Yamaha ET250 User manual

FOREWORD

This service manual provides technical in-

formation

the

1980

models including

its

features, differences

from

the

1979

models

and

new

service procedure.

Please read

this

manual

thoroughly

that

you can have a good knowledge

the

new

model and make

best

use

it in your sales

and after-service activities.

SERVICE

DEPARTMENT

YAMAHA

MOTOR

CO,. LTD.

NOTE:

--~---

The Research and Engineering Departments

Yamaha are

continually

striving to

further

perfect all models.

Improvements

and

modifications

are therefore inevitable.

light

this

fact, all specifications

within

this

manual are subject to change

without

notice.

Particularly

important

information

is dis-

tinguished in

this

manual by

the

following

notations:

NOTE:

A NOTE provides key

information

to make

procedures easier or cleaner.

CAUTION:

ACAUTION indicates special procedures

that

must

followed

to avoid change to

the

machine.

WARNING:

WARNING

indicates special procedures

that

must

followed

to avoid injury to a

machine

operator

or person inspecting or re-

pairing the machine.

·1980 ET250

CONTENTS

1. MODI·FICATIONS , ..

A. ENGINE , ...

8. DRIVE , 3

C. CHASSiS , 4

D. ELECTRICAL. , , 6

2. SERVICE 7

NEW

SERVICE PROCEDURE 7

B. MAINTENANCE INTERVALS 10

C. SPECiFiCATIONS 12

D. SPECIAL TOOLS 17

WIRE ROUTING

DIAGRAM

WIRING

DIAGRAM

ENGINE

1. Left crank

Due to use of a new type clutch, the

crankshaft is tapered at its end to

mount

the

clutch.

'79

model

Left

crank

(8F3-11412-00)

. 2. Bearing

(93306-30605)

3. Oil seal

(93102-32161)

Interchangeability: No

(Refer to

"8.

Drive, clutch.")

As a result. the bearing and oil seal in-

side diameters are changed from 32

mmto

mm.

'80

model

1. Left crank

(8J2-11412-00l

2.'

8earing(93306-30617)

3. Oil seal

(93102-30188)

-1

1980 ET250

2. Starter

The air duct is no longer provided be-

cause there

will

be no problem of

overheating. Accordingly, the insert for

mounting

the air

duct

on the starter

case is no longer used.

1. Air duct ...No longer used

(8G5-15471-001

2. Screw ... No longer used

(98506-050081

3. Plainwasher

No longer used

(92906-05200)

4. Starter case

(8F3-15711-01

)

-2-

NOTE:

------------,---

The

1979

model can also be used

without

installing the air duct.

B. DRIVE

Primary sheave

For better clutch operation and increased

durability, the new clutch has been adopted.

'79

model

1. Primary sheavecap complete

(8H7-17630-00l

2. Bolt

(90105-12009l

3. Washer

(90215-12084)

4. Washer

(90201-121911

5. Primary sliding sheavecomplete

(8F3-17620-00)

6. Compressionspring

(90501-55451)

7. Nut

190179-28088)

8. Washer

(90208-28003)

9. Spring set

(820-17644-00)

10. Cam

(8G5-17623-00)

11. Primary fixed sheavecomplete

(8E3-17610-00)

-3-

'80

model

1. Primary fixed sheave complete

(8H9-17610-00)

2. Primary sliding sheave

18H9-17621-00l

3. Bushing

(90389-39023)

4. Cap

(8H9-17631-00l

5. 8ushing

(90389-26022)

6. Bolt

(97311-06025)

Boll(97311-06040)

B. Spring washer

(92902-06100)

9. Spider (8H9-17627-00)

10. Slide 18A7-17653-00)

11. Pin with hole

(90240-07066)

12. Plate washer

(90201-06589)

13. Weight (8H9-17632-001

14. Collar(90387-096981

Interchangeability:

1980 ET250

15. Collar

(90387-06697)

16. Bolt

IBH9-17647-00l

17. Plate washer

(90201-06053)

1B. Cotter pin

(91402-25012)

19. Compression spring

(90501·55345)

20. Cam (BJ2-17623-00)

21. Hexagon bolt

(90101-06440\

22. Self locking nut

(95601-06100)

23. Platewasher

(90201-06727)

24. Platewasher

(90201-09728l

25. Platewasher

(90201-06750)

1980ET250

C. CHASSIS

1. Frame

(8H7-21910-00

--+

8K3-21910-00)

oFor better durability

the frame, the

engine hood material

changed from

aluminum to steel plate (Black coat-

ing).

oThe drive guard bracket is welded to

the hood for easy assembling.

oThe front part of

the

frame is painted

black as part of the new

1980

model

design.

Attl....Steel plate (blackl

Welded drive guard bracket

8K3-2191

0-00

can be used on both

and

'80

models.

8H7-21910-00

can

not

be used on

'80

model.

2. Steering gate

(8H7

-23871-00

K3-23871-00)

For easy assembling and maintenance,

the drive guard bracket is welded to the

steering gate.

Interchangeability: Yes

(The previous model's steering gate

(8H7-

23871-00

is interchangeable,

a set

with

the drive guard bracket (8

F3-77316-

01L

with

the

new

steering gate).

NOTE:

------------

Due to modifications in 1, and 2. above, the

1979

model's drive guard bracket 1 (8G5-

77315-00)

and bracket 2

(8F3-77316-01)

are no longer used.

3. Drive guard

(8F3-77311-01

--+

8G8-77311-00)

Due to use

the

new

type clutch, the

shape

the drive guard is changed.

'79

model

'80

model

8G8-77311-00

can be used on both

and

'80

models.

8F3-77311-01

can

not

be used on

'80

model.

4. Throttle

To keep the throttle cable end, which is

held by

the

throttle lever, from contact-

Lever(8G8-421:38-00

Lever

(8J5-42138-00)

and collar (9038,7-

19aOET250

ing the

throttle

grip, acollar is mounted

and the lever is properly curved.

Collar

(90387

·22726)

Lever

(8G8-42138-00)

can

not

be used

5. Tune-up label

(8K3-77743-00)

As an aid to service, a

tune-up

label is

attached to the intake silencer.

EI250

(BKal

SPECIFIKATIONER

1. BENSIN

2. MOTOROLJA

3. TANDSTIFT

4. ELEKTRODEAVSTAND

5. TANDINSTALLNING

6. LAoFART (BRANSLEl JUSTERINGSSKRUV

7. TOMGANGSVARVTAL

8. BRANSLENIVA

9. KEDJEHUS OWEVOLYM OCH VISKOSITET

450

cc, GEAROLJA

10. VARITORAVSTAND

11 VARIATOR SIDOFORSKJUTNING

12. MATTSPANNING

IS;RlJd~~~~~

• FOR YTTERLIGARE INFORMATION SE

DENNA MODELL.

• SPECIFIKATIONER!<ANANDRAS UTAN MEODELANOE.

-5

1980 ET250

D. ELECTRICAL

1. Main switch

(8F3-82508-20

----j.

8J5-82508-21)

For additional safety, the headlight and

'79

model

tailliqht

circuits are changed so

that

these lights are kept turned on as long

as the engine is in operation.

'80

model

Yellow Bille

ON ON/LIGHT

LIGHT

Gray

Black/White

Black

Interchangeability: No

2. Wire harness

(8H7-82590-20

8K3-82590-20)

For additional safety,

the

headlight and

taillight circuits are changed so

that

these lights are kept turned on as long

as the engine is in operation.

(Refer to

"2-E

Circuit Diagram.")

Interchangeability: No

-6-

3. Engine stop

switch

(8E3-83976-01

)

For additional safety, the engine stop

switch

is added.

1980 ET250

2. SERVICE

NEW

SERVICE

PROCEDURE

(New

service procedure applied to the

1980

ET250)

b. Remove

the

primary sheave assembly,

using the primary fixed sheave puller

bolt

and primary sheave holding tool.

Tool No.

90890-01879

Tool name

2. Disassembly

a. Separate

the

sliding sheave assembly

from the fixed sheave by rotating the

sliding sheave counterclockwise. .

Sheave sub-assembly tool

b. Install

the

sheave sub-assembly tool to

the primary sheave.

Tool No.

90890-01880

Tool name

Sheave holder

Tool name

Primary

shave

1. Removal

a. Remove the primary sheave

mounting

bolt, using the sheave holder.

Primary fixed sheave puller

bolt

1M18 P1.5)

90890-01881

1. Sheave sub-assembly tool

1 Primary fixed sheave puller

bolt

c. Loosen

the

six

bolts

securing

the

primary sheave cap and sliding sheave.

d. Remove

the

sheave subassembly tool.

The primary sheave cap and sliding

sheave cap

now

be disassembled.

3. Inspection

a. Check

the

tapered ends

the

crank-

shaft and primary fixed sheave for

scratches.

scratched unduly, replace.

If scratches are minor, burnish

with

emery cloth.

b. Check

the

primary sheave cap bushing

and sliding sheave bushing

for

wear.

beyond tolerance, replace

the

bushing.

1980 ET250

NOTE:

------------

If bushing is installed tightly, remove the bu-

shing using

the

bushing tool.

Bushing clearance,

limit

Small bushing Large bushing

Inside

0.25

mm (0.01

in)

0.25

mm (0.01 in)

Outside

0.25

mm (O.Ol in)

0.25

mm (0.01 in)

.' Tool name Tool No.

... X Free

from

grease

... Greasing point

for free

90890-01877

Bushing

tool

Checkthtrspider

and

rollerfof'slllooth

movement and wear.

e. Check both sheaves for warping. If

warped, replace.

4. Reassembly

.a. Oil the points shown in the illustration.

not

apply the grease on the portion

of X mark. For other parts. greasing is

unnecessary.

CAUTION:

-----'------..,

the

-nut

cotter

removed

for.

the

greasing,

replace

with

ne\iV

one

1 Bushing tool

-8

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