the fixed sheave is removed Remove the securing nut Secondary sheave holder 90890 01872 1 Secondary sheave holder ...

Page 50: ...circlip and collar into the jackshaft bearing cage 2 Thread the spring seat onto the jack shaft it has a left hand th read The spring seat must be tight or it will come loose when you preload the secondary sheave spri ng 3 Install the spring into the spring seat Be sure the spring is in one of the holes NOTE _ The three holes in the spring seat are for con venience only Seating the spring in a dif...

Page 51: ...key in the jackshaft and install the fixed sheave Grease the indicated point 4 6 CHAIN CASE 7 Install the washer and securing nut Torque the nut to specification Tightening torque 4 0 rn kq 29 ft lb 8 Wipe both sheaves They should be free from oil and grease 4 10 ...

Page 52: ...washers from both the drive and driven sprockets 8 Remove the drive chain and both sprockets 9 Remove the collar from behind each sprocket 10 Remove the three secu ring bolts and remove the chain case 4 11 11 Remove the jackshaft from the left side of the snowmobile B Inspection 1 Inspect the brake disc Place it on a sur face plate and check around the edges with a feeler gauge If the gap is uneve...

Page 53: ...ce in the chassis It may be helpful to block up the chassis to relieve the tension on the drive axle 4 12 4 Grease the bearing surfaces of the jack shaft Place the key in the jackshaft and install the jackshaft from the left side of the machine The splined end must go through the brake disc and into the chain case Align the keyway in the disc with the key on the jackshaft 5 Tighten the chain case ...

Page 54: ...ck nut to specification Chain deflection 8 15 mm 0 3 0 6 in Tightening torque 3 5 m kq 25 ft lb 1 Chain deflection 13 Install the chain case cover Torque the two bolts to specification Be sure the rubber gasket is properly seated on the chain case Tightening torque 1 6 m kq 12 ft lb 14 Add oil to the chain case until oil begins to flow from the oil drain bolt Recommended oil SAE 75W80 API GL3 Gear...

Page 55: ...cable from the handlebar Loosen the adjuster at the caliper then remove the cable 2 With a pair of pliers left the arm of each of the return springs off the chain case to release the preload 4 14 3 Remove the clevis pin and disassemble the brake ...

Page 56: ...e 3 Connect the brake cable to the handle bar 4 15 D Brake Adjustment The brake is adjusted at two points so that the gaps between the disc and pads are equal and within tolerance Proper adjustment will result in 6 7 mm 0 24 0 28 in free play between the brake lever and the brake lever holder 1 Loosen the lock nut on the screw inner pad adjusting screw until the inner brake pad is 0 2 1 0 mm 0 008...

Page 57: ... the carburetor so fuel will not spill when you turn the machine on its side Refer to 1 6 C Sealing the Carbure tor 4 16 3 Turn the machine on its side and lift the rear torsion spring off its seat to release the preload Repeat this procedure on the opposite side ...

Page 58: ...as necessary Apply a thread locking com pound to the securing bolts and torque the bolts to specification Tightening torque 7 0 m kg 51 ft lb 4 17 3 Inspect the guide wheels replace as necessary Apply a thread locking com pound and torque the bolt to specifica tion Tightening torque 2 3 m kg 17 ft lb 4 Replace any fatigued springs 5 Inspect both the front and rear stopper bands Replace if either i...

Page 59: ...n in the track and swing it into place in the chassis Install both front suspension mounting bolts Do not tighten them at this point 4 18 4 Grease the rear axle and install it in the rear pivot arm 5 Install both rear suspension mounting bolts 6 Tighten all four suspension mounting bolts and torque them to specification Tightening torque 4 5 rn kq 33 ft lb 7 Place the torsion springs on their seat...

Page 60: ...p and out of the chain case then out of the track A Removal I 1 Place an oil pan beneath the chain case and remove the chain case cover Let the oil drain into the oil pan 2 Remove the driven sprocket 3 Remove the secondary sheave Refer to 4 5 A II Removal 4 Remove the axle nut and washer remove the bearing cage Bearing Cage Drive Axle Bearing 4 19 ...

Page 61: ...ugs correctly engage the track 3 Install the bearing and the bearing cage onto the drive axle Torque the three bolts to specification Tightening torque 2 3 m kg 17 ft lb 4 Install the washer and the axle nut Torque the nut to specification Tightening torque 8 0 m kg 58 ft Ib Track deflection 25 30 mm 10 kg 1 0 1 2 in 22 Ib 5 Install the slide rail suspension Refer to 4 8 C II Installation 6 Reasse...

Page 62: ...indow When shifted to right Tighten the right track adjusting bolt and loosen the left track adjusting bolt 3 Check the track deflection It should equal the specified value 4 If it does not repeat the above proce dures until deflection equals specifica tion 5 Tighten the track adjusting lock nuts Torque to specification Track metal lL Forward Gap between slide runner and edge of track window When ...

Page 63: ...CHAPTER 5 CHASSIS 5 1 STEERING 5 1 A Assembly 5 1 B Adjustment 5 2 5 2 SKiS 5 3 A Inspection 5 3 B Assembly 5 4 5 3 OIL TANK 5 4 5 4 FUEL TANK 5 5 ...

Page 64: ...teering Column_ i A Assembly 1 Secure the steering relay rods with the universal joint attached to the outside arm Torque the flange nut to specifica tion and install a new cotter pin Tightening torque 3 0 m kg 22 ft lb 5 1 ...

Page 65: ...23 in B Ski width B Adjustment 1 Straighten the handlebars and check to see that the skis are parallel If not loosen the steering relay rod lock nut By turning the steering relay rod adjust the ski toe out to specification Torque the lock nut to specification Ski stance 750 mm 29 53 in Ski toe out 0 6 mm 0 0 23 in 5 2 2 The height of the handlebars can be adjusted to suit the rider s preference Af...

Page 66: ...ng torque 1 4 m kg 10 ft lb 2 Inspect the leaf spring and the spring re taining pins If the spring is fatigued or if a pin is worn replace them as necessary Torque the securing nut to specification and install a new cotter pin 5 3 Tightening torque Spring nut 1 4 m kg 10 ft Ib 3 Check the wear plate Replace it if it is worn ...

Page 67: ...it out 1 4 turn Tighten the slotted nut and install a new cotter pin 3 When installing the ski shock secure the bottom end to the ski then secu re the 5 3 OIL TANK top end to the ski column All collars should be greased and securing nuts should be torqued Be sure to install the shock with the word uyAMAHA facing upward Tightening torque 1 45 m kg 10 5 ft lb Oil Gauge Line OilLine l rf I iJ p 5 4 ...

Page 68: ...ed or damaged in any way replace them 2 Be sure all lines are secured in place by a retaining clip 3 Be su re that all Iines are routed as shown in the Cable Routing Diagram in the appendix The breather pipe must be routed so that no fuel will leak during operation 4 Replace the fuel filter each season 5 When reinstalling the fuel tank torque the four securing bolts to specification Tightening tor...

Page 69: ... 6 1 B Troubleshooting 6 1 C Ignition Timing 6 2 D Spark Gap Test 6 3 E Ignition Coil 6 4 F Spark Plug 6 4 G Pulser and Charge Coil 6 5 H C D 1 Unit 6 5 6 2 LIGHTING SYSTEM 6 6 A Circuit Diagram 6 6 B Headlight Beam 6 6 C Lighting Coil 6 7 D Voltage Regulator 6 7 ...

Page 70: ... spark is produced or weak Check of connections _____ JI Check lead wire connections for short circuits 1 OK Faulty Correct SparkS See 6 1 D Spark Gap Test F No spark S p a r k Plug is faulty OK Measure coil resistance See 6 1 G Pulser and Charge Coil FauIty Replace 6 1 ...

Page 71: ...uge with the needle into the stand C Ignition Timing 1 Remove the starter from the engine 2 Remove the spark plug and screw the dial gauge stand into the spark plug hole 4 Rotate the flywheel magneto until the piston is at top dead center T D C Set the dial gauge at zero Tighten the set screw on the dial gauge stand to secure the dial gauge assembly Rotate the flywheel back and forth to be sure th...

Page 72: ... starter and the spark plug Torque the plug to specification Tightening torque 2 8 m kg 20 ft lb D Spark Gap Test The entire ignition system can be checked for misfire and weak spark by using the Electro Tester If the ignition system will fire across a specified gap the entire ignition system is good If it will not fire across the gap pro ceed with the individual component tests until the problem ...

Page 73: ...Due to lean a mixture the spark plug rnelts Check the piston for holes or seizure No 6 Check the cooling system gasoline octane rating and ignition timing After replacing the spark plug with colder type tune the carburetor again starting with low speed tuning fIIo Primary coil resistance Secondary coil resistance F Spark Plu9 The Iife of a spark plug and its condition vary according to the habits ...

Page 74: ...esistance is not within specification the coil is not working Check the connections If the connections are good the coil is damaged internally it should be replaced Pocket tester 90890 03112 Charging coil resistance Black to Brown leads 426Q 10 at 20 C 68 F Pulser coil resistance Black to White Red leads 20Q 10 at 20 C 68 F 1 Yellow 2 Brown 3 Black 4 White Red 5 Flywheel magneto 6 Pocket tester 7 ...

Page 75: ...m direction The high beam must be directed downward at an angle of 1 2 0 to the horizontal line 2 Adjustment When necessary adjust the headlight beam by tightening or loosing the four headlight mounting screws Q __ 4 Horizontal line h Q 3 0 m 0 ft 7 6 m 25 ft h 26 mm 1 0 in 66 mm 2 6 in 6 6 o ...

Page 76: ...aced O 23Q 20 D Voltage Regulator Lighting coil resistance Black Yellow 0 23Q 20 at 20 C 68 F r Qx 1 1 Yellow 2 Brown 3 Black 4 White Red 5 Flywheel magneto 6 Pocket tester 7 Set tester at RX1 position Voltage regulator Instruments required for inspection Voltage Regulator Tester 90890 03090 Two 12V batteries One jumper Connect the tester batteries and the voltage regulator as shown in the illustr...

Page 77: ...tester Proceed with the tester 3 Test the regulator Slowly turn the tester knob clockwise the needle will move with the knob If the needle quickly returns to zero the moment it enters the black area on the scale then the working voltage of the thyristor is good the voltage regulator is working properly If the needle swings into the black area of the scale but will not return to zero the regulator ...

Page 78: ...ear 7 10 Top End 7 11 Bottom End 7 12 Carburetor 7 13 Intake 7 14 Primary Sheave 7 15 Secondary Sheave 7 16 Chain Case 7 17 Brake 7 18 Slide Rail 7 19 Suspension Wheels 7 20 Drive Axle 7 21 Steering 7 22 Ski 7 23 Ski Shock 7 24 Oil Tank 7 25 Fuel Tank 7 26 Electrical Components 1 7 27 Electrical Components 2 7 28 Control Cables 7 29 7 5 WIRING DIAGRAM 7 30 7 6 WI RE AND CABLE ROUTING 7 32 ...

Page 79: ...chamber type Piston Piston skirt clearance Measuring point Piston oversize Piston pin outside diameter x length Piston ring Piston ring design Top Piston ring design 2nd Ring end gap installed Top Ring end gap installed 2nd Small end bearing Type Big end bearing Type Fan cooled two stroke 5 port R246 246 ern 15 01 cu in 70 x 64 mm 2 76 x 2 52 in 6 1 1 Recoil hand starter C D II Autolube oil inject...

Page 80: ...lor code Autolube pump Minimum stroke Autolube pump Maximum stroke Autolube pump Reduction ratio Autolube pump Output Min 200 strokes Autolube pump Output Max 200 strokes Autolube pump wire free play Oil tank capacity Oil grade C Drive and track suspencion Transmission Type Drive ratio Engagement rpm Shift rpm Primary spring Part No Color code 1 24 x 55 mm 1 0 945 x 2 165 in Solid shaft 6306 speci...

Page 81: ... thickness Ski stance Ski toe out Steering linkage type Lock to lock angle ski Lock to lock angle steering column Front suspension Type Damper type Fuel tank Capacity Fuel grade 90508 40506 No painted 160 266 2 mm 10 47 0 08 In 11 3 mm 0 43 0 12 in 31 6 x 1 099 mm 1 24 x 43 3 in 26 mm 1 02 in Slide rail suspension Oil and gas damper Green Green No painted 8 5 mm 0 335 in 218 5 mm 8 60 in No 1 152 ...

Page 82: ...ign type Resistance 5kn 25 at 20 C 68 F C D I unit Model Manufacturer 8R4 YAMAHA Lighting system Lighting output 12V l00W Lighting coil resistance 0 23n 20 at 20 C 68 F Yellow Black Headlight type Semi shield Bulb wattage q ty 12V 60 60W x 1 pc Tail stop light wattage 12V 8W 23W A C regulator Model manufacturer TRIZ 50 HITACHI S85168 TOSHIBA Voltage 13 8 0 5V 7 2 Tightening torque Part to be tight...

Page 83: ... Ib Shaft 1 and frame M10 P1 25 5 5 m kg 40 ft lb Pivot arm 1 and sliding frame 1 M10 P1 25 5 0 m kg 36 tt lb Use Loctite Suspension wheel M12 P1 25 7 3 m kg 53 ft lbl Spring hook M8 P1 0 2 3 m kg 16 5 ft lb Sliding frame 1 M8 P1 25 2 3 m kg 16 5 ft Ib Rear guide wheel M8 P1 25 2 3 m kg 16 5 ft lb SIiding runner 1 M6 P1 0 0 25 m kg 2 ft lb Use Loctite Sliding runner 2 M6 P1 0 0 65 m kg 5 ft lb Sto...

Page 84: ...m 3 281 ft m 1 094 yd cm 0 3937 in mm 0 03937 in ee em3 0 03382 oz U S liq ee ern 0 06102 eu in lit liter 2 1134 pt U S liq lit liter 1 057 qt U S Iiq lit liter 0 2642 gal U S liq kg mm 56 007 Ib in kg em2 14 2234 psi lb in2 Centigrade oC 9 5 oC 32 Fahrenheit F 7 6 General torque A B specifications Nut Bolt m kg ft lb 10 mm 6mm 0 6 4 5 I 12mm 8mm 1 5 I 11 14mm 10mm 3 0 22 17 mm 12 mm 5 5 40 19mm 1...

Page 85: ...4 EXPLODED DIAGRAM 7 Plate Spring Drive d Limiter Bracket Hoo L RECOIL STARTER 7 7 ...

Page 86: ...FLYWHEEL MAGNETO 0 7 m kg 5 tt lb Coil Plate I I I I I I I I I I I I 7 5 m kg 54 ft lb Flywheel Magneto 1 r J I I 1 I I I I I I I I I I I I I I I I l Apply Thread Locking Compound JI C nk halt I 7 8 ...

Page 87: ...abond 5 To Gear Case Side Only Apply Yamabond 5 0 67 m kg 4 8 ft Ib Adjusitng Plate IGrease I Plunger Oil Pump Cover Minimum Pump Stroke 0 20 0 25 mm 0 0079 0 0098 in Maximum Pump Stroke 1 65 1 87 mm 0 0650 0 0736 in 7 9 ...

Page 88: ...OIL PUMP DRIVE GEAR 7 10 ...

Page 89: ...TOP END Cylinder 7 11 Cylinder Bolt 3 0 m kg 22 ft Ib Ring End Gap Free 6 5 mm 0 26 in Installed 0 20 0 40 mm 0 0078 0 016 in Piston Clearance Min 0 045 mm 0 0018 in Max 0 050 mm 0 0020 in ...

Page 90: ...BOTTOM END Bearing Support 7 12 ...

Page 91: ...CARBURETOR t Starter Jet a j OW f10WP 1 U P FIOO Main Jet 1 SIOWJet 7 13 ...

Page 92: ...INTAKE Pulse Pipe jj Fuel Pump 7 14 Carburetor Boot ...

Page 93: ...Spider Lever 7 15 ...

Page 94: ...SECONDARY SHEAVE 2 3 m kg 17 ft lb Bearing Cage 7 16 Fixed Sheave ...

Page 95: ...CHAIN CASE 7 17 ...

Page 96: ...BRAKE 7 18 ...

Page 97: ...SLIDE RAIL 0 4 m kg 3 ft Ib 4 5 m kg 33 ft lbl Front Axle IGrease I Wear Limit 8 5 mm 0 3 in 0 25 m kg 2 ft Ib 4 5 m kg 35 ft Ibl 7 19 ...

Page 98: ...SUSPENSION WHEELS 7 20 Guide Wheel k Compound Thread Loc mg 7 0 m kg 51 ft tb Suspension Wheel Thread Locking Compound 7 0 m kg 51 ft Ib ...

Page 99: ...178 4 mm 7 1 in 63mm 2 5 in 138 6 mm 5 5 in 105 6 mm 4 2 in Axle Nut I 8 0 m kg 58 ft lb Bearing Cage DRIVE AXLE 7 21 ...

Page 100: ...STEERING Outside Arm J r A Universal Join 1 Clamp 2 Handlebar 7 22 ...

Page 101: ... 1 4 rn kq 10 ft Ib 1 SKI ...

Page 102: ...SKI SHOCK 7 24 ...

Page 103: ...OIL TANK Oil Gauge Line 7 25 ...

Page 104: ...FUEL TANK 1 0 m kg 7 ft Ib 7 26 ...

Page 105: ...ELECTRICAL COMPONENTS 1 Voltage Regulator 7 27 Main Swith ...

Page 106: ...ELECTRICAL COMPONENTS 2 Engine Stop Switch 7 28 ...

Page 107: ...Throttle Lever CONTROL CABLE 7 29 ...

Page 108: ... V B B L e J l L mtlIi JttJ ro B G B VI I I i OFF ON OFF OFF RUN 7 5 WIRING DIAGRAM RUN Headlight 12V 6O 60W l Tether switch liB wi B Brake Iight switch I I L IG vi w o HI LO Voltage regulator COl magneto Color Code G Green B Black Y Yellow L Blue 0 Orange Gy Gray Br Brown B W BlacklWhite W R White Red G Y Green Yellow APPENDIX ...

Page 109: ...1 4 Good Bon Bad Mauvais 2 5 Bad Mauvais Bad Mauvais 3 6 Bad Mauvais Bad Mauvais ...

Page 110: ...YAMAHA MOTOR CO LTD IWATA JAPAN PRINTED IN U S A ...

Page 111: ..._YAMAHA SNOIMOBIIE SUPPLEMENTARY SERVICE MANUAL LIT 12618 00 70 8Y1 28197 10 ...

Page 112: ...is forwarded to all Authorized Yamaha Dealers as soon aspossible OVERSEAS SERVICE OVERSEAS OPERATIONS YAMAHA MOTOR CO LTO BR250TJ SUPPLEMENTAR SERVICE MANUAL I 1984 by Yamaha Motor Corporation U S A 1st Edition June 1984 All rights reserved Any reprinting or unauthorized usewithout the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A PIN L1T 12618 00 70...

Page 113: ... SHEAVE 6 Removal 7 Disassembly 7 Inspection 8 Reassembly 10 Installation 12 V BELT 12 Removal 12 Inspection 12 Reassembly 12 EXPLODED DIAGRAM 13 CARBURETOR 13 INTAKE 14 PRIMARY SHEAVE 15 DR IVE AXLE 16 SKI 17 SLIDE RAIL 18 SUSPENSION WHEELS 19 BUMPER 20 ELECTRICAL COMPONENTS 21 SPECI FICATIONS 22 GENERAL SPECIFICATIONS 22 MAINTENANCE SPECIFICATIONS 24 CABLE ROUTING 35 WIRING DIAGRAM 40 ...

Page 114: ...EXTERNAL VIEW 1 ...

Page 115: ...ks in the oil delivery pipe 0 Recoil starter Carburetor Operation of starter jet 0 Mixing adjuster pilot screw 0 Idle speed adjustment Operation and adjustment of oil pump Cylinder compression 0 Cylinder exhaust pipe decarbonize Spark plug condition gap and cleaning 0 Tightening of the cylinder DRIVE Tightness of bolts and nuts Wear on slide runners Primary drive system V belt 0 Secondary drive sy...

Page 116: ...y Check point 20 hrs or 40 hrs or 80 hrs or When Seasonally Oil Grease 400 km 800 km 1 600 km necessary Brand name 250 mil 500mi 1 000 mil ENGINE Starter case Oil pump control box 0 Aeroshell grease 1A or Pump drive cover 0 Esso Beacon 325 grease Oil in the oil tank o I YAMALUBE 2 cycle oil DRIVE Spider lever and pin 0 Spider roller and collar Molybedenum disulfide Secondary shaft and 0 snowmobile...

Page 117: ... a problem Throttle switch Engine Carburetor switch Throttle override system 1 Carburetor switch 2 Throttle stop screw 3 Throttle cable 4 Throttle switch 5 Throttle valve Description If during operation the throttle cable or carb should malfunction in anyway remove your hand from the throttle lever The throttle switch will be deactivated the ignition circuit will be interrupted and the engine will...

Page 118: ...ions then short the circuit on the wire harness side This will turn on the igni tion circuit and the engine can be restarted In this case the throttle override system will not work Go to your Yamaha dealer for immediate service L_ J Leads connection To carbo 1 Lead from wire harness Block diagram 2 Short COl unit B Y 5 Throttle switch Carbo switch B ...

Page 119: ...1 24 in Wear limit 28 mm 1 10 in Oiling Point Siiiiiil Greasing point X No oiling or greasing is allowed 6 Be sure the X on the sheave cap aligns with X on the spider Bushing clearance 0 25 mm 0 01 in Use molybdenum sprays liberally on the weights 1 Spider 2 Plain washer 3 Roller 4 Bushing 5 Primary sheavecap 6 Fixed sheave 7 Fi xed sheavestopper 8 V belt 9 Sliding sheave 10 Slider 11 Bush 12 Plai...

Page 120: ...ve the primary sheave rnountinq bolt with the Sheave Holder special tool as shown 1 SheaveHolder P NO YS 01880 2 SheavePuller P NO YS 01882 Disassembly 1 Loosen the six sheave cap securing bolts and remove the sheave cap and spring a Immerse the primary sheave assembly in appoximately BO C 176 F water for several minutes b Hold the lower piece of the Clutch Spider Separator special tool on a rigid...

Page 121: ... turning the Clutch Separator counterclockwise Inspection 1 Inspect the tapered ends of the crank shaft and fixed sheave for scratches If either is severely scratched replace it If scratches are minor burnish the component with emery cloth 2 Check the primary sheave cap bush and sliding sheave bush for wear If worn beyond tolerance replace the bush Primary sheave cap Sliding sheave Bush clearance ...

Page 122: ...pect the sliders for scratches or other damage If any replace them 4 Inspect the rollers for wear If any replace them 1 Roller 5 Inspect the weights for wear If any replace them 9 6 Check the spring Replace it if it is fatigued or damaged ...

Page 123: ...ve apply thread locking compound as LOCTITE 640 with PRIMER T to the thread portion bottom four threads of the spider 1 LOCTITE should be applied only to the specified area Never apply to the other areas 2 Do not use the clutch until LOCTITE has completely cured 10 Do not apply grease to the area marked X For other parts oiling is unnecessary 1 Apply LOCTITE 640 with PRIMER T 2 4 threads 3 Tighten...

Page 124: ... head must be to the right of the roller asshow in the illustration Tightening torque 5 Nm 0 5 m kg 3 6 ft Ib 1 Washer 2 Weight 3 Roller 4 Bolt 5 Turning direction 11 5 Install the primary sheave cap onto the spider asshown NOTE _ 1 Before installing the primary sheave cap use molybdenum sprays liberally on the weights 2 Be sure the IIX on the sheave cap aligns with the X on the spider 6 Secure th...

Page 125: ...6 in 3 Measure the length of the V belt It should be within specification if not replace the belt 3 Tighten the mounting bolts with the special tools to specification Tightening torque A 100 Nm 10 rn kq 72 ft Ib B 60 Nm 6 0 rn kg 43 ft lb Tighten the bolt to A to properly seat the primary sheave on the crankshaft Loosen the bolt then torque it to B the final torque V BELT Removal 1 Turn the second...

Page 126: ... EXPLODED DIAGRAM CARBURETOR t1 Starter Jet a Overflow Pipe Float Need 6 1 Main Jet 1 O R ng 0 it Main Jet cover i Slow Jet Q Carburetor Assembly 13 ...

Page 127: ...INTAKE Pulse Pipe Fuel Pump 14 Primer Pump Intake Silencer b retor Boot Car u ...

Page 128: ... 25 mm 0 01 in Be sure the X on the sheave cap aligns with X on the spider 14 Nm 1 4 m kg 10 ft Ib I Bushing clearance I 0 25 mm 0 01 in Use molybdenum sprays liberally on the weights Oiling Point Greasing point X No oiling or greasing is allowed 15 1 Spider 2 Plain washer 3 Roller 4 Bushing 5 Primary sheave cap 6 Fixed sheave 7 Fixed sheave stopper 8 V belt 9 Sliding sheave 10 Slider 11 Bush 12 P...

Page 129: ...DRIVE AXLE Drive Sprocket Axle Nut ftolbl I 8 a m kg 58 80 Nm 16 ...

Page 130: ...SKI ...

Page 131: ...SLIDE RAIL 18 ...

Page 132: ...SUSPENSION WHEELS 19 ...

Page 133: ...BUMPER Protector 4 Front Bumper 3 Flap itD Front Bumper Bind Screw 6 Bumper End r Spring Nut r Flanqe Bolt 20 ...

Page 134: ...ELECTRICAL COMPONENTS Throttle Lever Lever Holder R 21 ...

Page 135: ...ecoil hand starter Lubrication System YAMAHA Autolube system Engine Oil Type YAMALUBE 2 cycle oil Tank Capacity 1 75 L 1 54 Imp qt 1 85 US qt _ _ _ Transmission Oil Type Gear oil API GL 3 SAE 75 80 I Capacity 0 20 L 0 18 Imp qt 0 21 US qt Fuel Type Regular gasoline Tank Capacity 15 0 L 3 3 Imp gal 4 0 US gal Carburetor I Type I BD32 28 Manufacturer I KEIHIN Spark Plug i I Type i BR8HS Manufacturer...

Page 136: ...gth on Ground 110 mm 43 7 in Track Deflection 40 50 mm lo57 97 in 10 kg 22 Ib Brake Brake Type Disc brake Caliper swing type Operation Left hand Electrical Ignition System C D 1 ignition Generator System Flywheel magneto Battery Type Battery Capacity Headlight Type Halogen light Bulb Wattage x Pes Headlight GO 55W x 1 Tail Brake Light 8W 23W x 1 Meter Light 3AW x 1 23 ...

Page 137: ... 0 01 mm 0 0004 in 69 950 69 980 mm 2 754 2 755 in 10 mm 0 394 in 0 045 0 050 mm 0 0018 0 0020 in 72 25 mm 2 845 in 72 50 mm 2 854 in 1 0 mm 0 04 in Exhaust side Piston Pin Outside Diameter x Length Piston Ring Sectional Sketch End Gap Installed Side Clearance Coating Top Ring 2nd Ring Top Ring 2nd Ring Top Ring 2nd Ring Top Ring 2nd Ring 24 18 x 55 mm 0 71 x 2 71 in _ _ _ i Keystone B 1 2 mm 0 04...

Page 138: ... J P AJ AS Pw J Big End Bearing Type Small End Bearing Type rank Pin Outside Dia Crank Bearing Type Quantity Crankshaft Left Crankshaft Center Crankshaft Right Crank Oil Seal Type Size Quantity Crankshaft Left Crankshaft Center Crankshaft Right Connecting Rod Parallel Limit Intake Type Carburetor Type Manufacturer Quantity 1 0 Mark Main Jet Main Air Jet Jet Needle Needle Jet Pilot Jet Pilot Air Je...

Page 139: ...0 3 000 m 100 10 000 ftl 98 Fuel Pump Type Manufacturer Quantity Diaphragm type KEIHIN l Oil Pump Color Code Pink Plunger Diameter 5 5 mm 0 16 in Minimum Stroke 0 20 0 25 mm 0 0079 0 0098 in Maximum Stroke 1 65 1 87 mm O 0650 0 0736 in Reduction Ratio 1 45 Minimum Output at 200 stroke 0 95 1 19 cm 0 033 0 042 Imp oz 0 032 0 040 US oz Maximum Output at 200 stroke I 7 S4 8 S9 crrr 0 276 0 313 Imp oz...

Page 140: ...m 10 47 in 11 mm 0 433 in 8F2 17641 00 1 099 mm 43 26 in 31 6 mm 1 24 in 28 0 mm 1 10 in Primary Sheave Spring Part No Color Code Outside Dia x Wire Dia Pre load Set Length Spring Rate No of Coils Free Length Primary Sheave Weight Arm Part No Weight x Quantity Additional Weight type Hole Position 27 90501 553A5 Gold Red 55 0 x 5 5 mm 2 165 x 0 217 in 14 kg 61 5 mm 2 42 in 2 64 kg mm 4 9 66 8 mm 2 ...

Page 141: ...ode Torque Cam Angle Drive Chain Type No of Links Free Play Optional Sprocket Drive Sprocket Driven Sprocket Track Part No Width x Length Pitch x No of Links Thickness I A Height 8 o o 183 kq rnrn deq 15 9 lb in deq 9 9 105 mm 4 13 in 40 1 44 8 15 mm 0 32 0 59 in 11 12 13 14 21 22 23 24 8XO 47110 00 381 x 3 456 mm 15 0 x 136 1 in 64 mm 2 52 in x 54 5 5 mm 0 22 in 15 5 mm 0 61 in Deflection at 10 k...

Page 142: ...A Wear Limit B Front Rear Front Rear Front Rear BR250TJ 102 mm 4 02 in 76 mm 2 99 in 305 kq mrn 17 080 Ib in deg 9 5 mm 0 37 in 318 3 kq rnrn 17 825 Ib in deg 10 mm 0 39 in No 2 48 kg 106 Ib 0 3 rn s 48 kg 106 Ib OA rn s 45 kg 99 Ib 0 3 rn s 45 kg 99 Ib 0 3 rn s 15 mm 0 59 in 10 mm 0 39 in Track Drive Sprocket Wheel Material No on Teeth Rear Guide Wheel Material Outside Dia Brake Pad Thickness A W...

Page 143: ...82 mm 7 16 in 3 2 rnrn 0 13 in 3 0 8 0 mm 0 12 0 32 in Model Frame Frame Material Seat Height Luggage Box Location Steering Steering Angle Steering Angle Ski Alignment Ski Toe out Size Distance II A Right Left BR250TJ Steel Between seat and shroud 55 0 mm 2 17 in 55 0 mm 2 17 in Toe out 0 15 mm 0 0 59 in 1 960 mm 77 0 in 30 ...

Page 144: ...urer 2 3 4 5 6 7 Engine Speed x 103 r rnln F8R4 YAMAHA 20n 10 at 20 C 68 F W R B 426 2 10 at 20 C 68 F Br B 80F YAMAHA 8 9 Ignition Coil Model Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance F6T411 MITSUBISH I 11 mm 0 43 in at 3 000 r min 1 0n 15 at 20 C 68 F 5 9 kn 15 at 20 C 68 0 F Ignition Coil Model Manufacturer Minimum Spark Gap Primary Winding Resistanc...

Page 145: ...ng Coil Resistance 0 23Q 20 at 20 C 68 F Color Code Y B 30 I Q I OJ 0 20 OJ S s OJ J 10 f 2 3 4 5 6 7 8 9 Engine Speed x 103 r minl I Coil Resistance for Grip Warmer Color Code _ Voltage Regulator Type A C Type Model Manufacturer TR1Z 50 HITACHI 58516B TOSHIBA No Load Regulated Voltage 13 3 14 3 V 32 ...

Page 146: ...retighten Installation of secondary sheave M12 x P1 25 40 4 0 29 Bearing housing M8 x Pl 25 23 2 3 17 Secondary shaft and bearing collar Socket screw 6 0 6 4 3 Brake cliper and housing chain M10 x P1 25 50 5 0 36 Installation of drive chain sprocket M20 x Pl 25 60 6 0 43 Bolt Installation of driven chain sprocket M6 x Pl 0 I 5 8 0 58 4 2 Bolt Chain housing and frame M8 x P1 25 23 2 3 17 Installati...

Page 147: ...0723 ft Ib em kg 0 8680 in Ib kg 2 205 Ib g 0 03527 02 km lit 2 352 mpg km hr 0 6214 mph km 0 6214 mi m 3 281 ft m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03382 oz U S liq cc crn 0 06102 cu in lit liter 2 1134 pt U S liq lit liter 1 057 qt U S liq lit liter 0 2642 gal U S liq kg mm 56 007 Ib in kq crrr 14 2234 psi lb in2 Centigrade 0C 9 5 C 32 Fahrenheit lO F 34 tighten multi fastener assembl...

Page 148: ...BLE ROUTING 1 Throttle wire Band Hold the engine stop switch lead wire Clamp Wire harness assembly Clamp 35 Brake wire assembtv Band Hold both beam and brake light switch lead wires Clamp Clamp the hose C ...

Page 149: ...ad wire T O R S lead wire Grommet Band Clamp after gathering the terminals Clamp C D I unit To flywheel magneto Clamp Install together with bolts securing crankcases 1 and 2 E View t To head lamp Pipe joint T O R S lead wire Wire harness assembly Grommet 36 Body earth ...

Page 150: ...otector pipe Fuel level gauge To taillight Clip Pulse pipe Breather pipe Route under the fuel tank Protector pipe keep the hose away from the chain housing c vlew Pump wire assembly pump assembly Clip From fuel tank Autolube pump assembly 37 ...

Page 151: ...CABLE ROUTING 4 Starter lever installation Clamp 38 ...

Page 152: ...CABLE ROUTING 5 Recovery tank installation Tank fitting band Instrument panel 39 Hook Panel frame ...

Page 153: ...park plug COLOR CODE B Black L Blue G Green o Orange Y Yellow Br Brown C D I Unit B W _ _ __ _ _ _ H Tail Brake light EL r le v 1 Voltage regulator Main switch GIYI G Y LlWJ L I Headlight c tl G Y B B 0 y I I I Headlight beam switch Engine stop switch I i i Brake Iight switch J o J ...

Page 154: ... YAMAHA 1 rOR CO LTD PRINTED IN U S A ...

Page 155: ...YAMAHA SUPPLEMENTARY SERVICE MANUAL 880 28197 10 ...

Page 156: ...994 by Yamaha Motor Corporatlon U S A 1st Editionl May 1994 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A PIN LlT 21618 01 61 ...

Page 157: ...RVICE MANUAL 8Y1 28197 70 BR250T SUPPLEMENTARY SERVICE MANUAL 81X 28197 25 HOW TO USE THIS MANUAL Particularly important information is distin guished inthismanual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe or death to the machine operator a bystander or a person ins...

Page 158: ...erhaul Cooling system j Carburetion Electrical Specifications Optional kit Illustrated symbols to are used to identify the specifications which appear Filling fluid Lubricant Tightening Wear limit clearance Engine speed Special tool n V A Illustrated symbols to in the exploded dia gram indicate grade of lubricant and location of lubrication point Apply locking agent LOCTITE Apply Yamabond No 5 App...

Page 159: ...TROUBLESHOOTING 8 SPARK PLUG CAP 9 IGNITION COIL 9 SOURCE COIL 9 SPARK PLUG 10 THROTILE OVERRIDE SYSTEM T O R S 10 HANDLEBAR SWITCH RIGHT 11 CARBURETOR SWITCH 11 MAIN SWITCH 12 LIGHTING SYSTEM 13 CIRCUIT DIAGRAM 13 TROUBLESHOOTING 14 BULB S 15 HEADLIGHT BEAM SWITCH 15 SPECIFICATIONS 16 GENERAL SPECIFICATIONS 16 MAINTENANCE SPECIFICATIONS 18 ENGINE 18 POWER TRAIN 22 CHASSiS 26 ELECTRICAL 27 GENERAL...

Page 160: ...just below the front of the seat ENGINE SERIAL NUMBER The engine serial number CD is located on the right hand side of the crankcase NOTE _ The first three digits of these numbers are for model identification the remaining digits are the unit production number Starting Serial Number BR250TV 8BD 008101 NOTE _ Designs and specifications are subject to change without notice 1 ...

Page 161: ...FUEL SUB TANK 2 ...

Page 162: ... 1 4 Bolt 4 5 Plate 2 6 Clamp 2 Refer to the CABLE ROUTING section 7 Fuel suction hose 1 8 Breather hose 1 NOTE Unclamp and remove the breather hose from the fuel sub tank 9 Fuel level hose 1 NOTE Disconnect the fuel level hose connected to the upper part of the fuel sub tank then raise the tank so that the other fuel level hose the one connected to the lower part of the tank can be disconnected 1...

Page 163: ... __C I __ R CUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM L 1 L G Y L L o 4 ...

Page 164: ...t Voltage regulator Thumb warmer Grip warmer Grip warmer switch Option BR250T Standard equipment BR250TS Option B Black 0 Orange W R White Red L Blue R Red Y B Yellow Black Br Brown Y Yellow Y R Yellow Red Ch Chocolate B W Black White GIY GreenIYellow G Green BIY Black Yellow 1 13 11 50mm 2 0in 30mm 1 2in 5 NOTE Specified hole should be drilled for the Grip warmer switch installation Refer to the ...

Page 165: ...RICAL COMPONENT CD Mam switch IJENGINE STOpIJ I switch 3J Throttle switch Headlight beam switch Brake light switch Wire harness J Vol age regulator Ignition coil C D 1 unit ELECTRICAL COMPONENT IELEC I0 I 6 ...

Page 166: ...IGNITION SYSTEM CIRCUIT DIAGRAM CD Ignition coil Spark plug Throttle switch o Carburetor switch Main switch IGNITION SYSTEM IELECI0 I ENGINE STOP 0 CD switch IJ Unit C D I magneto 7 ...

Page 167: ...oil Check the IIENGINE STOP switch throttle switch carburetor switch and main switch OK Correct connection and or replace C D 1 unit 8 OUT OF SPECIFICATION IRepair or replace the spark plug OUT OF SPECIFICATION IReplace the spark plug cap OUT OF SPECIFICATION IReplace the ignition coil FAULTY IReplace the stator coil FAULTY Replace the handlebar switch right carburetor switch and or main switch ...

Page 168: ...Disconnect Ignition coil lead Orange Spark plug lead 2 Connect Pocket tester to ignition coil and spark plug lead 3 Measure Primary coil resistance CD Secondary coil resistance 8E061 SOURCE COIL 1 Disconnect C D I magneto lead and coupler Brown Black 2 Connect Pocket tester to C D 1 magneto lead and coupler 3 Measure Source coil pulser coil resistance Out of specification efleplace Source coil res...

Page 169: ... in THROTTLE OVERRIDE SYSTEM T O R S The ignition is turned off by the following switch ing functions when the throttle system fails AJ Idle 1 J Switch or Run Trouble starting Throttle OFF ON OFF switch Carburetor ON OFF OFF switch Engine RUN RUN STOP D Carburetor switch Throttle switch Throttlle cable Throttle stop screw 1I0N 6 IIOFF c 816 12 10 ...

Page 170: ...ontinuity x No continuity 4 Check Throttle switch continuity FauIty Replace Throttle switch Good condition position Throttle lever is 0 operated Throttle lever is not operated x 8E08l CARBURETOR SWITCH 1 Disconnect Carburetor switch lead 2 Connect Pocket tester 3 Check Carburetor switch continuity Faultv s Replace Carburetor switch Good condition position Throttle lever is x operated Throttle leve...

Page 171: ...ON SYSTEM aE101 MAIN SWITCH 1 Disconnect Main switch coupler CD 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Switch position Good condition OFF x ON 0 12 o Continuity x No continuity ...

Page 172: ...LIGHTING SYSTEM CIRCUIT DIAGRAM C D I magneto Speedometer light Brake light switch Tail brake light Headlight beam switch Headlight Voltage regulator L L I Hi f l L I Y G L G Y 13 ...

Page 173: ...LIGHT AND OR METER LIGHT DO NOT COME ON ICheck the bulbts JLOK Check the headlight beam switch and lighting coil Correct connection and or replace the voltage regulator 14 NO CONTINUITY IReplace the bulbts FAULTY Replace the headlight beam switch and or stator coif ...

Page 174: ...hot Do not touch the bulb until it cools down Headlight Meter light 3 Check Bulb s fi Tail brake light Terminal Good condition CD 0 CD 0 o Continuity HEADLIGHT BEAM SWITCH 1 Disconnect Headlight beam switch coupler 2 Connect Pocket tester to headlight beam switch coupler 3 Check Headlight beam switch continuity Faultv efteplace Switch Good fi Good position condition condition HI x 0 LO 0 x 15 0 Co...

Page 175: ...t 246 ern Bore x Stroke 70 x 64 mm 2 76 x 2 52 in Compression ratio 6 1 1 Starting system Recoil starter Lubrication system Separate Lubrication Engine oil Type YAMALUBE 2 Tank capacity 1 8 L 1 6 Imp qt 1 9 US qtl Drive chain housing oil Type Gear oil API lGL 3 SAE 75 or 80 Capacity 0 2 L 0 18 Imp qt 0 21 US qt Fuel Type Unleaded gasoline Tank capacity main tank 15 L 3 3 Imp gal 3 96 US gal sub ta...

Page 176: ... drive type Track width 381 mm 15 0 in Length on ground 1126 mm 44 3 in Track deflection mm l0 kg 22 Ib 40 50 mm 1 6 2 0 in Brake Brake type Caliper type disc brake Operation method Handle lever left handle operated Electrical Ignition system Manufacturer C D I YAMAHA Generator system Flywheel magneto Bulb wattage x Quantity Headlight 12V 60W 55W x 1 BR250T 12V 60W 60W x 1 BR250TS Tail Brake light...

Page 177: ...0 01 mm 0 0004 in 69 955 69 960 mm 2 7541 2 7543 in 10 mm 0 4 in o J 7 I D 0 045 0 050 mm 0 0018 0 0020 in Piston ring Sectional sketch Top ring 2nd ring End gap installed Top ring 2nd ring Side clearance Top ring 2nd ring Coating Top ring 2nd ring Keystone B 1 2 mm 0 05 in T 2 8 mm 0 11 in Plain B 1 2 mm 0 05 in T 2 8 mm 0 11 in 0 2 0 4 mm 0 008 0 016 in 0 2 0 4 mm 0 008 0 016 in 0 02 0 06 mm 0 0...

Page 178: ...C 0 03 mm 0 0012 in F tjo A Big end bearing Type Needle bearing Small end bearing Type Needle bearing Carburetor Type Quantity BD32 28 1 Manufacturer KEIHIN I D mark 80J 01 Main jet M J 105 Pilot jet P J 78 Pilot screw P S 1 1 4 Throttle valve Th V T 1 0 15 Valve seat size V S 1 4 Fuel level F L 13 17 mm 0 51 0 67 in Engine idle speed 1 000 1 200 r rnin Fuel pump Type Diaphragm Manufacturer KEIHIN...

Page 179: ...0 C 20 C Altitude 22 F 4 F 14 F 32 F 50 F 68 F I I I I I I 102 0 100 m 0 300 ft 105 STD 100 600 m 102 300 2 000 ft 105 STD 600 1 200 m 102 2 000 N 4 000 ft 105 STD 1 200 1 800 m Ill 100 4 000 N 6 000 ft 102 1 800 2 400 m 100 6 000 8 000 ft 102 2 400 3 000 m 100 8 000 10 000 ftl 98 Main jet number 20 ...

Page 180: ...lt 20 2 0 14 Cylinder head nut 25 2 5 18 Flywheel magneto 85 8 5 61 Crankcase upper and lower First 20 2 0 14 Tighten the bolts in Final 25 2 5 18 two stages Tightening sequence 1 710 3 5 0 0 0 0 0 8 2 0 4 Crankcase and gear unit 25 2 5 18 Oil pump and gear unit 8 0 8 5 8 With screw lock Starter pulley 15 1 5 11 Crankcase and engine bracket 25 2 5 18 21 ...

Page 181: ... 10 6 in 8 14 mm 0 31 0 55 in 89X 17641 00 1 095 1 103 mm 43 1 43 4 in 31 6 mm 1 24 in 28 0 mm 1 10 in Primary sheave spring Part number Color code Outside diameter Wire diameter Pre load Set length Spring rate Number of coils Free length Primary sheave weight arm Part number with bushing Weight Secondary sheave spring Part number Color code Outside diameter Wire diameter I I I I I 90501 50654 NO ...

Page 182: ...rive chain Type Number of links Track Part number Width Length Pitch Number of links Suspension setting position Stopper band hole position Front MAINTENANCE SPECIFICATIONS ISPECI0 1 BR250TfTS 183 kg mm 9 9 105 mm 4 13 in DID 40K 1 44 89X 47110 00 381 mm 15 0 in 3 456 mm 136 in 64 mm 2 52 in 54 No 2 23 ...

Page 183: ... Slide runner Thickness 13 5 mm 0 53 in Wear limit 8 5 mm 0 33 in Track sprocket wheel Material Polyethylene Number of teeth 9 Rear guide wheel Material Aluminum with rubber Outside diameter f2S191 mm 7 5 in Brake Pad thickness 7 3 mm 0 29 in Pad wear limit 1 mm 0 04 in Pad to disc clearance 0 2 1 0 mm 0 008 0 040 in Disc th ickness 3 2 mm 0 13 in Brake lever free play 6 7 mm 0 24 0 28 in 24 ...

Page 184: ... 36 Installation of drive chain sprocket 60 6 0 43 Bolt Installation of driven chain sprocket 5 8 0 58 4 2 Bolt Chain housing and frame 23 2 3 17 Installation of front axle L H and bearing 85 8 5 61 Front axle housing and frame 23 2 3 17 Front pivot shaft 65 6 5 47 Rear pivot shaft 65 6 5 47 Guide wheel shaft 80 8 0 58 Sliding runner 2 5 0 25 1 7 Lower end bracket 20 2 0 14 Lower end bracket and a...

Page 185: ...120 mm 4 72 in Thickness 1 6 mm 0 06 in Ski suspension Spring type Leaf spring Tightening torque Parts to be tightened Tightening torque Remarks Nm m kq ft lb Engine mounting bolt 30 3 0 22 Ski runner 14 1 4 10 Steering column and gate 13 7 1 37 10 Use lock washer Steering tie rod adjusting nut 25 2 5 18 Apply LOCTITE Steering lower bracket 13 7 1 37 10 Use lock washer Installation of steering col...

Page 186: ... Lighting coil resistance color code Coil resistance for grip warmer color code C D 1 unit manufacturer Ignition coil Model Manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Spark plug cap Type Resistance Charging system Type F85LIYAMAHA 20 Q 20 at 20 C 68 F Wh ite Hed Black 275 Q 20 at 20 C 68 F Brown Black 11 V 3 000 r rnln 15 V 6 000 r min 0 3 Q 20 at 20 C 68 F Ye...

Page 187: ... avoid warpage tighten multi fastenerassemblies in acrisscrossfashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperature I A L A Distance across flats B Outside thread diameter 28 A B General Torque nut bolt Specifications Nm rn kq ft lb 10mm 6mm 6 0 6 4 3 12 mm 8mm 15 1 5 11 14mm 1...

Page 188: ...harness Earth Grommet To headlight Clamp CD Throttle cable Clamp _ _ _ e t Band 80 I _ c 120 Clamp the wireharness Clip Wireharness Shroud Clamp the breather hose Brake cable Breather hose Clamp the wireharness D Primer pump hose C with primer pump Option J Headlight lead C without primer pump Wireharness Breather hose Brake cable 8 29 ...

Page 189: ...p Oil hose Clamp To flywheel magneto To crankcase To ignition coil t Oil hose To carburetor E CD Voltage regulator Grommet Wireharness J Fuel suction hose Fuel level hose Breather hose To C D 1 unit To meter i assembly c _ Fuel hose From primer pump gold color nozzle Joint J Fuel suction hose Primer pump hose Pulser hose A with primer pump Option A without primer pump 30 ...

Page 190: ...taillight Oil hose Breather hose j Passthe wireharness below the fuel tank Starter cable Fuel pump From recovery tank Throttle cable Brake cable Oil pump Oil hose Breather hose Pulser hose Fuel suction hose Indicator panel Oil tank Place the taillight lead coupler as shown 31 ...

Page 191: ...edometer lead Speedometer cable Starter cable Clamp Taillight lead BR250T Clamp J Band Recovery tank Headlight beam switch Tail Brake light lead Main switch Voltage regulator Grip warmer Grip warmer switch JlENGINE STOP switch 32 ...

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