o YAMAHA

SNOWMOBILE
SERVICE MANUAl
LI1-12618-00-41 884-28197-10
FOREWORD
This Service Manual has been written to acquaint the mechanic with the dis-
assembly, reassembly, maintenance, and troubleshooting procedures required
to provide optimum performance and longevity of the machine.
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.
In light of this fact, all specifications within this manual are subject to change
without 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 usewithout the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
LIT-12618-00-41
Particularly important information is distinguished in this manual by the
following notations:
NOTE:
WARNING:
A NOTE provides key information to make procedures easier or
clearer.
A CAUTION indicates special procedures that must be followed
to avoid damage to the machine.
A WARNING indicates special procedures that must be follow-
ed to avoid injury to a machine operator or person inspecting
or repairing the machine.
TABLE OF CONTENTS
GENERAL
ENGINE
CARBURETION
POWER TRAIN
CHASSIS
ELECTRICAL
APPENDIX
CHAPTER 1. GENERAL
1-1. EXTERNAL VIEW " 1-1
1-2. 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. Seali ng the Carburetor. 1-5
1-7. HIGH ALTITUDE TUNING 1-5
1-8. SPECIAL TOOLS 1-6
1-1. EXTERNAL VIEW
GENERAL
1-1
1-2. MACHINE IDENTIFICATION 1-3. TERMS
A. Frame Serial Number
The frame serial number is located on the
right-hand side of frame (just below the front
of seat). The first three digits identify the
model. This is followed by a dash. The
remaining digits identify the production
number of the unit.
Grease:
Unless other specified, use a low-tempera-
ture lithium base grease when instructed to
grease a part or component.
Thread-locking compound:
Use Loctite Lock N' Seal (blue), unless
other wise specified, when applying a
thread-locking compound to securing hard-
ware.
Oil:
Use Yamalube 2 to oil components unless
another oil is specified.
If a snowmobile will not be used for several
months, it should be stored in a proper place
so that both the engine and the track are not
damaged.
1. Completely drain the fuel tank, and dis-
connect the fuel line 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 the track.
7. Block the chassis so that the track is off
the floor.
8. Protect the snowmobile with a covering.
1-4. STORAGE
1-5. PRE-SEASON PREPARATION
8R4-000101 Starting frame serial number
B. Engine Serial Number
The engine serial number is located on the fan
case. The prefix indicates the engine type and
displacement. The prefix is followed by a
dash and the serial number. Normally both
the frame and engine serial numbers are
identical.
Starting engine serial number R246-000101
Perform the predelivery service as described
in the predelivery check list before operating
any snowmobile that has been stored for
several months.
1-2
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
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400 km 800 km 1,600 km
necessary
(2
ENGINE:
Tighteness of bolts and nuts
Bends, cracks, and wear
0
Abnormal noise 0
Loose connection and breaks in the fuel and pulse pipes
0
Loose connection and breaks in the oil pipes
0
Loose connection and breaks in the oil delivery 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 system 0
Sheave distance 0
Sheave offset
=
Brake pad wear 0
Brake operation and adjustment 0
Guide wheel rubber 0
Wear of track drive sprockets
Initial
100 km
I
Drive track adjustment (60mi) & 0
300km
(200mi) I
Breaks in drive track 0
Bends in front and rear axles 0 j
Check lock washers 0 !
Drive chain adjustment 0
i
Chain case oil level 0
** Retighten every 10 hours from the first use.
1-3
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400 km 800 km 1,600 km
necessary
(250 mil (500 mil (1,000 rni]
CHASSIS:
Tightness of bolts and nuts
0
Bends and cracks
0
Welded riveted, joints
0
Ski adjustment
0
Ski runner wear
0
Breaks in fuel tank 0
Cleaning of fuel tank
0
Fuel filter
0
Loose connection and breaks in fuel pipe 0
Breaks in oil tank 0
Oil filter
0
ELECTRICAL:
Wear, breakage of wire covering 0
Breaks in high-tension cord 0
Voltage regulator output 0
Operation of engine stop switch 0
Operation of tether switch 0
Headlight 0
Taillight 0
Brake light 0
B. Lubrication Intervals
Every
Check 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
sliding sheave
Front axle housing 0
Shaft 1 and shaft 2
Light all-purpose grease
(Slide rail)
0
Replace chain case oil 0
Gear oit API "GL-3"
SAE #75 or #80
CHASSIS:
Steering column lower
0
bearing
Light all-purpose grease
Steering column upper
0
bearing
Motor oil
Steering links 0
Ski column 0
Ski wear plate 0
Light all-purpose grease
Ski retaining pin 0
Brake cable end stopper
0
and brake lever
Esso Beacon 325 gear
1-4
C. Sealing the Carburetor
ALWAYS seal the carburetor before turning
a snowmobile on its side for service. This will
prevent fuel from spilling and creating a
hazard.
1. Plug the fuel-tank vent pipe.
2. Plug both float-bowl overflow pipes or
connect them together.
3. Drain float bowl.
1-7. HIGH ALTITUDE TUNING
To attain the best performance in high altitude conditions, carefully tune 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 seeif gearing is too high or low
NotOK OK
Adjust gearing as required
(Page4-12)
OK Not OK
Not OK OK
Check engagement speed and
shift performance
Not OK O K - - - - - r ~
High altitude
tuning OK
Adjust primary clutch as required
{Page4-1)
NotOK OK
Not 01<..
Adjust secondary clutch as required
{Page 4-1)
OK
1-5
'8. SPECIAL TOOLS
7.
13.
&-b.
4-d.
4-b.
3.
1.
2.
No. Description Tool No.
1 Dial Gauge 90890..Q3097..Q0
2 Dial Gauge Stand 90890-01195-00
3 Dial Gauge Needle (56 rnml 90890-03098-00
4 3-Way Puller A'ssy TLU90901-05-20 (U.S.A.)
4-a 3-Way Puller Attachment 90890-01803..Q0
4-b 3-Way Puller Attachment 90890-01804-00
4-c 3-Way Puller Screw 90890-01906-00
4-d Drive Handle 90890--1906-00
4-e 3-Way PuIler Body 90890..Q1848-00
4-f 3-Way Puller Attachment 90890..Q1873-00
5 Rotor Holding Tool 90890..Q1235..Q0
608 Primary SheavePuller (M18) TLS-90018-59-02 (U.S.A_)
90890-01898..Q0
6-b Primary SheavePuller 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
11 Electro Tester 90890..Q3021-00
12 AC Regulator Checker 90890..Q3090-00
13 Primary Sheave Holder TLS90018-80..Q0 (U.S.A,)
90890..Q1701-00
14 Secondary Sheave Holder 90890..Q1872-00
1-6
CHAPTER 2. ENGINE
2-1. ENGINE REMOVAL 2-1
2-2. DISASSEMBLY AND INSPECTION 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
ENGINE
2-1. ENGINE REMOVAL
You do not have to remove the engine in
order to service the following components:
Cylinder,
Piston,
Recoil Starter,
Flywheel Magneto, and
Carburetor
To remove the engine, remove or disconnect
the following components in the order given
below.
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. Hood Iimiter cable.
10. Three engine mounts; remove the engine.
2-1
2-2. DISASSEMBLY AND INSPECTION
A. Recoil Starter
Drive Plate Spring
Drive Pawl
Drive Plate
/
/
1. Remove the air shroud and the starter
from the engine.
2. Pull about four inches of starter rope
from the cutout in 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 items.
22
B. Flywheel Magneto
Flywheel Magneto
Fan
1. Using the rotor holding tool, loosen the
securing nut, and remove the flywheel
pulley from the magneto.
1. Rotor Holding Tool: 90890-01235
2. Remove the six securing bolts and re-
move 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 "Pulser
and Charge Coil.",
C. Oil Pump
Plunger
Adjusting Pulley
1. Loosen the four gear-case bolts, and
remove the gear case/oil pump assembly
from the engine.
2. Remove the two gear case screws and
open the gear case.
3. Remove the snap ring and the two
washers, and remove the drive gear. Note
the relative positions of the washer. The
wave washer is against the drive gear.
4. 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 stroke must be
checked. If a problem with the pump is
noted (such as excessive oil consump-
tion) proceed as follows:
6. Remove the oil pump cover.
24
7. Check the minimum pump stroke.
a. Turn the oil pump gear until the plunger
is at its maximum distance from the
pump body.
b. Using a feeler gauge, measure the gap
between the adjusting plate and the
raised bosson the adjusting puIley.
Minimum pump stroke:
0.2'" 0.25 mm (0.08'" 0.010 in)
1. Oil pump gear 2. Plunger 3. Minimum pump stroke
8. Measure the maximum pump stroke.
a. Pull the oil pump cable out of its sheath
as far as it will go. The cable must be
held in this taut position when measur-
ing maximum pump stroke. It may be
helpful to securely wrap duct tape
around the cable where it enters the
sheath.
b. Turn the oil pump gear until the plunger
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 adjusting shims
as required. Adding shims increases the
stroke, removing shims decreases the
stroke.
1. Adjusting shim
1O. Reinstall the adjusting plate and lock
nut. Torque the nut to specification.
Recheck maximum and minimum pump
stroke.
Tightening torque:
0.67 m-kg (4.8 ft-lb)
11. Grease the adjusting plate, and reinstall
the oil pump cover. Seal the cover with
Yamabond 5. Torque the screws to
specification.
Tightening torque:
0.2 m-kg (1.45 ft-Ib)
... Denotes a revision. Please remove and destroy the original page, and insert this revision page in its place.
D. Top End
This model has a one-piece cylinder and
cyl inder-head assembly. There is no cylinder
head to remove and service separately from
the cyl inder.
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 Pi n CI ip
4. Remove the piston and the small-end
bearing from the connecting rod.
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.
b. Check the pin and bearing for signs of
heat discoloration. If excessive (indenta-
tion on pin, etc.), replace the pin and the
bearing.
c. Check the small-end bearing for exces-
sive wear or damage. Check the rollers
for signs of flat spots. If such wear is
found, replace the pin and the bearing.
d. Apply a light film of oil to the pin and
bearing 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 piston rings.
b. Remove any carbon deposits from piston
crown.
c. Carefully remove any carbon deposits
from the ring grooves.
d. Hernove score marks and lacquer
deposits from the sides of the piston
using 600 -- 800 grit wet sandpaper.
Sand in a crisscross pattern. Do not sand
excessively.
e. Wash the piston in solvent, and dry it
with compressed air.
f. Measure the outside diameter of the
piston at the piston skirt.
The measurement shouId be made at a
point 10 mm (0.39 in) above the bottom
edge of the piston. Place the micrometer
at a right angle to the piston pin.
The maximum piston diameter subtract-
ed from the minimum cylinder diameter
gives the piston clearance. If the clear-
ance is beyond tolerance, hone the
cylinder to tolerance or bore it to the
next oversize and install an oversized
piston.
Piston clearance:
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 into the cylinder, and
measure the ring end gap with a feeler
gauge. Push the ring into the cylinder
with the piston crown so the ring will be
at a right angle to the cylinder bore. If
the end gap is not within specification,
replace the rings as a set.
Ring end gap, installed:
Minimum 0.20 mm (0.0079 in)
Maximum 0040 mm (0.0157 in)
4. Cylinder
a. Remove all carbon deposits from the
cylinder and from the ports. Carburetor
cleaner will help lift carbon from the
cyl inder head. Thoroughly wash the
cylinder in solvent, and blow it dry with
compressed air.
b. Inspect the cylinder walls for scratches.
If vertical scratches are evident, the
cylinder should be rebored or replaced.
c. Measure the cylinder wall wear at the
places shown in the illustration; use a
cyl inder bore gauge. If wear is excessive,
compression pressure will decrease; re-
bore or replace the cylinder.
----------
Standard Wear 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.
Honing
Whenever honing the cylinder on the BR250,
use a hone with a bumper device so the com-
bustion chamber will not be carelessly
damaged. Otherwise follow standard honing
procedures. Yamaha recommends the use of
an Ammco Hone. This kit includes all the
necessary piecesto properly hone the cylinder
on the BR250.
Ammco Hone Kit: TLU-03950-00-00
E. Bottom End
Oil-Pump Drive Sprocket
Engine Mounting Bracket
~ @ a e ~ 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.
3. Separate the crankcase halves by rapping
the indicated points with a rubber
mallet.
4. Remove the crankshaft.
Inspection
1. Crankcase
a. Thoroughly wash the case halves in a
mild solvent. Blow them dry with com-
pressed air.
b. Thoroughly clean the crankcase mating
surfaces.
c. Visually inspect the case halves for
cracks or damage.
d. Inspect the oil delivery passages in the
transfer ports for signs of blockage.
2. Bearings and oil seals
a. After cleaning and lubricating the bear-
ings, rotate the outer race with your
finger. If rough spots are noticed, replace
the bearings.
b. Check the oil seal lips for damage or
wear. Replace the seals as required.
b. Install bearings with their manufacturer's
marks or numbers facing outward. They
should be visible when intalled.
c. Install oil seals 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 connecting rod, crankpin,
and big-end bearing. Replace any defec-
tive or worn parts. Reassemble the
crankshaft, and recheck the rod axial
play.
Rod axial play:
Maximum: 2.0 mm (0.079 in)
b. Check the connecting rod side clearance
at the big end. If it exceeds specification,
disassemble the crankshaft and replace
any worn parts.
Rod side clearance
3. Bearing and oil seal installation
a. When install ing or removing the left
crankshaft bearing or oil seal, remove the
oil-pump drive sprocket. Replace it with
a new one during installation.
211
Minimum
0.25 mm (0.010 in)
Maximum
0.75 mm (0.030 in)
2-3. ASSEMBLY AND ADJUSTMENT
Tightening torque:
1.5 m-kg (10.8 ft-lb)
2. Thoroughly oil the bearing and the con-
necting rod.
3. Apply Yamabond 4 to the mating sur-
faces of the crankcase halves. Use
enough Yamabond to completely seal
the crankcase. An air leak can lead to
severe engine damage.
4. Carefully fit the lower crankcase half
onto the upper half. The oils seals and
the bearings must be properly seated in
both crankcase halves. Place the wire
bracket on the rear crankcase bolt as
shown in the photograph. Torque the
fou r crankcase bolts to specification.
5. Install the 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. Use a wedge if necessary.
A. Botton End
1. Place the crankshaft in the upper crank-
case half. Be sure the lip of each oil seal
and the nylon bearing support for the
right crankshaft bearing are properly
seated in the crankcase. The open side
of the bearing support must face the
front of the engine.
Tightening torque:
First 1.0 m-kg (7.2 ft-Ib)
Final 2.5 m-kg (18 ft-Ib)
2-12
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
2. Add oil to the crankcase through the oil
holes. Oil the connecting rod.
3. Cover the crankcase with a clean cloth so
nothing will fall into the crankcase.
4. Oil the small-end bearing and install it in
the connecting rod.
5. Oil the connecting rod, and install the
piston. The arrow on the piston 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: 2.5 m-kg (18 ft-lb)
Flywheel Magneto
2-14
Coil Plate
Coil Plate Damper
I
I
I
I
I
I
I
I
I
~
Fan
1. Feed the magneto leads through the
hole in the crankcase, and secure the
damper in the case.
2. Install the coil plate onto the crankcase.
Align the pry points on the plate with
the cutout in the crankcase. Apply a
thread-locking compound to both secur-
ing screws.
3. Place the woodruff key in the crank-
shaft, and install the flywheel magneto.
The keyway in the 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 fan. Torque the
securing nut to specification.
Tightening torque:
7.0 - 7.5 m-kg (51 - 54 ft-lb)
6. For timing adjustment (Refer to 6-1, C
"Ignition Timing.")
D. Recoil Starter
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.
2. Feed the starter rope into the sheave
dru m, knot the end, and fit the knot
into the cutout in the sheave drum.
3. Wind the starter rope 2-1/4 times
counterclockwise around the sheave
drum. Insert the drum in the starter case.
Be sure the inner hook on the starter
spring hooks around the post on the
sheave drum.
4. Install the drive pawl and the return
spring. Hook the spring around the first
post on the sheave drum as shown in the
photograph.
216
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 out of the cutout in the sheave
drum and form a loop. Rotate the sheave
drum five times couterclockwise to pre-
load the starter spring.
7. Check the starter. If it does not operate
smoothly, disassemble it, and reassemble
it correctly.
8. Install the recoil starter onto the engine.
Be sure the hood limiter bracket is on
the forward, upper bolt as shown in the
photograph.
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.
E. Oil Pump Gear Case
Tightening torque:
0.65 m-kg (4.7 ft-lb)
2-17
1. Place the washer on the oil pump drive
shaft, and insert the drive shaft into the
oil pump. Be sure the worm gear correct-
ly engages the oil pump gear in the
pump.
2. Secure the pump to the gear case. Use a
new gasket. Apply Yamabond 4 to the
gear case side of the gasket only.
3. Align the hole in the drive shaft with the
slot in the gear case and install the secur-
ing pin.
4. Thoroughly grease the outer edges of the
drive gear onto the oil pump drive shaft.
Be sure the gear correctly engages the
securing pin.
5. Secure the drive gear in place with the
two washers and the snap ring. Be sure
the wave washer is against the drive gear.
6. Grease the edges of the drive gear, and
install the gear case cover.
2-18
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
empty.
During predelivery.
There are two methods for bleeding the pump
on this model. Either will work very well.
1. Loosen the bleed screw at the pump. Oil
should begin to flow through the line.
Keep the bleed screw open until all air
has left the fuel Iine. Tighten the bleed
screw.
2. Start the engine and keep it running at
idle. Pull the pump stroke wire all the
way out to set the pump at maximum
stroke. Keep the pump operating at full
stroke for about two minutes. This will
bleed the air from the oil system.
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.
Primary Sheave, V-belt. and drive
guard (Refer to 4-4, D "Assembly")
Carburetor (Refer to 3-1, A III nstal-
lation")
PulsePipe
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
CHAPTER 3. CARBURETION
3-1. CARBURETOR 3-1
A. Removal 3-1
B. Disassembly 3-2
C. Inspection 3-2
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
CARBURETION
3-1. CARBURETOR
Carburetor Assembly
o
Main Jet cover--@
A. Removal
1. Disconnect 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.
B. Disassembly
1. Carefully remove the jets, float, etc.
Never, however, disassemble the throttle
valve or the throttle shaft. The threads
of the throttle shaft have been crimped
so the screw will not come lose. Once
the throttle valve is disassembled, it will
be very difficult to reassemble it correct-
ly. The original characteristics of this
carburetor will be difficult to reproduce,
thus performance will be adversely
affected.
2. Carefu Ily clean all parts. Blow the jets
and passages clear with compressed air.
Use a soft brush to clean the outside
surfaces so nothing will be scratched or
damaged. Do not use a wire or any such
object to clear a jet. This will deform the
jet and reduce performance.
3. Remove the carbon from the throttl-e
valve and adjacent area. Take care not to
scratch the throttle valve or bore.
C. Inspection
1. Inspect all jets and passages. They must
be clear.
2. Check the mating surfaces for wear.
Replace jets as required.
3. Check the float valve for damage. If
either the float seat or float needle are
damaged, replace both parts.
4. Check the pilot screw 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 slow jet.
3. Install the slow adjuster with its spring.
For adjustment (Refer to 3-2, E "Low
Speed Tuning".)
4. Install the clip onto the float needle.
5. Hook the float needle clip onto the float
tang. Install the float, and insert the
float needle into the float valve.
3-2
6. Measure the float level.
a. Incline the carburetor approximately 20
or 30 degrees until the float valve just
barely closes. The float should be resting
on the float needle, but not compressing
the spring.
b. Measure the distance from the carbure-
tor body to the top of the float.
Float height:
15 2 mm (0.59 0.08 in)
1. Float height
c. If the float height is not within specifica-
tion, examine the valve seat and the float
needle. If either is worn, replace them
both. If both are fine, adjust the float
height by bending the tang on the float.
d. Reinstall the float and recheck the float
height.
8. Reassemble the float.
9. Apply grease to the following areas so
they will not freeze:
Throttle return spring,
Throttle shaft,
Both spaces between the throttle shaft
and carburetor body,
Throttle lock washer,
E ~ c 1 i p , and
The wire holder attached to the throttle
valve.
E. Installation
1. Install the carburetor in the engine. Be
sure the air box boot and the carburetor
boot correctly engage the carburetor.
Secure the clamp on the carbu retor
boot, and carefully secure the air box
boot spring.
Do not overstrech the air box boot spring.
The spring can be damaged and will have to
be replaced.
2. Attach the throttle cable, starter cable,
oil pump cable, oil del ivery line, and the
pulse pipe. Refer to 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 (0to -20C)
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 damaged
or seized.
A. Carburetor Tuning Data
1. Standard specification
Carburetor BD3228/KEIHIN
1.0. Mark 8R401
Main jet #108
Slow adjuster (turn out) 11/4
Starter jet. #120
Slow jet #78
15 2.0 mm
Float height
(0.59 0.08 in)
~
-30C -20C -10
0
e OC 10C 20
0
e
(-22F) (_4F) (14F) (32F) (50F) (68F)
Altitude
I I J I I I
.. #105 It'
Seal level .. #108 ..
.......-#112 .....
....
#105 ...
"" 600 m (200 tt)
.. #108 ...
...#102 ....
"" 1200 m (4000 ft) .. #105 ..
"""'-'#108 ...
... #102 ..
"" 1800 m (6000 ft) .. #105 ..
.....--#108.....
......#100....
"" 2400 m (8000 ft] .. #102 ...
"""'-#105 ...
"" 3000 m or more .. #100 It'
(10000 ft) .. #102 ...
33
3. Fuel flow
High-speed tuning
Mid-range. I Full 0 en

1/2
rClosed
Low speed tuning
1. Starter jet
2. Throttle stop screw, pilot screw,
bypass, float level
3. Slow jet
4. Main jet
BR250 CARBURETOR (KEIHIN 803228)
Fuel Flow Chart
I
Total fuel 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
Routing Diagram.)
Lock nut tightening torque:
0.08 m-kg (0.6 ft-Ib)
Idle
1/4 1/2 3/4 1/1
Throttle opening
3A
-.-H__- Free play
1.5"'2.5 mm (0.06"'0.10 in)
1. Adjuster 2. Lock nut
1. Play 2. Adjusting screw 3. Lock nut
Free play between outer tube end
and adjuster:
1.5'" 2.5 mm (0.06'" 0.10 in)
3. Lock the adjusting screw by tightening
the nut.
C. Throttle Cable Adjustment
Set the throttle cable adjuster so that the free
play between the throttle cable outer tube
end and adjuster equals specification when
the throttle valve is closed (at idle).
Free play between outer tube end
and adjuster:
0.5'" 1.0 mm (0.2 '" 0.4 in)
E. Low Speed Tuning
The carburetor is built so that low speed
tuning can be done by adjusting the slow
adjuster and the throttle stop 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 the
engine runs at 2,000'" 2,500 rpm.
Stardard pilot screw (turns out):
1-1/4
1. Tighten the slow adjuster lightly, and
back it out from its lightly seated posi-
tion.
1. Slow adjuster
3. Play 2. Lock nut
1. Loosen the lock nut on the oil pump
cable adjusting screw.
2. Pull up the cable to its limit, and turn
the adjusting screw until the free play of
the outer cable is as specified below:
1. Adjuster
D. Oil Pump Cable Adjustment
3-5
4. Slowly loosen slow adjuster. As the slow
adjuster is loosened, the mixture will
become leaner and engine rpm will in-
crease. Adjust the slow adjuster to attain
the highest posstble engine speed.
5. Finally, turn the throttle stop screw
counterclockwise so that the engine runs
at 1, 100 rpm.
Idle speed: 1,100 100 rpm
1. Throttle stop screw
NOTE: _
If the engine shows poor performance in high
elevations or in an extremely cold area or
when it is suddenly accelerated or run at low
speeds, proceed as follows:
a. Replace the slow jet according to operat-
ing conditions.
Standard slow jet: # 78
F. Mid-range and High Speed Tuning
No adjustment is normally required, but
adjustment is sometimes necessary depending
on temperatures and/or altitude.
Mid-range speed and high-speed tuning (from
1/4 to full-throttle) can be done by adjusting
the main jet.
1. Run the engine at high speeds, and make
sure the engine operates smoothly.
2. Check 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.4 Replace the piston and spark plug.
Tune the carburetor again starting with
low-speed tuning.
Bad (Due to too lean a mixture, the
engine knocks.)
Check the piston for holes or seizu reo
No.5 Check the cooling system, gasoline octane
rating, and ignition timing. After replac-
ing the spark plug, tune the carburetor
again starting with low-speed tuning.
Bad (Due to lean a mixture, the spark
plug melts.]
Check the piston for holes or seizure.
No.6
Check the cool ing system, gasol ine octane
rating, and ignition timing. After replac-
ing the spark plug with colder type, tune
the carburetor again starting with low-
speed tuning.
1. Slow jet 2. Main jet
b. By repeating steps 1 to 5 above, adjust
the idle speed.
Idle speed: 1,100 100 rpm
3-6
1. Main jet
G. 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 snowmobileand possible injury
to the mechanic.
Place a rag under the carburetor so fuel does
not spread. Place the main jet cover bolt in a
clean place. Keep it away from fire. After
assembling the carburetor, firmly tighten the
rubber joint screw. Make sure the throttle
outer tube is in place and the throttle cable
moves smoothly. Clean the carburetor and
allow it to dry.
Trouble Check point Remedy Adjustment
Hard starting Insufficient fuel Add gasol ine
Excessive use of starter Clean spark plug Return starter lever to its seated
(Excessively opened choke) position.
Fuel passage is clogged or Clean Parts other than carburetor
frozen Clogged fuel tank air vent, clogg-
ed fuel filter, or clogged fuel
passage
Carburetor
Clogged or frozen air vent clogged
valve.
If water collects 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, back out
Slowresponse to throttle throttle stop screw so the engine
Engine tends to stall idles at specified speed.
Throttle stop screw Adjust Tightened to much - Engine speed
is higher.
Backed out too much Engine
does not idle.
Damaged slow adjuster Replace slow adjuster
Clogged bypass hole Clean
Clogged or loose slow jet Clean and retighten Remove slow jet, and blow it out
with compressed air.
Air leaking into carburetor Retighten band screw
joint
Defective starter valve seat Clean or replace
Overflow Correct
Poor performance at Clogged or loose slow jet Clean and retighten Remove slow jet, and blow it out
mid-range speeds with compressed air.
(Relative troubles)
Momentary slow response
to throttle
Poor acceleration Lean mixtures Overhaul carburetor
3-7
Trouble Check point Remedy Adjustment
Poor performance at Clogged air vent Clean I Remove the air vent pipe, and
normal speeds clean.
(Relative troubles)
Clogged or loose main jet Clean and retighten Remove main jet, and blow it out
Excess fuel consumption
Poor acceleration
with compressed air.
Overflow Check float and float valve
and clean
Poor performance at high Starter valve is left open Fully close valve Return starter lever to its home
speeds position.
(Relative troubles)
Clogged air vent Remove and clean
Power loss
Poor acceleration
Clogged or loose main jet Clean and retighten Remove main jet, and clean with
compressed air, then install.
Clogged fuel pipe Clean or replace
Dirty fuel tank Clean fuel tank
Air leaking into fuel line Check joint and retighten
Low fuel pump performance Repair pump or replace
Clogged fuel filter Replace
Clogged intake Check for ice, and remove
Abnormal combustion Lean mixtu 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
Power idling
scratch valve seat.
Poor performance at low,
mid-range, and high
Scraehed or unevenly worn Clean or replace float valve Valve seat is press-fitted to body.
speeds
float valve or valve seat and valve seat So body must be replaced if seat is
Excessive fuel consump-
damaged.
tion
Broken float Replace float
Hard starting
Incorrect float level If not within the specified
Power loss
Poor acceleration
range, check the following
parts and replace any
defective part.
Worn float tang Replace float Replace float assembly.
Worn pin Replace arm pin
Deformed float arm Replace float
3-3. INTAKE
Carburetor Boot
Air Box Boot
Pulse Pipe
1. Check to 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.
39
CHAPTER 4. POWER TRAIN
4-1. SHEAVE ALIGNMENT 4-1
4-2. CLUTCH TUNING 4-1
A. Clutch Setting Data 4-2
B. Changing Clutch Engagement and Shift RPM 4-3
4-3. V-BELT 4-3
A. Removal 4-3
B. Inspection 4-3
4-4. PRIMARY SHEAVE , .4-4
A. Removal 4-4
B. Disassembly 4-5
C. Inspection 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. Inspection 4-20
C. Assembly 4-20
D. Track Adjustment 4-20
POWER TRAIN
4-1. SHEAVE ALIGNMENT
1. Sheave distance: 2. Sheave offset:
266 2 mm (10.47 O.OS in) 11 3 mm (0.43 0.12 in)
1. Using the sheave gauge, check the sheave
offset. If the gauge does not contact the
primary and secondary sheaves at the
four indicated points, the sheave offset is
incorrect.
2. Check the sheave center-to-center
distance.
4-1
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:
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 when the
machine passes a point 200 ~ 300 m (650 ~
1000 ft) from the starting position after the
machine has been started at full-throttle from
a dead stop.
Normally, when a machine reaches shift rpm,
the vehicle speed increases but the engine
speed remains nearly constant. Under un-
favorable conditions, however (wet snow, icy
snow, hills, or rough terrain), engine speed
can decrease after the engine has reached
shifting rpm.
Engine rpm
t
Clutch
shifting rpm
Clutch
engagement rpm
Good condition
Clutch shifting rpm
Clutch engagement rpm
t Engine rpm
Bad condition
, __ Travelled distance
Starting position 200""" 300 m (650""" 1,000 ft)
A. Clutch Setting Data
1---------+---4Travelled distance
-----
Starting position 200'"'-' 300 m (650""" 1,000 tt)
S.T.D. spec. High altitude spec.
Engagement r.p.m. 3100 200 +-
Shifting r.p.m, 5750 50 +-
Parts No. 9050150654 +-
Set weight 15 kg (33Ib) +-
Primary spring
2.4 kg/mm (134 lb/in) Spring constant +-
Color None +-
Q'ty 8 p.c.s./unit +-
Roller shim
PartsNo. +-
Twist angle 160
0
+-
Secondary spring
Color None +-
_
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
adjust clutch engagement and clutch shifting
rpm, add or remove roller shims from the
spider as indicated by the chart .
.Clutch shifting rpm can also be adjusted by
changing the preload on the secondary sheave
spring: 160
0
and 280
0
160
0
is standard.
4-2
B. Changing Clutch Engagement and Shift RPM
~
Clutch engagement r.p.m. Clutch shifting r.p.m,
Decrease Increase Decrease Increase
Centrifugal force of rollers Add shims Remove shims Add shims Remove shims
Torsion spring
-
- Decrease Increase
Secondary spring
constant
Twist angle - - Smaller wind Greater wind
1. New: 31.5 mm (1.24 in) 2. Wear limit: 26 mm (1.02 in)
Length of V-Belt
1,099 mm (42.8 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 cha in 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 inspect the V-belt for signs of
damage. Replace the belt if it is
damaged.
2. Measure the width of the V-belt. If the
belt is worn beyond the wear limit,
replace it.
1. V-belt length
4-3
4-4. PRIMARY SHEAVE
Fixed Sheave
Bushing
Sheave Cap
Bushing
Spider
Spider Lever
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.
Primary sheave holder:
TL5-90018-80-00 (U.S. A.)
9089Q..01701
Primary sheave pu lIer:
90890-01898
1. Sheave holder
2. Sheave puller
4-4
B. Disassembly
1. Install the sheave subassembly tool in
the primary sheave.
Primary sheave subassembly tool:
90890-01858
1. Sheave sub-assembly tool
2. Loosen the six sheave-cap bolts.
3. Remove the sheave subassembly tool,
and remove the sheave cap.
C. Inspection
1. Inspect the tapered ends of the crank-
shaft and 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
Small bushing Large bushing
Inside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
Outside 0.25 mm (0.01 in) 0.25 mm (0.01 in)
3. Remove the sliding sheave from the
fixed sheave, and remove the spider.
4. Measu re the wear on the slider buttons.
If worn beyond specification, replace the
buttons.
Wear limit: 27.0 mm (1.06 in)
5. Inspect the slides in the sliding sheave
for scratches or other damage; replace
the sl iding sheave as required.
6. Disassemble 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, grease the indicated
points, but take care to keep the other
indicated areas from grease.
+- X Free from grease
+- Grease point
2. 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.
4. Install the cams. Be sure they are
correctly seated in the sliding sheave.
5. Install the spring and the sheave cap. Be
sure the /IX" on the sheave cap aligns
with the JlX" on the sliding sheave.
6. Install the primary sheave subassembly
tool and secure the sheave cap to the
fixed sheave. The two long bolts must
also secure the clutch cams in place.
Torque all six bolts to specification.
Primary sheave subassembly tool:
9089001858
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 spri ng washer.
11. Hold the primary fixed sheave with the
primary sheave holder, and torque the
sheave bolt to specification.
Primary sheave holder:
TLS-90018-80-00 (U.S.A.)
90890-01701
Tightening torque:
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.
A: 10 m-kq (72 ft-lb)
B: 5.8 m-kg (42 ft-lb)
SECONDARY SHEAVE
Ramp Shoe
.--

<:d. Colla, Bearlnq Cage '
. '" Spdng Seat
B"",ong
/3!!J; (J;;;1 fir.
,'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 sheaveholder
2. Using the 3 ~ w a y puller, remove the fixed
sheave.
3-WayPuller Ass'y: TLU-90901-05-20 (U.S.A.)
1. 3-WayPuller Body: 90890-01848
2. 3-Way Puller Attachment: 90890-01873
3. Remove the key from the [ackshaft.
4. Very carefully remove the secondary
sheave holder. The spring will force the
sheave out.
5. Remove the sliding sheave, the spring,
and the spring seat. The spring seat has a
left-hand thread. If it is difficult to
remove the spring seat, rap it with a
plastic mallet.
6. Remove the collar and the circlip from
the jackshaft bearing cage.
8. Inspection
1. Inspect both sheaves. If either is warped,
replace it.
2. Inspect the ramp shoes on the sliding
sheave; replace as necessary.
3. Check the sheave bushings for wear;
replace the sheave as required.
4. Check the spring. If it is fatigued or
damaged, replace it.
C. Assembly
1. Install the 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 differ-
ent hole will not change the spring preload.
4. Install the sliding sheave onto the jack-
shaft. Be sure the spring engages the hole
in the sheave.
5. Starti ng from the free position, rotate
the sliding sheave clockwise to preload
the spring, and push the sheave towards
the chain case. Lock the sliding sheave in
place with the secondary sheave holder.
Secondary sheave holder:
90890-01872
Preload:
Turning the sliding sheave 1/3 of a
turn from the free position (past one
ramp shoe) sets the spring at 160
0

Turning the sliding sheave 2/3 of a

tu rn from the free position (past two
ramp shoes) sets the spring at 280
0

Std. secondary spring preload:

160
0
(Twist augle)
6. Install the 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
A. Disassembly
1. Remove the secondary sheave from the
jackshaft (Refer to 4-5, A "Removal.")
2. Remove the bearing cage from behind
the jackshaft bearing.
3. Disconnect the brake cable from the
handlebar. It will be helpful to loosen
the cable at the caliper. The caliper need
not be disassembled.
4. Place an oil pan beneath the drain hole
under the chain case.
5. Remove the chain case cover, and let the
oil drain into the oil pan.
6. Loosen the chain tension.
7. Remove the securing hardware and
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 securing 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 uneven,
the disc is bent and must be replaced.
2. Inspect the bearing surfaces of the jack-
shaft. If worn or bent, replace the jack-
shaft.
3. Inspect the bearings in the chain case.
If the movement is rough or uneven,
replace the bearings.
4. Inspect the drive and driven sprockets;
replace if worn.
5. Inspect the drive chain; replace as neces-
sary.
6. Inspect the adjusting block. If the raised
boss is worn to the base of the block,
replace the block.
1 Wear limit 6 mm (0.24 in)
C. Gearing
Use the chart below to change the chain case
gearing to suit the local conditions and the
rider's driving style.
Higher gearing will increase the ma-
chine's top speed.
Lower gearing will increase the ma-
chine's acceleration and climbing ability.
Do not set the gearing to any of the indicated
(X) settings.
~
11T 12T 13T 14T
Driven gear
21T X X X
0
44
S.T.D.
22T X X 0 X
44
23T X
0
X X
44
24T
0
X X X
*44
* No. of chain links
D. Assembly
1. Grease the inner surfaces of the bearings
and oil seals in the chain case.
2. Place the brake disc between the brake
pads. Be sure the raised side of the disc
faces away from the chain case.
3. Loosely bolt the chain case in place 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 bolts and torque
them to specification.
Tightening torque:
2.3 m-kg (17 ft-Ib)
6. Install the jackshaft bearing on the left
side of the machine. Install the bearing
cage over the jackshaft bearing. Torque
the three bolts to specification.
Tightening torque:
2.3 m-kg (17 ft-lb)
7. Install the collar and the circlip into the
bearing cage.
8. Install both collars in the chain case. The
larger goes on the jackshaft, the smaller
on the drive axle.
9. Place both the drive and driven sprockets
in the drive chain, and install them in the
chain case. Be sure the stepped side of
the driven sprocket faces in towards the
engine.
10. Install the adjusting block.
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. Adjust the chain tension. Turn the
adjusting bolt until the chain deflection
equals specification. Torque the lock 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 Oil
413
1. Oil drain bolt
15. Install the secondary sheave onto the
jackshaft. (Refer to 4-5, C "Assembly.")
16. Reconnect and adjust the brake cable.
(Refer to 4-7, D "Brake Adjustment.")
4-7. BRAKE
A. Disassembly
1. Remove the brake cable from the
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.
414
3. Remove the clevis pin and disassemble
the brake.
B. Inspection
1. Check the brake pads. If either is worn
beyond the wear limit, replace the pads
as a set.
Wear limit: 1.0 mm (0.04 in)
1. Wear limit
2. Replace any fatigued return spring.
C. Assembly
1. When assembling the brake caliper, be
sure that hooked end of each return
spring is seated in the brake arm before
installing the clevis pin. Assemble the
brake as shown in the exploded illustra-
tion. Always usea new cotter pin.
2. Preload the lower spring first, then the
upper spring. Using a pair of pliers, lift
the spring up and over the chain case.
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 '"
0.04 in) from the brake disc.
2. Loosen the lock nut on the cable adjust
screw (outer pad adjusting screw) and
adjust until the outer pad is 0.2 '" 1.0
mm (0.008 ,..., 0.04 in) from the brake
disc.
3. Make sure both lock nuts are tight after
completing this procedure.
1. Inner pad adjusting screw 2. Outer pad adjusting screw
3. Outer pad arm 4. Inner pad arm
4-8. SLIDE RAIL SUSPENSION
A. Removal
1. Loosen the track.
2. Seal 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.
1. Spring seat
4. Remove the two suspension bolts from
one side of the machine, turn the
machine over, remove the remaining two
bolts, and remove the suspension from
the track.
B. Inspection
1. Inspect the hyfax. Replace them if they
are worn beyond the wear limit. Torque
the screws to specification.
Wear limit: 8.5 mm (0.3 in)
Slide runner securing screwtightening
torque: 0.25 m-kg (2 ft-lb)
1. Wear limit: 8.5 mm (0.3 in)
2. New: 13.5 mm (0.5 in)
2. Inspect the suspension wheels; replace 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 is frayed or
damaged.
When installing the stopper bands, always use
the standard setting. Another setting will
damage the rear shock. Torque the nut to
specification.
Tightening torque:
0.4 m-kg (3 ft-lb)
Standard setting:
Front band: Lower hole (#1 hole)
Rear band: Upper hole (#2 hole)
C. Installation
1. Grease the suspension where indicated in
the illustration.
2. Thoroughly grease the axle in the front
pivot arm. Tape the end caps in place.
This will hold the axle within the pivot
arm during installation of the suspen-
sion.
3. Place the suspension 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 seats.
8. Adjust the track tension. {Refer to 4-9,
D "Track Adjustment."}
4-9. DRIVE
7. Remove the track.
5. Remove the suspension. (Refer to 4-8, A
/I RemovaL")
6. Place the machine on its right side.
Remove the axle by lifting it up 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
B. Inspection
1. Check the track and cl ips for cracks,
damage, or wear. Replace the track or
clips as required.
2. Inspect the sprockets. If the lugs are
excessively worn, replace the sprockets.
3. Inspect the axle. If it is bent, excessively
scratched, or if the splines or threads are
damaged, replace the axle.
4. When pressing the sprockets onto the
axle, be sure the lugs on each sprocket
are opposite one another as shown in the
photograph. Locate each sprocket on the
axle whsre shown in the illustration.
2. Install the axle. Push the threaded end
up towards the secondary sheave, then
install the splined end into the chain
case. Be sure the lugs 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. Reassemble the chain case, and add oil.
(Refer to 4-6, D "Assernolv.")
D. Track Adjustment
The track tension should be adjusted so that
track deflection will equal specification when
the track is pulled at the middle by a force of
10 kg (22 lb].
178.4 mm
{7.1 in}
211.4 mm
(8,5 in)
63mm
(2.5 in)
138.6 mm
(5.5 in)
105.6 mm
(4.2 in)
~ w D \ 1
~ - - . . - - ~
~ ~ ~
Turning direction
C. Assembly
1. Place the track in the chassis. Be sure it
is positioned as shown in the illustration.
4-20
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.
No good
Slide runner
1. Lock nut
Good
Slide runner
2. Adjusting bolt
No good
Slide runner
Track metal
~
Forward
Gap between slide runner
and edge of track window.
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 shifted to left: Tighten the left track adjusting
bolt, and loosen the right track adjusting bolt.
Tightening torque:
3.5 rn-kq (25 ft-lb)
CHAPTER 5. CHASSIS
5-1. STEERI NG 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
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:
3.0 m-kg (22 ft-lb)
5-1
2. Install the steering column onto the
frame. Grease the upper and lower bear-
ings. Torque the bolts to specification
and bend the lock tab.
Tightening torque:
2.5 m-kg (18 ft-lb)
Tightening torque:
2.0 m-kg (15 ft-lb)
3. Connect the steering relay rods to the
steering column. Torque the flange nut
to specification and install a new cotter
pin.
Tightening torque:
2.5 m-kg (18 ft-lbl
Front
1. Ski spindle center
A C =0"'" 6 mm (0 ""' 0.23 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.
After adjusting the handlebars, alternate-
ly tighten the four securing bolts. Main-
tain the specified gap in the steering
clamps. Torque the bolts to specifica-
tion.
Tightening torque:
1.4 m-kg (10 tt-tb)
1. Clamp
2. HandJebar
5-2. SKIS
A. Inspection
1. Check the ski runner. Replace it if it is
excessively worn. Torque the nuts to
specification.
Tightening 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.
B. Assembly
1. After assembling the ski, thoroughly
grease the wear plate and all retaining
pins.
2. Carefully install the ski onto the ski
column. Tighten the securing bolt until
it is tight, then back 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
O i l L i n e ~ .......-l.
~ ~
rf
~
I
iJ
(p/
5-4
1. Check the oil line from the tank to the
pump. It should be free from all obstruc-
tions and shouId not be pinched or
damaged in any way. Replace as neces-
sary.
' ~ ~ Fuel Gauge Line
<,
I
1. Check all lines. If any are cracked,
crimped, 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 torque:
1.0 m-kq ( 7 ft-Ib )
CHAPTER 6. ELECTRICAL
6-1. IGNITION SySTEM 6-1
A. Circuit Diagram 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
ELECTRICAL
6-1. IGNITION SYSTEM
A. Circuit Diagram
B. Troubleshooting
No spark is produced or weak.
Check of connections _____~ - - - . J I Check lead wire connections for short circuits.
--1----------,
OK Faulty.Correct.
SparkS See 6-1, D"Spark Gap Test."
F=
No spark Spark.Plug is faulty.
OK
..
......................... Measure coil resistance.
(See 6-1, G "Pulser and Charge Coil.")
FauIty---------... Replace .
6-1
Faulty------.. Replace. OK
......................... Measure coil resistance.
'-----.---_......
(See 6-1, G "Pulser and Charge Coil.")
....................... Ignition coil test (See 6-1, E "Iqnition Coil.")
OK Replace.
C.D.I.?g See 6-1, H. "C.D.1. Unit."
+
Faulty Replace.
The engine starts but will not pick up speed.
................................. Clean or replace (See 6-1, F "Spark Plug.")
......................... Make continuity test
'---__--,--- ...J (See 6-1, G "Pulser and Charge Coil.")
OK
................ (See 6-1, C "lqnition Timing.")
................................ (See 6-1, H "C.D.1. Unit.")
L------------....Faulty
Dial gauge stand: 190890-01195
3. Insert the dial gauge 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
that the indicator needle does not go
past zero.
5. Starting from T.D.C., rotate the flywheel
counterclockwise until the dial gauge
reads 3-1/2 needle revolutions before
top-dead-center.
90890-03097
90890-03098 Dial gauge needle:
Dial gauge:
6-2
6. Slowly turn the flywheel clockwise until
the dial gauge indicates the specified
ignition timing.
Ignition timing (B.T.D.C.);
1.6 mm (0.062 in)
7. The marks on the coil plate should align
with the timing mark on the magneto. If
not, adjust the timing.
8. Loosen both coil plate screws.
9. Rotate the coil plate by using a screw-
driver at the pry points. Align the marks
on the coil plate with the mark on the
flywheel. Tighten the screws and torque
them to spec.
Tightening torque:
0.65 m-kg (5 ft-Ib)
6-3
10. Remove the dial gauge stands. Reinstall
the 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 is located.
Electro tester: 90890-03021
1. Thoroughly warm up the engine so that
all electrical components are at operating
temperatureo
2. Stop the engine, and connect the tester
as shown.

1. Electro-Tester 2. Plug wire from coil 3. Spark plug

3. Start the engine, and increase the spark
gap until misfire occurs.
Minimum spark gap: 9 mm (0.35 in)
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
tester.
d. Turn on the spark gap switch, and in-
crease the gap until misfire occurs.
nx1
63
001------+...
Minimum spark gap: 9 mm (0.35 in)
1. Battery 2. 6 mm (0.24 in)
Spark plug color
No.1
Good (Carburetor is tuned properly.)
No.2
Bad (Mixture is too rich.)
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.4 Replace the piston and spark plug.
Tune the carburetor again, starting with
low-speed tuning.
Bad (Due to too lean a mixture, the en-
gine knocks.)
Check the piston for holes or seizure.
No.5 Check the cooling system, gasoline octane
rating and ignition timing. After replacing
the spark plug, tune the carburetor again,
starting with low-speed tuning.
Bad (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 of the rider. You can
learn a great deal about the operating condi-
tion of an engine by studying the spark plug.
Examine the spark plug at each periodic
inspection, and replace it with a suitable plug.
Ask the customer how long and how fast
he rides his snowmobile, and recommend a
hot, standard, or cold plug accordingly.
Encourage your customers to change the
spark plug regularily. Their snowmobiles will
run better, and fuel consumption will remain
low.
Secondary coil
resistance
5.9 kn 20%
at 20C (68F)
Primary coil
resistance
1.0n 10%
at 20C (68
0
F)
2. Coil winding resistance tests
Use a pocket tester to determine resist-
ance and continuity of the primary and
secondary coil windings.
MITSUBISH
F6T411
Manufacturer
6-4
Inspection
Instruct the rider to:
1. Inspect the clean the spark plug every
400 km (250 mi) or 20 hours.
2. Clean the electrodes of carbon and
adjust the electrode gap.
3. Be sure to use the proper reach plug to
avoid overheating, fouling, or piston
damage.
Spark plug type: NGK BR8HS
Spark plug gap (use wire gap gauge):
0.6 - 0.7 mm (0.023 - 0.028 in)
Spark plug torque:
2.8 m-kg (20 ft-Ib)
G. Pulser and Charge Coil
Check the resistance of each coil as shown in
the illustartion. If the resistance 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 20C (68F)
Pulser coil resistance:
Black to White/Red leads:
20Q 10% at 20C (68F)
1. Yellow
2. Brown
3. Black
4. White/Red
5. Flywheel magneto
6. Pocket tester
7. Set tester at "RX1" position

426Q (Charge Coil)

(Pulser Coil)
20Q
i- L...:.._---,..,...
I
I
I
CDC] I
@ :
I
c::J----------
J
Pulser Coil ----
Charge Coil--
H. C.D.1. Unit
If the ignition system malfunctions and all of
the above components are working properly,
then the C.D.1. unit is faulty; replace it.
6-5
6-2. LIGHTING SYSTEM
A. Circuit Diagram
B. Headlight Beam
1. Inspection
Check the headlight beam 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 headl ight
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
\
C. Lighting Coil
Check the resistance between the yellow lead
and ground. If the resistance is not within
specification, the coil is not working. Check
the connections. If the connections are good,
the coil is broken internally; it should be
replaced.
O.23Q20%
D. Voltage Regulator
Lighting coil resistance:
Black &Yellow:
0.23Q 20% at 20C (68F)
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 illustration.
6-7
24V
0
0
0
Battery
0
0
+ 0
Tester
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.
611 []::J1211
REG
@ REGULATOR

CHECKER (f)
Light
YAMAHA 0
6\/ []::J12\/ ~
REG IIOLT ~
ElI] ~
e REGULATOR CHECKER (f)
Replace the regulator
2. Check the tester.
Set the right switch to JlREG." If the
lamp lights up, there is continuity in the
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 is faulty and should be
replaced.
Thyristor working voltage:
13.8 0.5 volts at 5,000 r/min
light is out
YAMAHA 0
611
OB
1211
~
REG f[) \/OLT @
e REGULATOR CHECKER (l
Regulator is good
6-8
CHAPTER 7. APPENDIX
7-1. SPECIFICATIONS 7-1
7-2. TIGHTENING TORQUE 7-4
7-3. CONVERSION TABLES 7-6
7-4. EXPLODED DIAGRAMS 7-7
Recoil Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-7
Flywheel Magneto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-8
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-9
Oil Pump Drive Gear 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
7-1. SPECIFICATIONS
A. General
APPENDIX
Model BR250F
Model:
Model (I.B.M. No.) BR250F (8R4)
Frame 1.0. &starting number 8R4-000101
Engine 1.0. &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)
Weight:
Net weight 130 kg (286.6 Ib)
B. Engine
Description:
Engine type
Engine model
Displacement
Bore x Stroke
Effective compression ratio
Starting system
Ignition system
Lubrication system
Cylinder:
Material
Bore size
Taper limit
Out of round limit
Combustion chamber volume
Compressionchamber 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.!.
IIAutolube" oil injection
Cast iron sleeves aluminum
70 mm (2.76 in)
0.05 mm (0.0020 in)
0.01 mm (0.0004 in)
24.8 crrr' (1.51 cu. in) with spark plug
Dome +Squish
0.045,...., 0.050 mm (0.0018'" 0.0020 in)
(10 mm from piston skirt end)
1st 70.25 mm (2.766 in)
2nd 70.50 mm (2.776 in)
18 x 55 mm (0.709 x 2.165 in)
Keystone
Plain
0.20'" 0.40 mm (0.0078'" 0.016 in)
0.20'" 0.40 mm (0.0078'" 0.016 in)
Needlebearing
Needlebearing
Crankshaft:
Crankshaft assembly width (A)
Crankshaft deflection (0)
Connecting rod big end side clearance (C)
Connecting rod small end deflection (P)
+ 0 ( 20 + 0.039 in]
56 _ 0.05 mm 2. 0.00197 In
0.02 mm (0.0008 in)
0.25 -- 0.75 mm (0.010 -- 0.030 in)
2.0 mm (0.079 in)
A
D rc1 D
CLUTCH SIDE c:t{r
100 mm (3.9 mm (3.1 in)
Crank pin outside diameter x length
Crank pin type
Crank bearing type (Left) x q'ty
Crank bearing type (Right) x q'tv
Crank oil seal type (Left) x q'ty
Crank oil seal type (Right) x q'tv
Carburetor:
Type & manufacturer/quantity
1.0. Mark
Main jet (M.J.)
Pilot screw (P.S.)
Throttle valve (Th.V.)
Valve seat (V.S.)
Float height
Idling engine speed
Lubrication:
Autolube pump - Color 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)0.945x 2.165 in)
Solid shaft
#6306 special x 1 pc.
#6305 special x 1 pc,
S03-30 x 1 pc,
505-25 x 1 pc,
B032-28 KEIHIN x 1 pc,
8R401
#108
1-1/4 turns out
t;;;; 1.0
1>1.4 mm (1)0.055 in)
15 2 mm (0.59 0.08 in)
1100 100 r/rnin
Pink
0.20 -- 0.25 mm (0.0079 -- 0.0098 in)
1.65 -- 1.87 mm (0.0650 -- 0.0736 in)
1/40
0.95 -- 1.19 crrr' (0.0321 -- 0.0402 oz)
7.84'" 8.89 ern" (0.2508 -- 0.3006oz)
25 1 mm (0.98 0.04 in) at idle
1.75
YAMALUBE 2-cycle
V-belt automatic centrifugal engagement
3.5: 1 ,..., 1 : 1
3100 200 r/min
5,700 -- 5,800 r/min
90501-50654
No painted
7-2
Secondary spring:
Part No.
Color code
Secondary spring pre-load (twist)
Sheave distance
Sheave off-set
Vbelt width and outer line length
V-belt wear limit
Track suspenison
Type
Damper type
Spring color code (Front)
Spring color code (Rear)
Slide runner wear limit
Stopper band length/Hole No. (Front)
Stopper band length/Hole No. (Rear)
Track width
Track deflection
Length on ground
Wheel sprocket material and number of teeth
Chain:
Type
Reduction ratio
Chain pitch x Number of links
Free play
Chain housing oil quantity
Chain housing oil grade
Brake:
Type
Brake pad thickness
Brake pad wear limit
Gap between pad and disc
D. Chassis
Frame:
Material
Steering system:
Caster (ski column)
Camber
Ski length x width x 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 mm (5.98 in) No.2
381 mm (15 in)
25""' 30 mm/10 kg (0.984 -- 1.18 in/22 lb]
600 mm (23.6 In)
Polyethylene 9T
Chain (#40K-l)
22/13 (1.692)
12.7 mm (0.5 in) x 44L
10
+ 5 mm (04+ 0.2 "In)
2 . - 0.08
200 crrr' (6.8 oz)
Gear oil API "GL3" (SAE #75 or 85)
Disc brake
7.3 mm (0.287 in)
1.0 mm (0.04 in)
0.2 - 1.0 mm (0.008 - 0.039 in)
Steel
25
0
980 x 120 x 1.6 mm (38.6 x 4.7 x 0.06 in)
750 mm (29.5 in)
0-6 mm (0--0.23 in)
Tie-rod
Right ski, L: 26.8 R: 30.5
Left ski, L: 30.5 R: 26.8
Right: 55
Left: 55
Leaf spring
Oil damper
15 liter (4 US.gal)
Regular gasoline
7-3
E. Electrical
Ignition system:
Type flywheel magneto (C.D.I. type)
Model/manufactu rer F8R4/YAMAHA
Voltage 12V
Pluser coil resistance 20n 10%at 20C (68F) (White/Red - Black)
Charging coil resistance 426n 10%at 20C (68F) (Brown - Black)
Ignition timing:
B.T.D.C. 1.6 0.1 mm (0.063 0.004 in)
Ignition coil:
Model: Manufacturer F6T411/MITSUBISHI
Spark gap 9 mm (0.4 in)/300 r/min
11 mm (0.6 in)/3,000 r/min
Primary winding resistance 1.0n 10%at 20C (68F)
Secondary winding resistance 5.9kn 20%at 20C (68F)
Diode (Yes or No) No
Spark plug:
Type & quantity NGK BR8HS x 1 pes,
Spark plug gap 0.6"'-' 0.7 mm (0.024"'-' 0.028 in)
Spark plug cap:
Type Resign type
Resistance 5kn 25% at 20C (68F)
C.D.I. unit:
Model/Manufacturer 8R4/YAMAHA
Lighting system:
Lighting output 12V-l00W
Lighting coil resistance 0.23n 20% at 20C (68F) (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 tightened Thread size Tightening torque Remarks
[Engine]
Spark plug M14 P1.25 2.8 m-kg (20 ft-lb]
Cylinder M8 P1.25 First: 2.0 m-kg (14.5 ft-lb)
Final: 2.5 m-kg (18 ft-lb]
Fl ywheel magneto M16 P1.9 7.3 m-kg (53 ft-lb)
Crankcase upper and lower M8 Pl.25 First: 1.0 rn-kq (7 ft-lb) I
with engine bracket
I
Final: 2.5 m-kg (18 ft-lb)
Tightening sequence
1
71
0
3
5 0
0 0
-
1--,
0 0
8 0
~ 4
2
Fan
I
M6 PLO I 0.7 m-kg (5.1 ft-lb) Use Loetite
7-4
Part to be tightened Thread size Tightening torque Remarks
Oil pump gear case M6 P1.0 0.7 m-kg (5.1 ft-Ib)
[Drive and track suspension]
Primary sliding sheave and cap M6 P1.0 1.1 m-kg (8 ft-lb)
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)
Installation of secondary sheave M12 P1.25 4.0 m-kq (29 ft-lb]
Installation of drive chain sprocket M12 P1.25 6.0 m-kg (43.5 ft-Ib) Usecotter pin
Installation of driven chain sprocket M8 P1.25 2.3 m-kg (16.5 ft-lb]
Chain housing and frame M8 P1.25 2.3 m-kg (16.5 ft-Ib)
Chain hosing cap M6 P1.0 0.65 m-kg (5 ft-lb)
Chain tensioner lock nut M10 P1.25 3.3 m-kg (24 ft-lb)
Installation of front axle L.H. M20 P1.0 8.0 m-kg (58 ft-lb)
Front axle housing and frame M8 P1.25 2.3 m-kg (16.5 ft-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]
Stopper 1 M6 P1.0 0.4 m-kg (3 ft-lb)
[Chassis]
Engine mounting bolt M10 P1.25 3.0 m-kg (22 ft-lb)
Ski runner M8 P1.25 1.4 m-kg (10 ft-lb)
Steering column and gate M8 P1.25 2.0 m-kg (14.5 ft-lb) Use lock
washer
Steering relay rod adjusting nut M10 P1.25 2.5 m-kg (18 ft-lb] Use Loctite
Outside arm and ski colume M10 P1.25 3.0 m-kg (22 ft-lb] Use lock
washer
Steering lower bracket M8 P1.25 2.0 m-kg (15 ft-Ib) Use lock
washer
Installation of steering column 1,2 M8 P1.25 1.45 rn-kq (10.5 ft-lb)
Steering relay ass'y M10 P1.25 3.0 m-kg (22 ft-lbl
Universal joint and outside arm M10 P1.25 2.5 m-kg (18 ft-lb)
7-5
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard
fasteners with standard 1.8.0. pitch threads.
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross fashion, in progressive stages, until full
torque is reached. Unless otherwise specified,
torque specifications call for clean, dry
threads. Components should be at room
temperature.
CONVERSION TABLES
METRIC TO INCH SYSTEM
Known Multiplier Result
rn-kq 7.233 ft-Ib
m-kg 86.80 in-lb
em-kg 0.0723 ft-lb
em-kg 0.8680 in-lb
kg 2.205 Ib
g 0.03527 oz
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
ee (em
3
) 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/em
2
14.2234 psi (lb/in
2
)
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 14 mm 8.5 51
22mm 16mm 13.0 94
INCH TO METRIC SYSTEM
Known Multiplier Result
ft-lb 0.13826 rn-kq
in-lb 0.01152 rn-kq
ft-lb 13.831 em-kg
in-lb 1.1521 em-kg
Ib 0.4535 kg
oz 28.352 g
mpg 0.4252 km/lit
mph 1.609 km/hr
mi 1.609 km
ft 0.3048 m
yd 0.9141 m
in 2.54 em
in 25.4 mm
oz (U.S. liq) 29.57 ee (ern")
cu.in 16.387 ee (em")
pt (U.S. liq) 0.4732 lit (liter)
qt (U.S. Iiq) 0.9461 lit (liter)
gal (U.S. liq) 3.785 lit (liter)
Ib/in 0.017855 kg/mm
psi (lb/irr") 0.07031 kg/em
2
Fahrenheit (F) 519 (oF) - 32 Centigrade (oC)
4 EXPLODED DIAGRAM 7.
. Plate Spring Drive
d Limit er Bracket Hoo
L
RECOIL STARTER
7-7
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
OIL PUMP
Apply
Yamabond 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
OIL PUMP DRIVE GEAR
7-10
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)
BOTTOM END
Bearing Support
7-12
CARBURETOR
t-Starter Jet

j
'<.
'1 " U 'P'
@-FIOO' .;<.

Main Jet
/)1
(...... ...

7-13
INTAKE
,
Pulse Pipe (jj)....
Fuel Pump
7-14
Carburetor Boot
Spider Lever
7-15
SECONDARY SHEAVE
2.3 m-kg (17 ft-lb]
Bearing Cage
7-16
Fixed Sheave
CHAIN CASE
7-17
BRAKE
7-18
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
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
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
STEERING
Outside Arm ~ ~
~ ~
J
r
A~ Universal Join'
~
1. C l a m p - - ~ -
2. Handlebar
7-22
... - ~ 1 . 4 rn-kq (10 ft-Ib) 1
SKI
SKI SHOCK
7-24
OIL TANK
Oil Gauge Line
725
FUEL TANK
1.0 m-kg (7 ft-Ib)
7-26
ELECTRICAL COMPONENTS (1)
Voltage Regulator
7-27
Main Swith
ELECTRICAL COMPONENTS (2)
Engine Stop Switch
7-28
Throttle Lever
CONTROL CABLE
7-29
COl unit
ro1
~ ~
CD
QQ
!Xl -l
(O/P SPEEDOMETER LIGHT)
f
9
-l
Main switch
i f B IB/W
S
>-Cl..JCDm
Taillight/brake light
, ~ L (12V 8/23W1
_. . GIY G/V : B B L-e:::J<:l-L
mtlIi . ~ , === ~ , , J t t J ~ ~ ~ ~ ~ r o
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
1
4
Good
Bon
Bad
Mauvais
2
5
Bad
Mauvais
Bad
Mauvais
3
6
Bad
Mauvais
Bad
Mauvais
YAMAHA MOTOR CO.,LTD.
IWATA,JAPAN
PRINTED IN U.S.A.
_YAMAHA
SNOIMOBIIE
SUPPLEMENTARY
SERVICE MANUAL
LIT.. 126180070 8Y1 .. 28197.. 10
FOREWORD
This supplementary service manual for the BR250TJ has been published to supple-
ment the BR250F service manual (LIT-12618-00-41). For complete information
on service procedures, it is necessary to use this Supplementary Service Manual
together with the following manual.
I BR250F Service Manual (LIT-12618-00-41) r
NOTE: _
The Research and Engineering Departments of Yamaha are continually striving to
further perfect all models. Improvements and modifications are therefore inevita-
ble.
In light of this fact, all specifications within this manual are subject to change
without notice. I nformation regarding changes is forwarded to all Authorized
Yamaha Dealers as soon as possible.
OVERSEAS SERVICE
OVERSEAS OPERATIONS
YAMAHA MOTOR CO., LTO.
BR250TJ
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
Particularly important information is distinguished in this manual by the follow-
i ng notations:
NOTE:
WARNING:
A NOTE provides key information to make procedures easier or
clearer.
A CAUTION indicates special procedures that must be followed
to avoid damage to the machine.
A WARN ING indicates special procedures that must be followed
to avoid injury to a machine operator or person inspecting or
repairing the machine.
CONTENTS
EXTERNAL VIEW 1
MAINTENANCE 2
Periodic Maintenance 2
Lubrication Intervals 3
THROTTLE OVERRIDE SYSTEM 4
Description 4
T.O. R.S. cancellation 5
Block diagram 5
POWER TRAIN 6
PRIMARY 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
DRIVE 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
EXTERNAL VIEW
-1-
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 ng.
Every
Check point
20 hrs. or 40 hrs. or 80 hrs. or
When
Seasonally
400 km 800 km 1,600 km
necessary
(250 mil (500 mil (1,000 mil
ENGINE:
Tighteness of bolts and nuts
0
Bends, cracks, and wear
Abnormal noise 0
Loose connection and breaks in the fuel and pulse pipes
Loose connection and breaks in the oil pipes
0
Loose connection and breaks 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 system 0
Sheave distance 0
Sheave offset 0
Brake pad wear 0
Brake operation and adjustment 0
Guide wheel rubber 0
Wear of track drive sprockets 0
Initial
100 km
Drive track adjustment (60mi} &
300 km
(200 mil
Breaks in drive track
0
Bends in front and rear axles 0
Check lock washers 0
Drive chain adjustment 0
Drive chain oil level
0
** Retighten every 10 hours from the first use.
-2-
Every
Check point
20 hrs. or 40 hrs. or 80 hrs, or
When
Seasonally
400 km 800 km 1,600 km
necessary
(250 mil (500mi) (1,000 mil
CHASSIS:
Tightness of bolts and nuts 0
Bends and cracks 0
Welaed riveted, joints
Ski adjustment 0
Ski runner wear 0
Breaks in fuel tank 0
Cleaning of fuel tank 0
Fuel filter
0
Loose connection and breaks in fuel pipe
:=
0
Breaks in oil tank 0
Oil filter 0
ELECTRICAL:
Wear, breakage of wire covering 0
Breaks in high tension cord 0
b=
Voltage regulator output
Operation of engine stop switch 0
Operation of throttle override system 0
Headlight 0
Taillight 0
Brake light 0
Lubrication Intervals
Every
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 grease
sliding sheave
Front axle housing 0
Shaft 1 and shaft 2
Light all-purpose grease
(Slide rail)
Replace chain case oil 0
Gear oil API "GL-3"
SAE #75 ....... #80
CHASSIS:
Steering column lower
0
~ all-purpose grease
bearing
Steering column upper
bearing
0
Motor oil
Steering links 0
Ski column 0
Ski wear plate 0
Light all-purpose grease
Ski retaining pin 0
Brake cable end stopper
0
and brake lever Esso Beacon 325 grease
-3-
THROTTLE OVERRIDE SYS.TEM
WARNING:
OFF
OFF
STOP
Trouble
ON
Run
OFF
RUN
ON .... OFF
RUN
ON
OFF
Idle or Starting
o
Before restarting the engine, make sure that
the cause of the malfunction has been cor-
rected and that the engine can be operated
without 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 stop.
Idle or Starting
ON ~ ~ / ' ~ '
Run
Trouble
OFF
n
-4-
(
T.O.R.S.
Cancellation
T.O.R.S. cancellation
If the engine cannot started due to carburetor
switch or throttle switch failure, first separate
the connections; 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
POWER TRAIN
PRIMARY SHEAVE
The bolt head must be inserted
as shown.
Bushing clearance:
0.25 mm (0.01 in)
Apply to bottom
four threads or
thread-locking
compound such
as "LOCTITE #640
with PRIMER Tn.
Belt width:
New: 31.6 mm (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. Plain washer
13. Weight
2. Remove the sliders, rollers and weights.
3. Remove the sliding sheave bush as
follows.
3. Weight 2. Roller 1. Slider
NOTE: _
For this operation, the special tools and
LOCTITE #640 with PRIMER "T" (required
for fixed sheave) are necessary. If these are
unavailable, avoid disassembling.
3. Remove the primary sheave assembly
with the Sheave Holder (special tool)
and Sheave Puller (special tool) asshown.
1. Sheave Holder (PING. YS01880)
Removal
1. Remove the drive guard, and remove the
V-belt.
2. Remove the blind cap, and remove the
primary sheave rnountinq bolt with the
Sheave Holder (special tool) as shown.
1. SheaveHolder (P/NO. YS01880)
2. SheavePuller (P/NO. YS01882)
Disassembly
1. Loosen the six sheave cap securing bolts,
and remove the sheave cap and spring.
a. Immerse the primary sheave assembly in
appoximately BOC (176F) water for
several minutes.
b. Hold the lower piece of the Clutch
Spider Separator (special tool) on a
rigid table usingasuitable mounting bolts.
Then, install the Clutch Separator
Adapter onto the Separator.
1. Lower piece of the Clutch Spider Separator
(PING. YS28890A)
2. Clutch Separator Adapter (P/NO. Y5-34480)
3. Mounting bolt
c. Fit the primary sheave assembly onto
the Adapter, and secure the supporting
plates.
-7-
NOTE: _
Securely fit the projections of the Adapter
into the fixed sheave holes.
f. Remove the spider, sliding sheave and
fixed sheave from the Clutch Spider
Separator.
g. Remove the sliding sheave bush from the
sliding sheave with Bushing Tool (special
tool) as shown.
1. Bushing Tool (special tool) 2. Bush
1. Supporting plate
d. Set the upper piece of the Clutch Spider
Separator onto the spider as shown.
e. Remove the fixed sheave and fixed
sheave stopper by 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
0.25 mm (0.01 in) 0.25 mm (0.01 in)
<Limit>
To loosen the fixed sheave, high torque is
required. Therefore, make sure the primary
sheave and special tools are placed securely
also take care not to crack the fixed sheave.
8-
1. Feeler gauge 2. Primary sheavecap
1. Feeler gauge 2. Sliding sheave
3. Inspect 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.
Reassembly
When reassembling the primary sheave,
reverse the disassembly procedure. Note the
following points:
1. Before reassembling the primary sheave,
the sheaves should be lubricated with
the low-temperature grease and motor
oil as illustrated.
....... ~ Oiling Point
~ Greasing point
....... X No oiling or greasing is allowed
2. Before tightening the fixed sheave, 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 the fixed sheave with the special
tools to specification.
Before securing the fixed sheave, fit the fixed
sheave stoppers onto the spider shaft.
To tighten the fixed sheave, high torque is
required. Therefore, make sure the primary
sheave, vise and special tools are placed
securely also take care not to crack the fixed
sheave.
Tightening torque:
200 Nm (20.0 rn- kg, 145 ftlb)
1. Fixed sheavestopper
4. Install the (oilers and weights into the
sliding. sheave and spider.
Torque the roller securing bolts to
specification.
NOTE: _
1. Be sure there is a washer on each side of
the roller and weight.
2. The bolt 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 the primary sheave cap with
the securing bolts. Torque the bolts to
specification.
NOTE: _
Check the movement of the sliding sheave. If
it is not smooth, disassemble the primary
sheave. Then, reassemble it correctly.
Tightening torque:
14 Nm (1.4 rn- kg, 10 ft-Ib)
Installation
When installing the primary sheave, reverse
the removal procedure. Note the following
points:
1. Before installing the primary sheave,
clean the oil off the tapered portion
of the crankshaft using a lacquer thinner.
2. Before tightening the primary sheave
mounting bolt, apply engine oil to the
thread portion of the mounting bolt and
its contact surface with the spring
washer.
Inspection
1. Visually inspect the V-belt for signs of
damage. Replace the belt, if it is
damaged.
2. Measure the width of the V-belt. If the
belt is worn beyond the wear limit,
replace it.
Belt width:
New: 31.6 mm (1.24 in)
Wear limit: 28.0 mm (1.10 in)
\
\
\
\
\
\
I
I
\
\
\
Belt length:
1,099 mm (43.26 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 ftlb)
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 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,
remove it from the primary sheave.
1. New 2. Wear limit
12 -
1. V-belt length
Reassembly
When reassembly the V-belt, reverse the
removal procedure. Note the following points:
1. Before installing the V-belt, clean the
oil off the fixed sheaves and sliding
sheaves using a lacquer thinner.
. EXPLODED DIAGRAM
CARBURETOR
t1--Starter Jet

Overflow Pipe
@--Float

.,/
Main Jet

'1

O-R;ng ---0 it
Main Jet
)i

Slow Jet -----Q,

Carburetor
Assembly
-13 -
INTAKE
Pulse Pipe
Fuel Pump
-14
Primer Pump
Intake Silencer
b ret or Boot ' ----Car u
The bolt head must be inserted
as shown.
PRIMARY SHEAVE
Apply to bottom
four threads or
thread-lockinq
compound such
as" LOCTITE #640
with PRIMER T".
Belt width:
New: 31.6 mm (1.24 in)
Wear limit: 28 mm (1.10 in)
Bushing clearance:
0.25 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. Plain washer
13. Weight
DRIVE AXLE
Drive Sprocket
Axle Nut ftolbl!
I (8 a mkg, 58 80 Nm .
-16-
SKI
SLIDE RAIL
-18 -
SUSPENSION WHEELS
-19-
BUMPER
Protector 4
Front Bumper 3
Flap
~ ~
~
'itD Front Bumper
Bind Screw (@ (@6-----
~ Bumper End
> ~
. '
'..' r.
Spring Nut
r Flanqe Bolt
/
-20-
ELECTRICAL COMPONENTS
Throttle Lever
Lever
Holder (R)
21
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model BR250TJ
Model Code Number: 8Y1
Frame Starting Number: 8Y1-000101
Engine Starting Number: 8Y1-000101
Dimensions:
Overall Length 2,925 mm (115.2 in)
Overall Width 950 mm ( 37.4 in)
Overall Height 1,115mm( 43.9 in)
Weight:
With Oil and Full Fuel Tank 184 kg (406 Ib)
Engine:
Engine Type Two-stroke
Cooling System Axial fan air cooled
Cylinder Arrangement Forward-incline, single cylinder
Displacement 246 cm' (15.0 cu.in)
Bore x Stroke 70 x 64 mm (2.76 x 2.52 in)
Compression Ratio 6.1 : 1
Start ing System Recoil 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
I
NGK
Gap 0.6'"" 0.7 mm (0.024'"" 0.028 in)
Transmission:
Primary Reduction System V-Belt
Primary Reduction Ratio 3.5 : 1 "" 1 : 1
Clutch type Automatic centrifugal engagement
Secondary Reduction System Chain (#40K-1)
Secondary Reduction Ratio 24/11 (2.18)
Reverse System No
Chassis:
Frame Type Monocock (Steel)
Caster 25
Ski Stance 750 mm (29.5 in)
-22-
Model BR250TJ
Suspension:
Front Suspension Type Leaf spring, oil damper
Rear Suspension Type Slide rail
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)
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/55Wx 1
Tail/Brake Light 8W/23W x 1
Meter Light 3AW x 1
-23
a
MAINTENANCE SPECIFICATIONS
Engine
Model
Cylinder head:
Volume (With spark plug)
Warp Limit
Cylinder:
Material
Bore Size
Taper Limit
Out-of-Round Limit
Piston:
Piston Size (D)/Measuring Point (a)
o
/ ~ ~ -
D '7
Clearance between Piston & Cylinder
Oversize 1st
2nd
3rd
4th
Piston Pin Hole Off- Set
BR250TJ
33.1 -- 33.7 cm' (2.02 -- 2.06 cu.in)
Aluminum alloy with special cast iron sleeve
70.000 -- 70.020 mm (2.756 ""' 2.757 in)
<0.05 mm (0.0020 in) >
<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 (0.047 in)
T:::: 2.8 mm (0.110 in)
Plain
B:::: 1.2 mm (0.047 in)
T 2.8 mm (0.110 in)
0.20 -- 0.40 mm (0.0079'" 0.00157 in)
0.20 -- 0.40 mm (0.0079 -- 0.00157 in)
0.03 -- 0.07 mm (0.0008 -- 0.0024 in)
0.02"" 0.06 mm (0.0008"" 0.0024 in)
Parkerizing
Parkerizing
Model
Crankshaft:
Crank Width" F"
Assembly Width"An
Connecti ng Rod Small End Free Play "B"
Connecting Rod Big End Clearance "C"
Crankshaft Deflection "0":
Measuring Point - 1
-2
-3
4
Inside Diameter for Crank Pin
BR250TJ
55.95 -- 56.00 mm (2.202 -- 2.362 in)
2.0 mm (0.080 in)
0.25"'" 0.75 mm (0.010'" 0.030 in)
0.02 mm (0.0008 in)
0.02 mm (0.0008 in)
23.900 -- 23.915 mm (0.941 -- 0.942 in)
100 mm /3.9 in) 80 mm (3.1 in)
I
~
&
Jl
~
-1- Il
LlH [
.'--'
:=J
R/H
~
JL
:/
(M.J.)
(M.AJ.l
(P.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 Jet
Air Screw
Power Jet
25-
. __ .__.._...._--_._... _---
Needle bearing
23.987'" 24.000 mm (0.9444'" 0.9449 in)
#6306
#6305
S03-30, 72, 71, GS
505-25/ 48, 8/ GS
<0.05 mm (0.0020 in) >
Piston valve
B032-28/KEIHIN
80JOO
#105
#78
#100
1 and 1/4 turns out
Model BR250TJ
Power Air Jet (Pw.A.J.) -
Starter Jet (G.S.) # 120
Valve Seat Size (V.S.) 1.4
Idling Engine Speed 1,100 100 r/min
Float Arm Height (F.H.) 15 2.0 mm (a.59 O.OS in)
High Altitude Tuning
~
-30C -20C -10C OC 10C 20C
Altitude
(-22F) (_4F) (14F) (32.
oF)
(50F) (6SoF)
#105
Sea level
~
#102
-600 m
#105
(2,000 ftl #102
"""1,200 m #105
(4,000 ft]
#102
-1,800 m #102
(6,000 ft)
#100
-2,400 m #102
(8,000 ttl #100
-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, 0.265 - 0.301 US oz)
Pump Cable Adjustment 24""'" 26 mm (0.94 -- 1.02 in)
: : d : : : ~ ~
Cool i ng System:
Cooling Fan Belt Tension -
Crankcase Tightening Sequence:
1
710
3
5
0
0 0
- --
0 0
8
~
2 0 4
.
-26-
Model
Transmission:
Type
Rangeof Ratio
~ n g a g e m e n t RPM
Shift RPM
Sheave Center Distance" A"
Sheave Offset "B"
V-belt:
Part No.
Outside Circumference
Width II A"
Wear Limit "B"
BR250TJ
V-belt Automatic
3.5 : 1 -- 1 : 1
Approx. 2,800 r/min
Approx. 5,700 r/min
266 mm (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 (2.63 in)
8VO-1763200
46.1 9 x 3 pes
None
None
Model
Secondary Sheave Spring:
Part No.
Color Code
Outside Dia. x Wire Dia.
Twist Angle
Hole Position (Sheave Side) *
(Spring Seat Side)**
8R250TJ
90580-40080
None
50 x 4.0 mm (1.968 x 0.157 in)
160
0
*
Spring Rate
No. of Coils
Free Length
Color Code
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 kg (22 lb)
-28-
40 -- 50 mm (1.57 -. 1.97 in)
Model
Track Suspension:
Front Travel
Rear Travel
Front Suspension Spring:
Spring Rate
Wire Dia.
Rear Suspension Spring:
Spring Rate
Wire Dia.
Suspension Setting Position:
Stopper Band Hole Position
Shock Absorber:
Damping Force (Extension)
Damping Force (Compression)
Slide Runner:
Thickness II 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"
Wear Limit "B"
- 29-
Polyethylene
7
Alminium
191 mm (7.52 in)
7.3 mm (0.287 in)
1.0 mm (0.039 in)
Model BR250TJ
Padto Disc Clearance
Disc Outside Dia.
Disc Thickness
Brake Lever Free Play*
Chassis
0.2'" 1.0 mm (0.008'" 0.039 in)
182 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
Electrical
Model BR250TJ
Voltage:
Ignition System:
Ignition Timing
Advanced Timing
Advancer Type
(B.T.D.C.)
(B.T.D.C.)
12V
1.6 mm (0.063 in) 16 at 5,500 r/min
I
r----+----+---+---J----+----+-J-+--+----+---J----+-----t-i--+--J
i
2 If----+--t-- --j-----t-- --t-.-+---t--+---t---j---t---I----r---j---i--i
I
I
I
I
i
!----f--f-------r---+---+--+---l --j----+- +..._-j-._-+--t---+--t---+
I
o
I /V
OJ
c
'E
t=
c:
o
:2
c
E:
_.... -_. --_._--_._._._--
CDI:
Model/Manufacturer
Pickup Coil Resistance
Color Code
Charge Coil Resistance
Color Code
COl Unit Model/Manufacturer
2 3 4 5 6 7
Engine Speed ( x 10
3
r/rnln)
F8R4/YAMAHA
20n 10% at 20C (68F)
(W/R B)
426[2 10% at 20C (68F)
(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 20C (68F)
5.9 kn 15% at 20C (68
0
F)
Ignition Coil:
Model/Manufacturer
Minimum Spark Gap
Primary Winding Resistance
Secondary Winding Resistance
Spark Plug Cap:
Type
Model/Manufacturer
Resistance
Resin
L05E/NGK
5.0 k[2 25%
Flywheel Magneto:
Model/Manufacturer
Charging Current-Day
Charging Current-Night
(Min.)
(Max.)
(Min.)
(Max.)
F8R4/YAMAHA
- 31-
Model BR250TJ
Charging Coil Resistance -
Color Code -
Lighting Voltage (Min.) 11.8 V/3,000 r/min
(Max.) -
Lighting Coil Resistance 0.23Q 20% at 20C (68F)
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 10
3
r/minl
!
I
Coil Resistance for Grip Warmer -
. Color Code
-_.
Voltage Regulator:
Type A.C. Type
Model/Manufacturer TR1Z50/HITACHI,58516B/TOSHIBA
No Load Regulated Voltage 13.3 "'14.3 V
- 32-
Tightening torque
Tread size
Tightening torque
Remarks Part to be tightened
Nm mkg ftlb
[Engine]
Spark plug M14 x P1.25 28 2.8 20
Cylinder head (bolt) M8 x P1.25 20 2.0 14
Cylinder head (nut) M10 x P1.25 25 2.5 18
Flywheel magneto M16 x P1.9 73 7.3 53
Crankcase upper and lower
First: M8 x P1.25 10 1.0 7.2
Final: 25 2.5 18
Tightening sequence
fOl J6l
J6l A J---r




r-
.r==
:Q)


IL

\gF=iQJf-L
Crankcaseand gear unit M8 x P1.25 25 2.5 18
Oil pump and gear unit M5 x PO.8 8 0.8 5.8 with screw lock
Starter pulley M8 x P1.25 15 1.5 11
Crankcase and engine bracket M8 x P1.25 25 2.5 18
[Drive and track suspension]
Primary sliding sheave and cap M6 x P1.0 11 1.1 8.0
Installation of primary sheave
Initial: UNF 1/2" 100 10 72 Use motor oil
60 6.0 43 Loosen once and
retighten.
I nstallation 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
I nstallation of drive chain sprocket M20 x Pl.25 60 6.0 43 Bolt
I nstallation 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
Installation of front axle L. H. M22 x Pl.0 85 8.5 61
and bearing
Front axle housing and frame M8 x P1.25 23 2.3 17
Front pivot shaft M10 x P1.25 65 6.5 47
Rear pivot shaft M10 x P1.25 65 6.5 47
Guide wheel shaft M12xP1.25 80 8.0 58
Sliding runner M6 x Pl.0 2.5 0.25 1.7
Lower end bracket M8 x P1.25 20 2.0 14
Lower end bracket and absorber M6 x P1.0 2 0.2 1.4 Loctite@
Front arm 1 and 2 M10 x P1.25 45 4.5 32
I nstallation of ski M10 x P1.25 45 4.5 32
[Chassis]
Engine mounting bolt M10 x P1.25 52 5.2 37
Ski runner M8 x P1.25 14 1.4 10 Use self-locking
nut and Loctite@
-33-
Part to be tightened
Tightening torque
Remarks Thread size
Nm rn-kq ft-lb
Steering column and gate M8 x P1.25 13.7 1.37 10 Use lock washer
Steering tie rod adjusting nut M10 x P1.25 25 2.5 18 Loctite
Steering lower bracket M8 x P1.25 13.7 1.37 10 Use lock washer
Installation of steering column 1,2 M8 x P1.25 13.7 1.37 10
Steering relay adjusting nut M10 x P1.25 25 2.5 18 Loctite
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fas-
teners with standard I.S.O. pitch threads.
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage,
General torque
A B specifications
(Nut) lBoltl
Nm rn-kq
10 mm 6 mm 6 0.6
12 mm 15 1.5
14 mm 30 3.0
55 5.5
85
130
CONVERSION TABLES
METRIC TO INCH SYSTEM
Known Multiplier Result
m-kg 7.233 ft-Ib
rn-kq 86.80 in-Ib
crn-kq 0.0723 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 (cm
3
) 0.03382 oz (U.S. liq)
cc (crn") 0.06102 cu.in
lit (l iter) 2.1134 pt (U.S. liq)
lit (liter) 1.057 qt (U.S. liq)
lit (l iter) 0.2642 gal (U.S. liq)
kg/mm 56.007 Ib/in
kq/crrr' 14.2234 psi (lb/in
2
)
Centigrade (0C) 9/5 (C) + 32 Fahrenheit lO F)
-34-
tighten multi-fastener assemblies in a criss-
cross fashion, in progressive stages, until full
torque is reached. Unless otherwise specified,
torque specifications call for clean, dry
threads. Components should be at room
temperature.
INCH TO METRIC SYSTEM
Known Multipl ier lesult
ft-Ib 0.13826 m-kq
ln-Ib 0.01152 m-kq
ft-Ib 13.831 em-kg
inIb 1.1521 em-kg
Ib 0.4535 kg
oz 28.352
9
mpg 0.4252 km/lit
mph 1.609 krn/hr
mi 1.609 km
ft 0.3048 m
yd 0.9141 m
in 2.54 em
in 25.4 mm
oz (U.S. liq) 29.57 ee (em
3
)
cu.in "16.387 ce (crn")
pt (U.S. liq) 0.4732 lit (liter)
qt (U.S. liq] 0.9461 lit (liter)
gal (U.S. liq) 3.785 lit (liter)
Ib/in 0.017855 kg/mm
psi (lb/in? ) 0.07031 kg/cm
2
Fahrenheit (0 F) 5/9 (F) - 32 Centigrade (C)
CABLE 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
CABLE ROUTING (2)
A-View
Brake light switch lead wire
Beam switch lead 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
CABLE ROUTING (3)
BView
Recovery tank
Protector 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 -
CABLE ROUTING (4)
Starter lever installation
Clamp
- 38-
CABLE ROUTING (5)
Recovery tank installation
Tank fitting band
Instrument panel
39 -
Hook
Panel frame
WIRING DIAGRAM
G/Y GreenIYellow
B/W.....Black/White
BIY ...Black/Yellow
W/R White/Red
Spark 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= . !

1
Voltage
regulator
Main switch

LlWJ-L I
Headlight


. Y B B
. 0 y I I I ,
Headlight beam
switch
Engine stop switch
I i i
Brake Iight switch
J

o
J
YAMAHA 1 ~ , ~ : r O R CO.,LTD.
PRINTED IN U.S.A.
YAMAHA
SUPPLEMENTARY
SERVICE MANUAL
880-28197-10
BR250TV
SUPPLEMENTARY SERVICE MANUAL
1994 by Yamaha Motor Corporatlon, U.S.A.
1st Edition
l
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
FOREWORD
This Supplementary Service Manual has been
prepared to introduce new service and new data
for the 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
SUPPLEMENTARY SERVICE MANUAL:
8X4-28197-20
BR250T(J)
SUPPLEMENTARY SERVICE MANUAL:
8Y1-28197-70
BR250T
SUPPLEMENTARY SERVICE MANUAL:
81X-28197-25
HOWTO USE THIS MANUAL
Particularly important information is distin-
guished inthismanual by the following notations:
&
The Safety Alert Symbol means ATTENTION!
BECOMEALERT! 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 inspecting or
repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
CD


@ @
CHAS
.J.-


IENGI
"""""""
IICOOLI :I: I
@
(j)

ICARsl 'ill IELECII:JI

@
ISPEclo---l IOPTlol

rol
@
B
@

@>
[l:]
@
[ij]
@ @
1
a
CJI

) @
1
1 1
m
@ @


OE031
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols CD to @ are designed as
thumb tabs to indicate the chapter's number and
content.
CD General information
Periodic inspection and adjustment
@ Chassis
@ Power train
Engine overhaul
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
Apply engine oil
) Apply gear oil
@ Apply molybdenum disulfide oil
@ Apply wheel bearing grease
@ Apply low-temperature lithium-soap base grease
Apply molybdenum disulfide grease
CONTENTS
GENERAL INFORMATION 1
MACHINE IDENTIFICATION 1
FRAME SERIAL NUMBER 1
ENGINE SERIAL NUMBER 1
CHASSiS 2
FUEL SUB TANK 2
JOB INSTRUCTION CHART 3
ELECTRiCAL 4
CIRCUIT DIAGRAM 4
ELECTRICAL COMPONENT 6
IGNITION SYSTEM 7
CIRCUIT DIAGRAM 7
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 TORQUE SPECIFICATIONS 28
CABLE ROUTING 29
MACHINE IDENTIFICATION I I ~ ~ ~ I ~ I
1E001
GENERAL
INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number CD is located on the
right-hand side of the frame (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-
FUEL SUB TANK
-2-
JOB INSTRUCTION CHART
FUEL SUB TANK ICHASI ~ I
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.
1 Oil tank cap 1
2 Screw 4
3 Nut 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.
10 Fuel sub tank 1
Reverse the removal procedure for installa-
tion.
-3-
:-:-__C:.:I, __ R.CUIT DIAGRAM
ELECTRICAL
CIRCUIT DIAGRAM
L
. ~ ~ : '
:"
, 1-
L G/Y
L
L
o
-4-
G) Ignition coil
Spark plug
Throttle switch
@ Carburetor switch
Main switch
"ENGINE STOP" switch
(j) C.D.I. unit
C.D.1. magneto
Speedometer Iight**
COLOR CODE
CIRCUIT DIAGRAM
<iQ) Brake light switch
Tail/Brake light
@ Headlight beam switch
@ Headlight
@ 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 illustration for location
and size.
ELEC!RICAL COMPONENT
CD Mam switch
IJENGINE STOp
IJ
.
I\ switch
\3J Throttle switch
@ Headlight beam switch
Brake light switch
Wire harness
(J) V o l ~ a g e regulator
Ignition coil
C.D.1. unit
ELECTRICAL COMPONENT IELECI0 I
-6-
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-
IGNITION SYSTEM IELECI0 I
8E021
TROUBLESHOOTING
NO SPARK OR WEAK SPARK.
ICheck the spark plug gap.
JL OK
iCheck the spark plug cap resistance.
ICheck the ignition coil resistance.
ICheck the stator coil.
Check the IIENGINE STOP" switch, throttle
switch, carburetor switch and main switch.
~ O K
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.
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
[::J11 Spark plug cap resistance:
~ 5 k11 at 20
0
e (68F)
Primary coil resistance:
0.411 20% at 20
0
e(68F)
Secondary coil resistance:
7.1 kn 20% at 20
0
e (68F)
8E051
IGNITION COIL
1. 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 resistance: CD
(Brown - Black)
275 o 20% at 20
0
e (68F)
Pulser coil resistance:
(White/Red - Black)
20 11 20% at 20
0
e (68F)
-9-
IGNITION SYSTEM
377000
8E031
SPARK PLUG
1. Remove:
Spark plugs
2. Check:
Spark plug
Standard spark plug:
BR9ES (NGK)
Spark plug gap:
0.6 - 0.7 mm (O.024 - 0.028 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-
IGNITION SYSTEM IELECI0 I
8E071
HANDLEBAR SWITCH (RIGHT)
"ENGINE STOP" switch and throttle switch
1. Disconnect:
Handlebar switch (riqhtl.coupler G)
2. Connect:
Pocket tester (90890-03112, YU-03112)
3. Check:
"ENGINE STOP" switch continuity
Faultv-efteplace.
Switch position Good condition
RUN (pull) x
OFF (push) 0
0: Continuity 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 lever is not
0
operated.
- ~ +
I () \:$I (
Ir '
o
B B/Y
I I
-11-
0: Continuity
0: Continuity
x: No continuity
x : No continuity
IGNITION 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
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-
- -
LIGHTING SYSTEM IELECI0 I
8E141
TROUBLESHOOTING
HEADLIGHT, TAIL LIGHT AND/OR METER LIGHT DO NOT COME ON.
ICheck the bulbts),
JL OK
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.

LIGHTING SYSTEM
BULB (S)
1. Remove:
Headlight bulb
Tail/brake light bulb
Meter light bulb
2. Connect:
Pocket tester
(to bulb terminals)
A 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.
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: Continuity x: No continuity
GENERAL SPECIFICATIONS ISPECIa-I
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)
Overall width 950 mm (37.4 in) t-
Overall height 1,120 mm (44.1 in) 1,100 mm (43.3 in)
Weight: 175 kg (386 Ib) 153 kg (337 Ib)
Model BR250TrrS
Minimum turning radius:
Clockwise 3.7 m (12.1 ft)
Counterclockwise 3.7 m (12.1 ft)
Engine:
Engine type Air cooled 2-stroke
Induction system Piston valve
Cylinder arrangement Forward inclined single cylinder
Displacement 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 tank) 9.3 L (2.05 Imp gal, 2.46 US gal)
Carburetor:
Type/Quantity BD32-28
Manufacturer KEIHIN
Spark plug:
Type BR8HS
Manufacturer NGK
Gap 0.6 ..., 0.7 mm (0.02 ..., 0.03 in)
Transmission:
Primary reduction system V-belt
Primary reduction ratio 3.5 '" 1.0:1
Clutch type Automatic centrifugal engagement
Secondary reduction system Chain
Secondary reduction ratio 24/10 (2.40) (BR250T)
23/12 (1.92) (BR250TS)
-16-
GENERAL SPECIFICATIONS ISPECI 0--1
Model BR250T/TS
Chassis:
Frame type Monocoque
Caster 25
Ski stance (center to center) 750 mm (29.5 in)
Suspension:
Front suspension type Leaf spring
Rear suspension type Slide rail suspension
Track:
Track type Internal 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 12V 8W/23W xl
Speedometer light 12V 3.4W xl
-17-
MAINTENANCE SPECIFICATIONS ISPECI c:r-I
MAINTENANCE SPECIFICATIONS
ENGINE
Model
Cylinder:
Material
Bore size
<Taper limit>
<Out-of-Round limit>
Piston:
Piston size (D)
Measuring point
Piston to-Cylinder clearance
BR250T/TS
Aluminum alloy with cast iron sleeve
70.00 '" 70.02 mm (2.756 '" 2.757 in)
0.05 mm (0.0020 in)
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 (0.0008 '" 0.0024 in)
0.02 '" 0.06 mm (0.0008 '" 0.0024 in)
Chrome plated/Parkerrizing
Chrome plated/Parkerrizing
-18-
MAINTENANCE SPECIFICATIONS ISPECI 0--1
Model BR250TfTS
Crankshaft:
Crank width II A" 55.95 ... 56.00 mm (2.203 ... 2.205 in)
Connectingrod small end free play IIF" 2 mm (0.08 in)
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)
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
Oil pump:
Pump cable free play 24 '" 26 mm (0.94 '" 1.02 in)
-19-
MAINTENANCE SPECIFICATIONS ISPECI 0--1
Model
I
BR250rffS
High altitude settings
~
-30C -20C -10C
ooe
10C 20C
Altitude
(-22F) (-4F) (14F) (32F) (50F) (68F)
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-
MAINTENANCE SPECIFICATIONS ISPECI0--1
Tightening torque:
Part to be tightened
Tightening torque
Remarks
Nm rn-kq ft-lb
Spark plug 28 2.8 20
Cylinder head (bolt) 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-
POWER TRAIN
Model
MAINTENANCE SPECIFICATIONS ISPECI cr--I
BR250T/TS
Transmission:
Type
Range of ratio
Engagement RPM
Shift RPM
Sheave center distance JI A"
Sheave offset "B"
,Jiiiiiiiia.. B
V-Belt:
Part number
Outside circumference
Width "A"
Wear limit "B"
A
B
I'
V-belt automatic
3.5 ""' 1.0:1
2,900 ""' 3,500 r/min (BR250T)
2,600", 3,200r/min (BR250TS)
5,600 '" 7,200 r/min (BR250T)
5,400 ""' 6,000 r/rnin (BR250TS)
264""' 268 mm (10.4 ,... 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 PAINTED
55 mm (2.2 in)
5 mm (0.2 in)
15 kg (33 Ib}/61.5 m (2.42 in)
24 N/mm (2.4 kg/mm, 134 Ib/in)
4.08
67.8 mm (2.67 in)
8V8-W176A-00
45.7 1 9 (1.61 0.04 oz)
90508-40080
NO PAINTED
50 mm (1.97 in)
4 mm (0.16 in)
-22-
Model
Hole position
Sheave side-spring seat side
(twist angle)
Spring rate
Number of coils
Free length
Drive 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-
MAINTENANCE SPECIFICATIONS ISPECI0-1
Model BR250TffS
Shock absorber: Damping force
Front
Extension 80 kg/0.3 m/s
Compression 50 kg/0.3 rn/s
Rear
Extension 48 kg/0.3 m/s
Compression 45 kg/0.3 mls
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-
MAINTENANCE SPECIFICATIONS ISPECIcr-I
Tightening torque:
Parts to be tightened
Tightening torque
Remarks
Nm rn-kp ft-lb
Primary sliding sheave and cap 11 1.1 8.0
Installation of primary sheave
First: 100 10 72 Tighten the bolts in
Final: 60 6.0 43 two stages. See NOTE.
Installation of secondary sheave 40 4.0 29
Bearing housing 23 2.3 17
Secondary shaft and bearing collar 6 0.6 4.3
Brake caliper and housing chain 50 5.0 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 absorber 2 0.2 1.4 Apply LOCTITE
Front arm 1 and 2 45 4.5 32
Installation of ski 45 4.5 32
NOTE: _
Tightening steps:
1. Tighten the bolt. 120Nm (12 m kg, 85 ft Ib).
2. Loosen it completely.
3. Retighten it. 60Nm (6.0 m kg, 43 ft lb),
-25-
CHASSIS
MAINTENANCE SPECIFICATIONS ISPECI0--1
Model BR250TfTS
Frame:
Frame material Steel
Steering:
Lock to lock angle (left) 24.6(R Ski), 28. P (L Ski)
(right) 28.1
0
(R Ski), 24.6(L Ski)
Ski alignment Toe-out
Toe-out size o"" 6 mm (0 "" 0.24 in)
Ski:
Ski material Steel
Length 980 mm (38.6 in)
Width 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 column 1, 2 13.7 1.37 10
Steering relay adjusting nut 25 2.5 18 Apply LOCTITE
-26-
MAINTENANCE SPECIFICATIONS ISPECI 0-1
9E041
ELECTRICAL
Model
Voltage:
Ignition system:
Ignition timing (B.T.D.C.)
12V
16.5/3,000 r/rnin
BR250Trrs
u
ci
r:
e:i 20
-

8 10
';:;
'2
E
o 246 8
Engine speed (x 10
3
r/mln)
10
C.D.I.:
Magneto model/Manufacturer
Pickup coil resistance
(color code)
Source coil resistance
(color code)
Lighting voltage-(minimum)
Lighting voltage-(maximum)
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 20C (68F)
(Wh ite/Hed - Black)
275 Q 20% at 20C (68F)
(Brown - Black)
11 V/3,000 r/rnln
15 V/6,000 r/min
0.3 Q 20% at 20C (68F)
(Yellow - Black)
0.8 Q 20% at 20C (68F)
(Red - Black)
8AU-00/YAMAHA
86B-00IYAMAHA
3 mm (0.12 in)
0.4 Q 20% at 20C (68F)
7.1 kQ 20% at 20C (68F)
Resin type
5 kQ at 20C (68F)
Flywheel magneto
-27-
GENERAL TORQUE SPECIFICATIONS ISPECI g--I
9E051
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasteners
with standard I.S.0. pitch threads. Torque specifi-
cations for special components or assemblies are
included intheapplicable sections of this book. To
avoid warpage, tighten multi-fastener assemblies
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 10mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19mm 14mm 85 8.5 61
22mm 16mm 130 13.0 94
CABLE ROUTING ISPECI a-I
CABLE ROUTING
Band
@) Starter cable
Speedometer
cable
Brake cable
Clamp
Clamp the wireharness
and pulser hose.
Wireharness
@ Earth
@ Grommet
@ To headlight
\
Clamp
CD Throttle cable
Clamp
__----.::.._--e:t'
Band
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-
CABLE ROUTING ISPECI 0--1
Clamp
E
To oil pump
@ Clamp the fuel hose, oil hose,
pulser hose and wireharness.
@ Breather hose
Fuel level hose
@ Band
~ ~ _ @ To carburetor switch
/ @ To fuel pump
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-
CABLE ROUTING ISPECI 0-1
CD Fuel level hose
Sub tank
Fuel suction hose
@ To 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
@ Placethe taillight lead
coupler as shown.
-31-
CABLE ROUTING 1SPECI0--1
@ Speedometer 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-