Yamaha BR250F User manual

YAMAHA

SNOWMOBILE

SERVICE

MANUAl

LI1-12618-00-41

884-28197-10

FOREWORD

This Service Manual has been

written

acquaint the mechanic

with

the dis-

assembly, reassembly, maintenance, and troubleshooting procedures required

provide

optimum

performance and longevity

the machine.

The

information

herein should be closely studied

avoid unnecessary repairs

and to provide the owner

with

a sound, safe, dependable machine.

NOTE;

The

Research

and Engineering Department

Yamaha is continually striving

further

perfect all models. Improvements and modifications are therefore

inevitable.

light

this fact, all specifications

within

this manual are subject

change

without

notice.

Information

regarding changes is forwarded to all Authorized

Yamaha Dealersassoon asavailable.

YAMAHA

MOTOR CO., LTD.

SERVICE

DEPARTMENT

BR250F

SERVICE

MANUAL

Motor

Corporation, U.S.A.

1st edition, June 1981

All

rights reserved.

Any

reprinting or

unauthorized use

without

the

written

permission

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

make procedures easier or

clearer.

CAUTION

indicates special procedures

that

must be followed

avoid damage

the machine.

WARNING

indicates special procedures

that

must be

follow-

avoid

injury

to a machine operator or person inspecting

or repairing the machine.

TABLE

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. Sealing

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

the

unit.

Grease:

Unless

other

specified, use a low-tempera-

ture

lithium base grease when instructed

grease a

part

component.

Thread-locking

compound:

Use Loctite® Lock N' Seal (blue), unless

other

wise specified, when applying a

thread-locking

compound

securing hard-

ware.

Oil:

Use Yamalube 2

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

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

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

off

the

floor.

8. Protect

the

snowmobile with acovering.

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

the

predelivery check list before operating

any snowmobile

that

has been stored for

several months.

1-2

1~6.

MAINTENANCE

Periodic

Maintenance

Perform

the

various inspections

and

services

the

indicated intervals; however use

this

schedule as

aguide only. Depending

upon

the

operating

conditions,

certain

components

may

require

fre-

quent

servicing.

Every

Check

point

20 hrs. or 40 hrs.

80 hrs. or When Seasonally

400

km 800 km

1,600

km necessary

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

Recoil starter

Carburetor

•

Operation

starter

jet

•

Mixing

adjuster

(pilot

screw) 0

•Idle speed adjustment 0

Operation and adjustment

oil

pump

Ignition

timing

Cylinder

compression 0

Cylinder/exhaust

pipe decarbonize 0

Spark plug

condition,

gap, and cleaning 0

Tighten the

cylinder**

DRIVE;

Tightness

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

track

drive sprockets

Initial

100 km I

Drive

track

adjustment

(60mi)

300km

(200mi)

Breaks in drive track 0

Bends in

front

and rear axles 0j

Check

lock

washers 0!

Drive chain adjustment 0i

Chain case oil level 0

Retighten every 10 hours

from

the

first

use.

1-3

Every

Check

point

20 hrs.

hrs.

80 hrs.

When Seasonally

400

800

1,600

km necessary

(250

mil

(500

mil

(1,000

rni]

CHASSIS:

Tightness

bolts

and

nuts

Bends and cracks 0

Welded riveted,

joints

Ski

adjustment

Ski

runner

wear 0

Breaks in fuel

tank

Cleaning

fuel

tank

Fuel

filter

Loose

connection

and breaks in fuel pipe 0

Breaks in oil

tank

Oil

filter

ELECTRICAL:

Wear, breakage

wire

covering 0

Breaks in high-tension

cord

Voltage regulator

output

Operation

engine

stop

switch 0

Operation

tether

switch 0

Headlight

Taillight

Brake

light

B. Lubrication Intervals

Every

Check

point

20 hrs. or 40 hrs,

80 hrs.

When Seasonallv Oil/Grease

400

800

1,600

km necessary Brand name

{250

mil

(500

mil

(1,000

mil

ENGINE:

Starter

case 0

Oil

pump

control

box

0Aeroshell grease

A or

Pump

drive cover 0Esso Beacon

325

grease

Oil in the oil

tank

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

Light

all-purpose grease

(Slide rail) 0

Replace chain caseoil 0Gear oit API

"GL-3"

SAE

#75

#80

CHASSIS:

Steering

column

lower

bearing

Light

all-purpose grease

Steering

column

upper

bearing

Motor

oil

Steering

links

Ski

column

Ski wear plate 0

Light

all-purpose grease

Ski retaining

Brake cable end stopper 0

and brake lever Esso Beacon

325

gear

1-4

C. Sealingthe Carburetor

ALWAYS

seal

the carburetor before turning

asnowmobile 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

out-

lined below.

Confirm

STD

settings

•

Carburetor

(Page3-3)

•

Ignition

timing

(Page6-2)

•Spark plug (Page6-5)

Adjust

main

jet

size according

the

chart

!(Page3-3)

Test main

jet

size

(performance &plug colour)

Not

Adjust

main

jet

size

(Page3-6) •

II I

Not

Check to seeif gearing is

too

high or

low

NotOK

Adjust

gearing as required

(Page

4-12)

Not

OK OK Check engagement speed and

shift

performance

Not

OK-----r~

High

altitude

tuning

Adjust

primary

clutch

asrequired

{Page

4-1)

NotOK

Not

01<..

Adjust

secondary

clutch

asrequired

{Page

4-1) OK

1-5

'·8. SPECIAL TOOLS

13.

&-b.

4-d.

4-b.

No. Description Tool No.

1Dial Gauge 90890..Q3097..Q0

2Dial GaugeStand 90890-01195-00

3Dial Gauge Needle (56 rnml 90890-03098-00

4 3-Way Puller A'ssy TLU·90901-05-20 (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

Rotor

Holding Tool 90890..Q1

235..Q0

608

Primary SheavePuller (M18) TLS-90018-59-02 (U.S.A_)

90890-01898..Q0

6-b Primary SheavePuller

Attachment

90890-01899..Q0

7Primary SheaveSubassembly

Tool

TLS-9091 0-60-00

90890-01858-00

8Bushing Tool 90890..Q1883..Q0

9SheaveGauge 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 SheaveHolder TLS·90018-80..Q0 (U.S.A,)

90890..Q1701-00

14 Secondary SheaveHolder 90890..Q1872-00

1-6

Table of contents

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