Yamaha BR250F Service Manual
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Yamaha BR250F Service Manual

Yamaha BR250F Service Manual

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o YAMAHA
SNOWMOBILE
SERVICE MANUAl
LI1-12618-00-41
884-28197-10

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  • Page 1 YAMAHA SNOWMOBILE SERVICE MANUAl LI1-12618-00-41 884-28197-10...
  • Page 2 The information herein should be closely studied to avoid unnecessary repairs and to provide the owner with a sound, safe, dependable machine. NOTE; The Research and Engineering Department of Yamaha is continually striving to further perfect all models. Improvements and modifications are therefore inevitable.
  • Page 3 TABLE OF CONTENTS GENERAL ENGINE CARBURETION POWER TRAIN CHASSIS ELECTRICAL APPENDIX...

  • Page 4: Table Of Contents

    CHAPTER 1. GENERAL 1-1. EXTERNAL VIEW " 1-2. MACHINE IDENTIFICATION 1-3. TERMS 1-4. STORAGE 1-5. PRE-SEASON PREPARATION 1-6. MAINTENANCE A. Periodic Maintenance B. Lubrication Intervals C. Seali ng the Carbu retor. 1-7. HIGH ALTITUDE TUNING 1-8. SPECIAL TOOLS...

  • Page 5: External View

    GENERAL 1-1. EXTERNAL VIEW...

  • Page 6: Machine Identification

    1-2. MACHINE IDENTIFICATION 1-3. TERMS A. Frame Serial Number Grease: The frame serial number is located on the Unless other specified, use a low-tempera- right-hand side of frame (just below the front ture lithium base grease when instructed to of seat). The first three digits identify the grease a part or component.

  • Page 7: Maintenance

    1~6. MAINTENANCE A. Periodic Maintenance Perform the various inspections and services at the indicated intervals; however use this schedule as a guide only. Depending upon the operating conditions, certain components may require more fre- quent servicing. Every When 20 hrs. or 40 hrs.

  • Page 8: Lubrication Intervals

    Every When 20 hrs. or 40 hrs. or 80 hrs. or Seasonally Check point necessary 400 km 800 km 1,600 km (250 mil (500 mil (1,000 rni] CHASSIS: Tightness of bolts and nuts Bends and cracks Welded riveted, joints Ski adjustment Ski runner wear Breaks in fuel tank Cleaning of fuel tank...

  • Page 9: Sealing The Carburetor

    C. Sealing the Carburetor ALWAYS seal the carburetor before turning 1. Plug the fuel-tank vent pipe. a snowmobile on its side for service. This will 2. Plug both float-bowl overflow pipes or prevent fuel from spilling and creating a connect them together. hazard.

  • Page 10: Special Tools

    '·8. SPECIAL TOOLS 4-b. 4-d. &-b. Description Tool No. Dial Gauge 90890..Q3097..Q0 Dial Gauge Stand 90890-01195-00 rnml Dial Gauge Needle (56 90890-03098-00 TLU·90901-05-20 (U.S.A.) 3-Way Puller A'ssy 3-Way Puller Attachment 90890-01803..Q0 3-Way Puller Attachment 90890-01804-00 3-Way Puller Screw 90890-01906-00 Drive Handle 90890--1906-00 3-Way PuIler Body 90890..Q1848-00...
  • Page 11 CHAPTER 2. ENGINE 2-1. ENGINE REMOVAL 2-2. DISASSEMBLY AND INSPECTION A. Recoil Starter B. Flywheel Magneto C. Oil Pump D. Top End 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.

  • Page 12: Chapter 2. Engine

    ENGINE 2-1. ENGINE REMOVAL 3. Carburetor (Refer to 3-1, A "Removal.") You do not have to remove the engine in 4. D-handle from the starter rope. Knot the order to service the following components: rope so it will not be pulled into the Cylinder, starter case.

  • Page 13: Disassembly And Inspection

    2-2. DISASSEMBLY AND INSPECTION A. Recoil Starter Drive Pawl Drive Plate Drive Plate Spring 1. Remove the air shroud and the starter 3. Remove the securing nut, and carefully from the engine. disassemble the starter. Note the relative 2. Pull about four inches of starter rope position of each piece.

  • Page 14: Flywheel Magneto

    B. Flywheel Magneto Flywheel Magneto 1. Using the rotor holding tool, loosen the 3-Way Puller Ass'y: TLU-90901-05-20 (U.S.A.) securing nut, and remove the flywheel 1. 3-Way Puller: 90890-01848 pulley from the magneto. 3-Way Puller Attachment: 90890-01803 3. 3-Way Puller Attachment: 90890-01804 Rotor Holding Tool: 90890-01235 4.

  • Page 15: Oil Pump

    Oil Pump Plunger Adjusting Pulley Oil Pump Drive Shaft 5. Remove the drive shaft from the oil 1. Loosen the four gear-case bolts, and pump. Inspect the bearing surfaces of remove the gear case/oil pump assembly the shaft and the gear teeth. If any part from the engine.
  • Page 16 7. Check the minimum pump stroke. 9. If either the maximum pump stroke or a. Turn the oil pump gear until the plunger the minimum pump stroke does not is at its maximum distance from the equal specification, remove the adjusting pump body.

  • Page 17: Top End

    Remove a piston pin ip from the piston, and remove the pin with the universal piston-pin puller. Universal piston-pin puller: YU-01304 Remove the piston and the small-end bearing from the connecting rod. MS623 BR250F Service Manual Revised 1/82...
  • Page 18 Inspection 1. Piston pin and bearing inspection. a. Check the piston pin for signs of wear. If any wear is evident, replace the pin and the bearing. 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.
  • Page 19 3. Piston rings a. Check the rings for scoring. 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: (0.26 Approx.
  • Page 20 Otherwise follow standard honing Standard Wear limit ---------- procedures. Yamaha recommends the use of 70.00 .., 70.02 mm 70.05 mm an Ammco Hone. This kit includes all the Cylinder bore (2.756 -2.757 in) (2.776 in) necessary piecesto properly hone the cylinder 0.05mm...

  • Page 21: Bottom End

    E. Bottom End ~@ ae~o~ Right Crankshaft aearing Oil-Pump Drive Sprocket Engine Mounting Bracket Disassembly Remove the four crankcase bolts. Note Remove the engine mounting bracket the position of the wire bracket. You from the crankcase. will have to reinstall it on the same bolt.
  • Page 22 3. Separate the crankcase halves by rapping b. Install bearings with their manufacturer's indicated points with a rubber marks or numbers facing outward. They mallet. should be visible when intalled. c. Install oil seals with their manufacturer's marks also facing outward. d.

  • Page 23: Assembly And Adjustment

    2. Thoroughly oil the bearing and the con- c. Check the crankshaft assembly runout with a dial gauge. If the ru nout is not necting rod. 3. Apply Yamabond 4 to the mating sur- within specification, the crankshaft parts faces of the crankcase halves.

  • Page 24: Top End

    B. Top End rCYlinder Bolt Cylinder Small End Bearing Install the piston rings as shown in the illustration. Piston crown ////// / / /////(JUJ/J//J//// _ _':1 ' - - - - - . . ; ; : 0 . . , , - 'l//7//7//// /77//7//7//7//7 Piston ring...

  • Page 25: Flywheel Magneto

    7. Oil the piston, and install the cylinder 2. Add oil to the crankcase through the oil holes. Oil the connecting rod. onto the crankcase. Use a new cylinder 3. Cover the crankcase with a clean cloth so gasket. Torque the four cylinder bolts to specification.

  • Page 26: Recoil Starter

    5. Install the flywheel pulley. The two cut- 1. Feed the magneto leads through the outs on the edge of the pulley must be hole in the crankcase, and secure the opposite the holes in the fan. Torque the damper in the case. securing nut to specification.
  • Page 27 1. Hook the outer book of the starter spring around the post in the starter case. Carefully wind the spring counter- clockwise, and fit the spring into the case. Thoroughly grease the spring after installation. 5. Install the drive plate spring, spring collar, and the drive plate.

  • Page 28: Oil Pump Gear Case

    Tightening torque: 0.65 m-kg (4.7 ft-lb) 9. Install the air shroud. Use a washer and lock 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.
  • Page 29 7. Install the oil pump gear box onto the 1. Place the washer on the oil pump drive engine. Be sure the drive gear correctly shaft, and insert the drive shaft into the engages the oil pump drive gear on the oil pump.

  • Page 30: Engine Installation

    2-4. ENGINE INSTALLATION 1. Place the engine in the chassis. Torque the three engine mounts to specification. Tightening torque: Bolt: 3.0 m-kg (22 tt-lb) Nut: 1.4 rn-kq (10 ft-lb] 2. Install or connect the following compo- nents in the order given below. •...
  • Page 31 CHAPTER 3. CARBURETION 3-1. CARBURETOR A. Removal B. Disassembly C. Inspection D. Assembly E. Installation 3-2. TUNING AND ADJUSTMENT A. Carburetor Tuning Data B. Starter Cable Adjustment C. Throttle Cable Adjustment D. Oil Pump Cable Adjustment E. Low Speed Tuning F.

  • Page 32: Chapter 3. Carburetion

    CARBURETION 3-1. CARBURETOR Starter Jet ® Carburetor Assembly Main c o v e r - - @ Removal 2. Loosen the clamp on the carburetor 1. Disconnect the pulse pipe, oil pump boot and remove the carburetor. Do not cable, oil delivery pipe, throttle cable, lose a spring from the air box boot.

  • Page 33: Disassembly

    B. Disassembly 6. Measure the float level. 1. Carefully remove the jets, float, etc. a. Incline the carburetor approximately 20 Never, however, disassemble the throttle or 30 degrees until the float valve just valve or the throttle shaft. The threads barely closes.

  • Page 34: Installation

    9. Apply grease to the following areas so 3-2. Tuning and Adjustment they will not freeze: The carburetor is set at the factory to run at Throttle return spring, temperatures of 32° F to _4° F (0° to -20°C) Throttle shaft, at seal level.

  • Page 35: Starter Cable Adjustment

    3. Fuel flow High-speed tuning Mid-range. Full ~~rq~:=========1t1:t====n:~~:E!=::~Elt====tt===ll=!~ttj1~~ -----~~---_1\:-__t__+_I_______/.I----_:_~..L--~__+_~~l_!_ rClosed Low speed tuning 1. Starter jet Throttle stop screw, pilot screw, bypass, float level Slow jet Main jet BR250 CARBURETOR (KEIHIN 8032·28) B. Starter Cable Adjustment Fuel Flow Chart Pu II the starter cable outer tube upward, and adjust the free play between the outer tube Total fuel flow end and adjuster to specification by turning...

  • Page 36: Throttle Cable Adjustment

    Free play - . - H__- 1.5"'2.5 mm (0.06"'0.10 in) 2. Lock Adjuster 1. Play 3. Lock Adjusting screw Free play between outer tube end Lock the adjusting screw by tightening and adjuster: the nut. 1.5'" 2.5 (0.06'" 0.10 Low Speed Tuning The carburetor is built so that low speed C.

  • Page 37: Low Speed Tuning

    4. Slowly loosen slow adjuster. As the slow F. Mid-range and High Speed Tuning adjuster is loosened, the mixture will No adjustment is normally required, but become leaner and engine rpm will in- adjustment is sometimes necessary depending crease. Adjust the slow adjuster to attain on temperatures and/or altitude.

  • Page 38: Troubleshooting

    WARNING: Never remove the main jet cover bolt while the engine is hot. Fuel will flow out of the float chamber which could ignite and cause damage to the snowmobile and possible injury to the mechanic. Place a rag under the carburetor so fuel does not spread.
  • Page 39 Adjustment Trouble Check point Remedy I Remove the air vent pipe, and Poor performance at Clogged air vent Clean normal speeds clean. (Relative troubles) Clogged or loose main jet Clean and retighten Remove main jet, and blow it out • Excess fuel consumption with compressed air.

  • Page 40: Intake

    3-3. INTAKE Pulse Pipe Air Box Boot Carburetor Boot 2. Inspect the air box boot and the carbure- 1. Check to see that fuel moves from the fuel tank, to the fuel pump, then to the tor boot. Replace as necessary. Replace the air box boot springs if either is carburetor.
  • Page 41 CHAPTER 4. POWER TRAIN 4-1. SHEAVE ALIGNMENT 4-2. CLUTCH TUNING A. Clutch Setting Data B. Changing Clutch Engagement and Shift RPM 4-3. V-BELT A. Removal B. Inspection 4-4. PRIMARY SHEAVE , .4-4 A. Removal B. Disassembly C. Inspection D. Assembly 4-5.

  • Page 42: Chapter 4. Power Train

    POWER TRAIN 4-1. SHEAVE ALIGNMENT 3. If either the center-to-center distance or the offset is not within specification, check the engine mounts. If the engine has been mounted correctly, the engine mounting bracket, the frame, or both are bent. Replace as required. Sheave gauge: TLS-9091O-47-02 (U.S.A.) 90890-01702 Center-to-center:...

  • Page 43: Clutch Setting Data

    Engine rpm Engine rpm Good condition Bad condition Clutch Clutch shifting rpm shifting rpm Clutch engagement rpm Clutch engagement rpm 1---------+---4 Travelled distance _ _ Travelled distance ----- Starting position 200""" 300 m (650""" 1,000 Starting position 200'"'-' 300 m (650""" 1,000 A.

  • Page 44: Changing Clutch Engagement And Shift Rpm

    B. Changing Clutch Engagement and Shift RPM r.p.m. Clutch engagement Clutch shifting r.p.m, Increase Increase Decrease Decrease Centrifugal force of rollers Add shims Remove shims Add shims Remove shims Torsion spring Decrease Increase constant Secondary spring Twist angle Smaller wind Greater wind 4-3.

  • Page 45: Primary Sheave

    4-4. PRIMARY SHEAVE Fixed Sheave Bushing Spider Sheave Cap Spider Lever Bushing A. Removal 1. Remove the drive guard, 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.

  • Page 46: Disassembly

    B. Disassembly Bushing clearance, limit Large bushing Small bushing Install the sheave subassembly tool in Inside 0.25 mm (0.01 in) 0.25 mm (0.01 in) the primary sheave. Outside 0.25 mm (0.01 in) 0.25 mm (0.01 in) Primary sheave subassembly tool: 90890-01858 1.

  • Page 47: Assembly

    Remove the sliding sheave from the Disassemble inspect the spider fixed sheave, and remove the spider. levers; replace any worn parts. Reassem- Measu re the wear on the slider buttons. ble the levers with new cotter pins. If worn beyond specification, replace the buttons.
  • Page 48 Install the bushing and the spider into the sliding sheav'e. Be sure the bottons correctly engage the slider. 3. Thread the sliding sheave onto the fixed sheave. Install the cams. Be sure they are correctly seated in the sliding sheave. 8.

  • Page 49: Secondary Sheave

    SECONDARY SHEAVE ~jrCliP <: Colla, Bearlnq Cage ~~~ ~ ~~Irl '" Spdng Seat B"",ong (J;;;1 /3!!J; fi r . Ramp Shoe 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.

  • Page 50: Inspection

    NOTE: 3~way 2. Using the puller, remove the fixed sheave. The three holes in the spring seat are for con- venience only. Seating the spring in a differ- ent hole will not change the spring preload. 3-Way Puller Ass'y: TLU-90901-05-20 (U.S.A.) 1.

  • Page 51: Chain Case

    Std. secondary spring preload: (Twist augle) 7. Install the washer and securing nut. Torque the nut to specification. Tightening torque: Install the key in the jackshaft, and 4.0 rn-kq (29 ft-lb) install the fixed sheave. Grease the indicated point. 8. Wipe both sheaves. They should be free from oil and grease.

  • Page 52: Disassembly

    A. Disassembly 1. Remove the secondary sheave from the jackshaft (Refer to 4-5, A "Removal.") Remove the bearing cage from behind the jackshaft bearing. Remove the jackshaft from the left side of the snowmobile. Inspection 1. Inspect the brake disc. Place it on a sur- face plate and check around the edges with a feeler gauge.

  • Page 53: Gearing

    5. Inspect the drive chain; replace as neces- 4. Grease the bearing surfaces of the jack- sary. shaft. Place the key in the jackshaft, and 6. Inspect the adjusting block. If the raised install the jackshaft from the left-side of boss is worn to the base of the block, the machine.
  • Page 54 11. Secure the drive and driven sprockets onto their respective shafts. Torque the securing hardward to specification. Use a new cotter pin with the drive sprocket. Tightening torque: Drive sprocket nut: 4.0 rn-kq (29 ft-lbl Driven sprocket bolt: 2.3 rn-kq (17 ft-lb) 12.

  • Page 55: Brake

    4-7. BRAKE A. Disassembly Remove the clevis pin and disassemble 1. Remove the brake cable from the the brake. handlebar. Loosen the adjuster at the cal iper, 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.

  • Page 56: Inspection

    D. Brake Adjustment B. Inspection The brake is adjusted at two points so that Check the brake pads. If either is worn the gaps between the disc and pads are equal beyond the wear limit, replace the pads and within tolerance. Proper adjustment will as a set.

  • Page 57: Slide Rail Suspension

    4-8. SLIDE RAIL SUSPENSION A. Removal 3. Turn the machine on its side, and lift the Loosen the track. rear torsion spring off its seat to release the preload. Repeat this procedure on 2. Seal the carburetor so fuel will not spill when you turn the machine on its side.

  • Page 58: Inspection

    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] Replace any fatigued springs. 5. Inspect both the front and rear stopper bands. Replace if either is frayed or 1.

  • Page 59: Installation

    Installation 1. Grease the suspension where indicated in the illustration. 4. Grease the rear axle, and install it in the 2. Thoroughly grease the axle in the front rear pivot arm. pivot arm. Tape the end caps in place. 5. Install both rear suspension-mounting This will hold the axle within the pivot arm during installation of the suspen- bolts.

  • Page 60: Drive

    4-9. DRIVE Drive Axle Bearing Bearing Cage Remove the suspension. (Refer to 4-8, A A. Removal RemovaL") 1. Place an oil pan beneath the chain case, and remove the chain case cover. Let the 6. Place the machine on its right side. Remove the axle by lifting it up and out oil drain into the oil pan.

  • Page 61: Inspection

    B. Inspection 2. Install the axle. Push the threaded end 1. Check the track and clips for cracks, up towards the secondary sheave, then damage, or wear. Replace the track or install the splined end into the chain clips as required. case.
  • Page 62 1. Turn the track by running the engine. 2. Loosen the lock nuts, and turn both the right and left track adjusting bolts until the track is aligned with the slide rail as illustrated. 2. Adjusting bolt 1. Lock nut No good Good No good...
  • Page 63 CHAPTER 5. CHASSIS 5-1. STEERING A. Assembly B. Adjustment 5-2. SKiS A. Inspection B. Assembly 5-3. OIL TANK 5-4. FUEL TANK...
  • Page 64 CHASSIS 5-1. STEERING Steering 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: m-kg (22 ft-lb)
  • Page 65 Install the steering column onto the Tightening torque: frame. Grease the upper and lower bear- 2.5 m-kg (18 ft-lb) ings. Torque the bolts to specification and bend the lock tab. Tightening torque: 2.0 m-kg (15 ft-lb) Front 1. Ski spindle center B.
  • Page 66 5-2. SKIS A. Inspection Tightening torque: 1. Check the ski runner. Replace it if it is Spring nut: 1.4 m-kg (10 ft-Ib) excessively worn. Torque the nuts to specification. 3. Check the wear plate. Replace it if it is worn. Tightening torque: 1.4 m-kg (10 ft-lb] Inspect the leaf spring and the spring re-...
  • Page 67 B. Assembly top end to the ski column. All collars 1. After assembling the ski, thoroughly should be greased, and securing nuts grease the wear plate and all retaining should be torqued. pins. Be sure to install the shock with the word uy AMAHA"...
  • Page 68 damaged in any way. Replace as neces- Check the oil line from the tank to the sary. pump. It should be free from all obstruc- tions and shouId not be pinched or Fuel Gauge Line <, 1. Check all lines. If any are cracked, 4.
  • Page 69 CHAPTER 6. ELECTRICAL 6-1. IGNITION SySTEM A. Circuit Diagram B. Troubleshooting C. Ignition Timing D. Spark Gap Test E. Ignition Coil F. Spark Plug G. Pulser and Charge Coil. H. C.D.1. Unit 6-2. LIGHTING SYSTEM A. Circuit Diagram B. Headlight Beam C.

  • Page 70: Chapter 6. Electrical

    ELECTRICAL 6-1. IGNITION SYSTEM A. Circuit Diagram B. Troubleshooting No spark is produced or weak. _____ ~---.JI Check of connections Check lead wire connections for short circuits. --1----------, F a u l t y . Correct. SparkS "Spark Gap See 6-1, D Test."...

  • Page 71: Ignition Timing

    ......Measure coil resistance. ' - - - - - . - - - _..(See 6-1, G "Pulser and Charge Coil.") Faulty------.. Replace......Ignition coil test (See 6-1, E "Iqnition Coil.") Replace. C.D.I.?g See 6-1, H. "C.D.1. Unit." Faulty •...

  • Page 72: Spark Gap Test

    10. Remove the dial gauge stands. Reinstall 6. Slowly turn the flywheel clockwise until the starter and the spark plug. Torque the dial gauge indicates the specified ignition timing. the plug to specification. Ignition timing (B.T.D.C.); Tightening torque: 2.8 m-kg (20 ft-lb) 1.6 mm (0.062 in) The marks on the coil plate should align D.

  • Page 73: Ignition Coil

    E. Ignition Coil 1. Coil spark gap test a. Remove the ignition coil from the frame. b. Connect the Electro Tester as shown. c. Connect a fully charged battery to the 0 0 1 - - - - - - +... tester.

  • Page 74: Pulser And Charge Coil

    Inspection G. Pulser and Charge Coil Instruct the rider to: Check the resistance of each coil as shown in 1. Inspect the clean the spark plug every the illustartion. If the resistance is not within 400 km (250 mi) or 20 hours. specification, the coil is not working.

  • Page 75: Lighting System

    6-2. LIGHTING SYSTEM A. Circuit Diagram B. Headlight Beam 2. Adjustment 1. Inspection When necessary, adjust the headlight Check the headlight beam direction. The beam by tightening or loosing the four high beam must be directed downward headlight mounting screws. at an angle of 1/2 to the horizontal line.

  • Page 76: Lighting Coil

    C. Lighting Coil Lighting coil resistance: Check the resistance between the yellow lead & Black Yellow: and ground. If the resistance is not within 0.23Q 20% at 20°C (68°F) ± specification, the coil is not working. Check the connections. If the connections are good, the coil is broken internally;...
  • Page 77 Inspection 1. Check the battery voltage. Set the left and right switches to "VOLT" and Jl12V". If the checker needle reads 20 volts or more, battery voltage is sufficient. YAMAHA []::J 12\/ IIOLT ElI] REGULATOR CHECKER Replace the regulator Light...
  • Page 78 CHAPTER 7. APPENDIX 7-1. SPECIFICATIONS 7-2. TIGHTENING TORQUE 7-3. CONVERSION TABLES 7-4. EXPLODED DIAGRAMS Recoil Starter........7-7 Flywheel Magneto.

  • Page 79: Chapter 7. Appendix

    APPENDIX 7-1. SPECIFICATIONS A. General Model BR250F Model: Model (I.B.M. No.) BR250F (8R4) 1.0. & Frame starting number 8R4-000101 1.0. & Engine staritng number R246-000101 Dimension: Overall length 2,360 mm (92.9 in) Overall width (std) 870 mm (34.3 in) Overall height (w/windshield) 940 mm (37.0 in)
  • Page 80 Crankshaft: 0.039 Crankshaft assembly width (A) 56 _ 0.05 0.00197 0.02 mm (0.0008 in) Crankshaft deflection (0) 0.25 -- 0.75 mm (0.010 -- 0.030 in) Connecting rod big end side clearance (C) Connecting rod small end deflection 2.0 mm (0.079 in) c:t{r CLUTCH SIDE 100 mm (3.9...
  • Page 81 Secondary spring: Part No. 90508-40506 Color code No painted Secondary spring pre-load (twist) 160° ± ± Sheave distance 2 mm (10.47 0.08 In) Sheave off-set 11 ± 3 mm (0.43 ± 0.12 in) V·belt width and outer line length 31.6 x 1,099 mm (1.24 x 43.3 in) V-belt wear limit 26 mm (1.02 in) Track suspenison...

  • Page 82: Tightening Torque

    E. Electrical Ignition system: Type flywheel magneto (C.D.I. type) Model/man ufactu rer F8R4/YAMAHA Voltage Pluser coil resistance 20n ± 10% at 20°C (68°F) (White/Red - Black) Charging coil resistance 426n ± 10% at 20°C (68°F) (Brown - Black) Ignition timing: B.T.D.C.
  • Page 83 Part to be tightened Thread size Tightening torque Remarks Oil pump gear case P1.0 0.7 m-kg (5.1 ft-Ib) [Drive and track suspension] Primary sliding sheave and cap 1.1 m-kg (8 ft-lb) P1.0 Installation of primary sheave UNF 1/2" Initial: 10 m-kg (72.5 ft-lb) Use motor oil Loosen once and retighten: 6.0 m-kg (43.5 ft-Ib)

  • Page 84: Conversion Tables

    GENERAL TORQUE SPECIFICATIONS General torque specifications (Nut) This chart specifies torque for standard (Bolt) m-kg ft-lb fasteners with standard 1.8.0. pitch threads. 10 mm Torque specifications for special components or assemblies are included in the applicable 12mm sections of this book. To avoid warpage, tighten multi-fastener assemblies in a criss- 14mm 10mm...

  • Page 85: Exploded Diagrams

    EXPLODED DIAGRAM RECOIL STARTER d Lim iter Bracket Drive Plate Spring...

  • Page 86: Flywheel Magneto

    FLYWHEEL MAGNETO 0.7 m-kg (5 tt-lb) 7.5 m-kg (54 ft-lb) Flywheel Magneto / / r - - - - - - - - - - - ---------, Coil Plate <, <, "' " <, <, ,..-----.."'" Apply Thread ' " Locking <, -/--...

  • Page 87: Oil Pump

    OIL PUMP Oil Pump Cover Apply Yamabond 5 Minimum Pump Stroke: 0.20-0.25 <0.0079-0.0098 Maximum Pump Stroke: 1.65 - 1.87 <0.0650 - 0.0736 0.67 m-kg (4.8 ft-Ib) Adjusitng Plate Grease Plunger Apply Yamabond 5 To Gear Case Side Only...

  • Page 88: Oil Pump Drive Gear

    OIL PUMP DRIVE GEAR 7-10...

  • Page 89: Top End

    TOP END Cylinder Bolt 3.0 m-kg (22 ft-Ib) Cylinder 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) 7-11...

  • Page 90: Bottom End

    BOTTOM END Bearing Support 7-12...

  • Page 91: Carburetor

    CARBURETOR Starter Jet § ~OW'f10WP' '<. " <. (..@-FIOO'.; SIOWJet~ Main Jet 7-13...

  • Page 92: Intake

    INTAKE Fuel Pump (jj)..Pulse Pipe Carburetor Boot 7-14...
  • Page 93 Spider Lever 7-15...

  • Page 94: Secondary Sheave

    SECONDARY SHEAVE Bearing Cage Fixed Sheave 2.3 m-kg (17 ft-lb] 7-16...

  • Page 95: Chain Case

    CHAIN CASE 7-17...

  • Page 96: Brake

    BRAKE 7-18...

  • Page 97: Slide Rail

    SLIDE RAIL 4.5 m-kg (35 ft-Ibl 0.4 m-kg (3 ft-Ib) Front Axle Grease 4.5 m-kg (33 ft-lbl Wear Limit: 0.25 m-kg (2 ft-Ib) (0.3 7-19...

  • Page 98: Suspension Wheels

    SUSPENSION WHEELS 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 7-20...

  • Page 99: Drive Axle

    DRIVE AXLE 138.6 mm (5.5 105.6 178.4 mm 63mm (4.2 (7.1 (2.5 Bearing Cage Axle Nut 8.0 m-kg (58 ft-lb) 7-21...

  • Page 100: Steering

    STEERING Clamp--~-· Handlebar Outside Arm Universal Join' 7-22...

  • Page 101: Ski

    ·-~1.4 rn-kq (10 ft-Ib)

  • Page 102: Ski Shock

    SKI SHOCK 7-24...

  • Page 103: Oil Tank

    OIL TANK Oil Gauge Line 7·25...

  • Page 104: Fuel Tank

    FUEL TANK 1.0 m-kg (7 ft-Ib) 7-26...

  • Page 105: Electrical Components

    ELECTRICAL COMPONENTS (1) Main Swith Voltage Regulator 7-27...
  • Page 106 ELECTRICAL COMPONENTS (2) Engine Stop Switch 7-28...

  • Page 107: Control Cables

    CONTROL CABLE Throttle Lever 7-29...
  • Page 108 Main switch 7-5 WIRING DIAGRAM B IB/W Brake Iight switch IG/vi (O/P SPEEDOMETER LIGHT) Headlight (12V 6O/60W) Taillight/brake light VI I ,JttJ~~~~~ro (12V 8/23W1 mtlIi _. . L-e:::J<:l-L Tether switch liB/wi ..>-Cl..JCDm COl unit Voltage regulator COl magneto Color Code Green Gray Black...
  • Page 109 Good Mauvais Mauvais Mauvais Mauvais 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 FOREWORD This supplementary service manual for the BR250T has been published to supple- ment the BR250F service manual (L IT-12618-00-41). For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.
  • Page 113 CONTENTS EXTERNAL VIEW MAINTENANCE Periodic Maintenance Lubrication Intervals THROTTLE OVERRIDE SYSTEM Description T.O. R.S. cancellation Block diagram POWER TRAIN PRIMARY SHEAVE Removal Disassembly Inspection Reassembly Installation V-BELT Removal Inspection Reassembly EXPLODED DIAGRAM CARBURETOR INTAKE PRIMARY SHEAVE , .. , DR IVE AXLE, SLIDE RAIL SUSPENSION WHEELS BUMPER...
  • Page 114 EXTERNAL VIEW...

  • Page 115: Bends, Cracks, And Wear

    MAINTENANCE Periodic Maintenance Perform the various inspections and services at the indicated intervals; however use this schedule as a guide only. Depending upon the operating conditions, certain components may require more fre- quent servici Every When 20 hrs. or 40 hrs. or 80 hrs.

  • Page 116: Bends And Cracks

    Every When 20 hrs. or 40 hrs. or 80 hrs, or Check point Seasonally necessary 400 km 800 km 1,600 km (250 mil (500mi) (1,000 mil CHASSIS: Tightness of bolts and nuts Bends and cracks Welaed riveted, joints Ski adjustment Ski runner wear Breaks in fuel tank Cleaning of fuel tank...
  • Page 117 THROTTLE OVERRIDE SYS.TEM Description WARNING: If during operation the throttle cable or carb Before restarting the engine, make sure that should malfunction in anyway, remove your the cause of the malfunction has been cor- hand from the throttle lever. The throttle rected and that the engine can be operated switch will be deactivated, the ignition circuit without a problem.
  • Page 118 This will turn on the igni- tion circuit and the engine can be restarted. In this case, the throttle override system will To carbo not work. Go to your Yamaha dealer for immediate service. T .O .R .S. Cancellation L_-----J 1.
  • Page 119 POWER TRAIN PRIMARY SHEAVE The bolt head must be inserted as shown. Be sure the "X" on the sheave cap "X" aligns with on the spider. Bushing clearance: 0.25 (0.01 Apply to bottom four threads or thread-locking compound such #640 as "LOCT with PRIMER Bushing clearance:...
  • Page 120 Removal 2. Remove the sliders, rollers and weights. 1. Remove the drive guard, and remove the V-belt. Remove the blind cap, and remove the primary sheave rnountinq bolt with the Sheave Holder (special tool) as shown. 1. Slider 2. Roller 3.
  • Page 121 NOTE: f. Remove the spider, sliding sheave and Securely fit the projections of the Adapter fixed sheave from the Clutch Spider into the fixed sheave holes. Separator. g. Remove the sliding sheave bush from the sliding sheave with Bushing Tool (special tool) as shown.
  • Page 122 1. Feeler gauge 2. Sliding sheave 6. Check the spring. Replace it, if it is Inspect the sliders for scratches or other fatigued or damaged. damage. If any, replace them. Inspect the rollers for wear. If any, replace them. Roller 5.
  • Page 123 Reassembly When reassembling primary sheave, reverse the disassembly procedure. Note the following points: 1. Before reassembling the primary sheave, the sheaves should be lubricated with Do not apply grease to the area marked X. the low-temperature grease and motor For other parts, oiling is unnecessary. oil as illustrated.
  • Page 124 5. Install the primary sheave cap onto the spider as shown. To tighten the fixed sheave, high torque is NOTE: required. Therefore, make sure the primary Before installing the primary sheave cap, sheave, vise and special tools are placed use molybdenum sprays liberally on the securely also take care not to crack the fixed weights.
  • Page 125 Inspection Installation 1. Visually inspect the V-belt for signs of When installing the primary sheave, reverse the removal procedure. Note the following damage. Replace the belt, if it is points: damaged. Before installing the primary sheave, 2. Measure the width of the V-belt. If the clean the oil off the tapered portion belt is worn beyond the wear limit, of the crankshaft using a lacquer thinner.
  • Page 126 . EXPLODED DIAGRAM CARBURETOR t1-- Starter Jet ® Overflow Pipe Need~ -----Q, Float Slow Jet Carburetor Assembly Main Jet <~ -------..~ ~ ~/6:1 ® ---0 O-R;ng cover~ Main Jet -13 -...
  • Page 127 INTAKE Primer Pump Intake Silencer Fuel Pump Pulse Pipe ----Car u b ret o r Boot...
  • Page 128 PRIMARY SHEAVE bolt head must be inserted as shown. Be sure the "X" on the sheave cap "X" aligns with on the spider. Bushing clearance: 0.25 mm (0.01 in) 14 Nm (1.4 m-kg, 10 ft-Ib) Apply to bottom four threads or thread-lockinq compound such as"...
  • Page 129 DRIVE AXLE Drive Sprocket ftolbl! Axle Nut 80 Nm m·kg, 58 -16-...
  • Page 131 SLIDE RAIL -18 -...
  • Page 132 SUSPENSION WH EELS -19-...
  • Page 133 BUMPER Flap Protector 4 'itD Front Bumper 6----- (@ (@ Bind Screw Bumper End >~ '.. ' Spring Nut Flanqe Bolt Front Bumper 3 -20-...
  • Page 134 ELECTRICAL COMPONENTS Throttle Lever Lever Holder (R)
  • Page 135 70 x 64 mm (2.76 x 2.52 in) Compression Ratio 6.1 : 1 Start i ng System Recoil hand starter Lubrication System: YAMAHA Autolube system Engine Oil: Type Y AMALUBE 2-cycle oil Tank Capacity 1.75 L (1.54 Imp qt, 1.85 US qt) - -- - - ~ - - _ .
  • Page 136 BR250TJ Model Suspension: Leaf spring, oil damper Front Suspension Type Slide rail Rear Suspension Type Track: Track Type Internal drive type Track Width 381 mm (15.0 in) Length 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)
  • Page 137 MAINTENANCE SPECIFICATIONS Engine Model BR250T Cylinder head: Volume (With spark plug) 33.1 -- 33.7 cm' (2.02 -- 2.06 cu.in) Warp Limit Cylinder: Material Aluminum alloy with special cast iron sleeve Bore Size 70.000 -- 70.020 mm (2.756 ""' 2.757 in) <...
  • Page 138 BR250TJ Model Crankshaft: Crank Width" F" Assembly Width" 55.95 -- 56.00 mm (2.202 -- 2.362 in) 2.0 mm (0.080 in) Connecti ng Rod Small End Free Play "B" Connecting Rod Big End Clearance "C" 0.25"'" 0.75 mm (0.010'" 0.030 in) Crankshaft Deflection "0": Measuring Point - 1 0.02 mm (0.0008 in)
  • Page 139 BR250TJ Model Power Air Jet (Pw.A.J.) (G.S.) Starter Jet ¢ Valve Seat Size (V.S.) ± Idling Engine Speed 1,100 100 r/min ± ± Float Arm Height (F.H.) 2.0 mm (a.59 O.OS in) High Altitude Tuning 20°C -30°C -20°C -10°C O°C 10°C (_4°F) (6SoF)
  • Page 140 Model BR250TJ Transmission: Type V-belt Automatic Range of Ratio 3.5 : 1 -- 1 : 1 ~ngagement Approx. 2,800 r/min Shift RPM Approx. 5,700 r/min Sheave Center Distance" A" 266 mm (10.47 in) Sheave Offset "B" 11 mm (0.433 in) V-belt: Part No.
  • Page 141 Model 8R250T Secondary Sheave Spring: 90580-40080 Part No. Color Code None Outside Dia. x Wire Dia. 4.0 mm (1.968 0.157 in) Twist Angle Hole Position (Sheave Side) (Spring Seat Side)** Spring Rate 183 kq-rnrn/deq (15.9 lb-in/deq) No. of Coils Free Length 105 mm (4.13 in) Color Code Torque Cam Angle...
  • Page 142 Model BR250T J Track Suspension: Front Travel 102 mm (4.02 in) Rear Travel 76 mm (2.99 in) Front Suspension Spring: Spring Rate 305 kq/mrn (17,080 Ib!in)!deg Wire Dia. 9.5 mm (0.37 in) Rear Suspension Spring: Spring Rate 318.3 kq/rnrn (17,825 Ib!in)!deg Wire Dia.
  • Page 143 Model BR250TJ Pad to Disc Clearance 0.2'" 1.0 mm (0.008'" 0.039 in) Disc Outside Dia. 182 mm (7.16 in) Disc Thickness 3.2 rnrn (0.13 in) Brake Lever Free Play* 3.0'" 8.0 mm (0.12 -- 0.32 in) Chassis Model BR250TJ Frame: Frame Material Steel Seat Height...
  • Page 144 +... !----f--f-------r---+---+--+---l _-j-._-+--t---+--t---+ II--j-.-+--~__+-_l_-+--+--t---+--+--+_--+-_+_-+___+-+____i Engine Speed ( x 10 3 r/rnln) --_._--_._._._-- - _ ..CDI: Model/Manufacturer F8R4/YAMAHA ± Pickup Coil Resistance 10% at 20°C (68°F) Color Code (W/R ± Charge Coil Resistance 426[2 10% at 20°C (68°F) Color Code...
  • Page 145 BR250TJ Model Charging Coil Resistance Color Code Lighting Voltage (Min.) 11.8 V/3,000 r/min (Max.) ± Lighting Coil Resistance 0.23Q 20% at 20°C (68°F) Color Code > > ....Engine Speed ( r/minl Coil Resistance for Grip Warmer . Color Code Voltage Regulator: Type A.C.
  • Page 146 Tightening torque Tightening torque Tread size Remarks Part to be tightened ft·lb m·kg [Engine] M14 x P1.25 Spark plug Cylinder head (bolt) M8 x P1.25 Cylinder head (nut) M10 x P1.25 Flywheel magneto M16 x P1.9 Crankcase upper and lower First: M8 x P1.25 Final:...
  • Page 147 Tightening torque Part to be tightened Thread size Remarks rn-kq ft-lb Steering column and gate M8 x P1.25 13.7 Use lock washer 1.37 Steering tie rod adjusting nut M10 x P1.25 Loctite® Steering lower bracket M8 x P1.25 13.7 1.37 Use lock washer Installation of steering column 1,2 M8 x P1.25...
  • Page 148 CABLE ROUTING (1) assembtv Brake wire Throttle wire Band Hold both beam and brake light Band Hold the engine stop switch lead wire switch lead wires Clamp Clamp the hose "C Clamp Wire harness assembly Clamp - 35-...
  • Page 149 CABLE ROUTING (2) A-View Brake light switch lead wire Beam switch lead wire T.O.R.S. lead wire Pipe joint Grommet Band - Clamp after gathering To flywheel magneto the terminals T.O.R.S. lead wire Clamp - Install together with bolts Clamp securing crankcases 1 and 2 C.D.I.
  • Page 150 ROUTI CABLE NG (3) B·View Recovery tank Breather pipe Protector pipe Fuel level gauge To taillight . . . Route under the fuel tank Protector pipe keep the hose away from the chain housing c-vlew Pump wire assembly Clip Pulse pipe pump assembly Clip From fuel tank...
  • Page 151 CABLE ROUTING (4) Clamp installation Starter lever - 38-...
  • Page 152 CABLE ROUTING (5) Recovery tank installation Instrument panel Tank fitting band Hook Panel frame 39 -...
  • Page 153 WIRING DIAGRAM COLOR CODE Main switch B ..Black GreenIYellow Blue B/W ..• . Black/White G . . . • . . . Green BIY . . . • • • Black/Yellow Orange White/Red Brake Iight switch Yellow...
  • Page 154 1~,~:rOR • YAMAHA CO.,LTD. PRINTED IN U.S.A.
  • Page 155 YAMAHA SUPPLEMENTARY SERVICE MANUAL 880-28197-10...
  • Page 156 BR250TV SUPPLEMENTARY SERVICE MANUAL ©1994 by Yamaha Motor Corporatlon, U.S.A. 1st Edition 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 BR250TV. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with fol- lowing manual: BR250F SERVICE MANUAL: 8R4-28197-10 BR250G SERVICE MANUAL: 8V6-28197-20 BR250H...
  • Page 158 OE031 ® ILLUSTRATED SYMBOLS II~~~I~I II:grl~1 (Refer to the illustration) Illustrated symbols are designed as thumb tabs to indicate the chapter's number and IP~:RIClDI content. .J.- CHAS General information ® Periodic inspection and adjustment Chassis ® ® Power train ® IENGI Engine overhaul """""""...
  • Page 159 CONTENTS GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER CHASSiS FUEL SUB TANK JOB INSTRUCTION CHART ELECTRiCAL CIRCUIT DIAGRAM ELECTRICAL COMPONENT IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING SPARK PLUG CAP IGNITION COIL SOURCE COIL SPARK PLUG THROTILE OVERRIDE SYSTEM (T.O.R.S.) HANDLEBAR SWITCH (RIGHT) CARBURETOR SWITCH MAIN SWITCH...

  • Page 160: General Information

    II~~~ I~I MACHINE IDENTIFICATION 1E001 GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number is located on the right-hand side of the crankcase.

  • Page 161: Chassis

    FUEL SUB TANK...

  • Page 162: Job Instruction Chart

    ICHASI FUEL SUB TANK JOB INSTRUCTION CHART Order Job name/Part name Q'ty Remarks Removal of fuel sub tank Remove the parts in the order in which they Fuel are listed. Brake cable Extract the fuel from the fuel sub tank usi n9 a pump.

  • Page 163: Electrical

    :-:-_ _C:.:I,__ R.CUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM :" , 1-· • L G/Y...
  • Page 164 CIRCUIT DIAGRAM <iQ) Ignition coil Brake light switch ® ® Tail/Brake light Spark plug ® Headlight beam switch Throttle switch Carburetor switch Headlight ® Voltage regulator Main switch ® Thumb warmer* "ENGINE STOP" switch C.D.I. unit Grip warmer* ® ® C.D.1.

  • Page 165: Electrical Component

    ELEC ELECTRICAL COMPONENT ELEC!RICAL COMPONENT Mam switch ® IJENGINE STOp IJ I§\ switch Throttle switch Headlight beam switch ® Brake light switch ® Wire harness Vol~age regulator ® Ignition coil ® C.D.1. unit...

  • Page 166: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM ® "ENGINE STOP" Ignition coil CD " switch ® Spark plug . .. Unit ® ® Throttle switch C.D.I. magneto Carburetor switch ® Main switch...

  • Page 167: Troubleshooting

    ELEC IGNITION SYSTEM 8E021 TROUBLESHOOTING NO SPARK OR WEAK SPARK. OUT OF SPECIFICATION Check the spark plug gap. Repair or replace the spark plug. OUT OF SPECIFICATION Check the spark plug cap resistance. Replace the spark plug cap. OUT OF SPECIFICATION Check the ignition coil resistance.

  • Page 168: Spark Plug Cap

    IGNITION SYSTEM 8E041 SPARK PLUG CAP 1. Remove: • Spark plug cap 2. Connect: • Pocket tester (to spark plug cap) 3. Measure: • Spark plug cap resistance [::J 11 Spark plug cap resistance: 5 k11 at 20 (68°F) 8E051 IGNITION COIL 1.

  • Page 169: Spark Plug

    IGNITION SYSTEM 8E031 SPARK PLUG 1. Remove: • Spark plugs 2. Check: • Spark plug Standard spark plug: BR9ES (NGK) 377000 Spark plug gap: 0.6 - 0.7 (O.024 - 0.028 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) The ignition is turned off by the following switch- ing functions when the throttle system fails.

  • Page 170: Handlebar Switch (Right)

    ELEC IGNITION SYSTEM 8E071 HANDLEBAR SWITCH (RIGHT) "ENGINE STOP" switch and throttle switch 1. Disconnect: • Handlebar switch (riqhtl.coupler 2. Connect: • Pocket tester (90890-03112, YU-03112) 3. Check: • "ENGINE STOP" switch continuity Faultv-efteplace. Good condition Switch position RUN (pull) OFF (push) 0: Continuity x : No continuity...

  • Page 171: Main Switch

    IGNITION SYSTEM aE101 MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester 3. Check: • Main switch continuity Faulty Replace. Switch position Good condition Continuity x : No continuity -12-...

  • Page 172: Lighting System

    LIGHTING SYSTEM CIRCUIT DIAGRAM ® C.D.I. magneto Headlight beam switch ® Speedometer light Headlight Brake light switch Voltage regulator ® Tail/brake light L G/Y ® -13-...

  • Page 173: Troubleshooting

    ELEC LIGHTING SYSTEM 8E141 TROUBLESHOOTING HEADLIGHT, TAIL LIGHT AND/OR METER LIGHT DO NOT COME NO CONTINUITY Check the bulbts), bulbts). Replace the FAULTY Check the headlight beam switch and lighting coil. Replace the headlight beam switch and/ or stator coif. Correct connection and/or replace the voltage regulator.

  • Page 174: Bulb (S)

    LIGHTING SYSTEM BULB (S) ® 1. Remove: • Headlight bulb • Tail/brake light bulb • Meter light bulb 2. Connect: • Pocket tester (to bulb terminals) WARNING Keep flammable products and your hands away © from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.

  • Page 175: Specifications

    Ia-I SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model BR250T BR250TS Model code number: 8BD2 8BC2 & Frame Engine starting number: 8BD-008l0l 8BC-001101 Dimensions: Overall length 2,945 mm (115.9 in) 2,425 mm (95.5 in) 950 mm (37.4 in) Overall width Overall height 1,120 mm (44.1 in) 1,100 mm (43.3 in) Weight:...
  • Page 176 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: Maintenance Specifications

    c:r-I SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model BR250T/TS Cylinder: Aluminum alloy with cast iron sleeve Material Bore size 70.00 '" 70.02 mm (2.756 '" 2.757 in) 0.05 mm (0.0020 in) <Taper limit> 0.01 mm (0.0004 in) <Out-of-Round limit> Piston: Piston size (D) 69.955 '"...
  • Page 178 0--1 ISPECI MAINTENANCE SPECIFICATIONS Model BR250TfTS Crankshaft: Crank width A" 55.95 ... 56.00 mm (2.203 ... 2.205 in) Connecting rod small end free play 2 mm (0.08 in) I I F " Connecting rod big end side clearance "D" 0.25 ... 0.75 mm (0.01 ... 0.03 in) Crankshaft deflection "C": C 0.03 mm (0.0012 in) ..-.
  • Page 179 0--1 ISPECI MAINTENANCE SPECIFICATIONS Model BR250rffS High altitude settings -20°C -10°C -30°C 10°C 20°C (-22°F) (-4°F) (14°F) (32°F) (50°F) (68°F) Altitude #102 0", 100 m (0 ... #105 (STD) #102 100", 600 m (300 ... 2,000 #105 (STD) #102 600 ... 1,200 m 4,000 (2,000 #105 (STD)
  • Page 180 I0--1 SPEC MAINTENANCE SPECIFICATIONS Tightening torque: Tightening torque Part to be tightened Remarks rn-kq ft-lb Spark plug Cylinder head (bolt) Cylinder head (nut) Flywheel magneto Crankcase upper and lower First: Tighten the bolts in Final: two stages. Tightening sequence Crankcase and gear unit Oil pump and gear unit With screw lock Starter pulley...

  • Page 181: Power Train

    cr--I ISPECI MAINTENANCE SPECIFICATIONS POWER TRAIN Model BR250T/TS Transmission: Type V-belt automatic Range of ratio 3.5 ""' 1.0:1 Engagement RPM 2,900 ""' 3,500 r/min (BR250T) 2,600", 3,200r/min (BR250TS) Shift RPM 5,600 '" 7,200 r/min (BR250T) 5,400 ""' 6,000 r/rnin (BR250TS) Sheave center distance A"...
  • Page 182 I0--1 SPEC MAINTENANCE SPECIFICATIONS Model BR250TfTS Hole position Sheave side-spring seat side (twist angle) Spring rate kg/mm Number of coils Free length 105 mm (4.13 in) Drive chain: Type DID 40K-1 Number of links Track: Part number 89X-47110-00 Width mm (15.0 in) Length 3,456 mm (136 in)
  • Page 183 I0-1 SPEC MAINTENANCE SPECIFICATIONS Model BR250TffS Shock absorber: Damping force Front Extension 80 kg/0.3 Compression 50 kg/0.3 rn/s Rear Extension 48 kg/0.3 Compression 45 kg/0.3 Slide runner: Thickness 13.5 mm (0.53 in) 8.5 mm (0.33 in) Wear limit Track sprocket wheel: Polyethylene Material Number of teeth...
  • Page 184 Icr-I SPEC MAINTENANCE SPECIFICATIONS Tightening torque: Tightening torque Parts to be tightened Remarks ft-lb rn-kp Primary sliding sheave and cap Installation of primary sheave First: Tighten the bolts in Final: two stages. See NOTE. Installation of secondary sheave Bearing housing Secondary shaft and bearing collar Brake caliper and housing chain Installation of drive chain sprocket...

  • Page 185: Chassis

    I0--1 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model BR250TfTS Frame: Frame material Steel Steering: (left) 24.6° (R Ski), 28. P (L Ski) Lock to lock angle (right) 28.1 (R Ski), 24.6° (L Ski) Ski alignment Toe-out o "" Toe-out size 6 mm (0 "" 0.24 in) Ski: Ski material Steel...

  • Page 186: Electrical

    (Yellow - Black) ± Coil resistance for grip warmer 0.8 Q 20% at 20°C (68°F) (color code) (Red - Black) C.D.1. unit manufacturer 8AU-00/YAMAHA Ignition coil: Model/Manufacturer 86B-00IYAMAHA Minimum spark gap mm (0.12 in) ± Primary coil resistance 0.4 Q 20% at 20°C (68°F)

  • Page 187: General Torque Specifications

    g--I ISPECI GENERAL TORQUE SPECIFICATIONS 9E051 GENERAL TORQUE General Torque Specifications (nut) (bolt) SPECIFICATIONS ft-lb rn-kq This chart specifies torque for standard fasteners 10mm with standard I.S.0. pitch threads. Torque specifi- 12 mm cations for special components or assemblies are included inthe applicable sections ofthis book.

  • Page 188: Cable Routing

    ISPECI CABLE ROUTING CABLE ROUTING Throttle cable ® Brake cable ® Clamp _ _----.::.._--e:t' ® Band (80)...I..-_~ ® Brake cable ® Band Breather hose Starter cable Primer pump hose C (with primer pump*) * Option Clamp the wireharness ® ® Brake cable Clamp ®...
  • Page 189 0--1 ISPECI CABLE ROUTING To ignition coil To C.D.1. unit !""'-. ® To meter assembly -c _,," '''' .."" Band ® To carburetor Breather hose Voltage regulator ® Fuel level hose ® Oil hose ® Clamp Breather hose To carburetor switch To fuel pump ®...
  • Page 190 ISPECI CABLE ROUTING ® Breather hose Fuel level hose ® Sub tank ® Fuel suction hose To taillight--- ® Oil hose Pass the wireharness below the fuel tank. ® ® Throttle cable From recovery tank Indicator panel Brake cable Oil tank Starter cable Place the taillight lead coupler as shown.
  • Page 191 I0--1 SPEC CABLE ROUTING Speedometer lead ® Speedometer cable ® Starter cable ® Clamp Taillight lead BR250T ® Clamp Band ® Recovery tank Main switch ® ® Voltage regulator Headlight beam switch ® Grip warmer Grip warmer switch ® Tail/Brake light lead JlENGINE STOP"...

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