Yamaha ET250D Manual

_YAMAHA

supp

[Frame serial number: 8J5-038101

8J5-049999 ]

Engine serial number: S246-038101

S246-049999

LIT

-12618-00-22

8J5-28197-10

1980 ET250D

CONTENTS

(

NEW SERVICE PROCEDURE

...................

...

.....

...

................................. 1

2. MAINTENANCE INTERVALS

.....

....

............

...

...............

...

...................

3. SPECiFiCATIONS

.....

...................................

....

...

..........

........

....

.............. 8

4. SPECIAL TOOLS

.........

.. ..

......

....

......

...

........

....

...........

....

...

......

WIRING

DIAGRAM

...

....................................

.......

...

....

...

( 6. WIRE ROUTING

DIAGRAM/PIPING

AND

CONTROL

CABLE

DIAGRAM

...

........

...................

.... ..

........................

...

...................

....

NEW

SERVICE

PROCEDURE

ew service procedure applied

the

1980

ET250D)

c A.

Primary

sheave

For better clutch operation and durability, a

new

clutch has been adopped.

Primary fixed sheave

Primary sliding sheave

3 _ Bushing (Large)

4_ Cap

5_ Bushing (Small)

Bolt

Spring

washer

9 _ Spider

10_

ider

11.

with

hole

_ Plate

washer

Weight

14_

Collar

15_

Collar

16_

Bolt

17_

Plate

washer

18_

Cotter

19_

Compr

ession spring

20_

Cam

21.

Hexagon

bolt

22_

U-

nut

23_

Plate

washer

24_

Plate

washer

1980

ET250D

Removal

Remove the

primary

sheave

mounting

bolt

using

the

sheave holder.

Tool name Tool No.

Sheave holder

90890-01880

Sheave

holder

b. Remove the

primary

sheave assembly,

using the

primary

fixed sheave puller

bolt

and

primary

sheave holding tool.

Tool name

Primary fixed sheave puller

bolt

Pl.5)

Primary fixed sheave

puller

bolt

2. Disassembly

Tool No.

90890

01881

Separate

the

sliding sheave assembly

from

the

fixed sheave by

rotating

the

sliding sheave counterclockwise.

Install

the

sheave sub-assembly

tool

the

primary

sheave.

Tool name Tool No.

Sheave sub-assembly

tool

90890-01879

1 Sheave sub-assembly

tool

Loosen the six

bolts

securing the

primary sheave cap and sliding sheave.

Remove

the

sheave subassembly tool.

The

primary

sheave cap and sliding

sheave cap

now

be disassembled.

3. Inspection

Check the tapered ends

the

crank-

shaft and

primary

fixed sheave for

scratches. If scratched unduly, replac

If scratches are minor, burnish

with

emery

cloth.

Check the

primary

sheave cap bushing

and sliding sheave

bushing

for

wear.

beyond tolerance, replace

the

bushing.

bushing clearance,

limit

Small bushing Large bushing

Inside 0.

(0.01 in) 0.

(0.01 in)

Outside

0.25

(0.01 in) 0.

(0.01 in)

)

(

NOTE:--------------------------

bushing is installed tightly, remove the bu-

shing using the bushing tool.

-3-

1980 ET250D

Tool name Tool No.

Bushing

tool

90890-01877

1. Bushing tool

Check the compression spring for free

length.

excessively fatigued, rep!ace.

Check the spider and roller

for

smooth

movement

and wear.

Check both sheaves

for

warping.

warped, replace.

4. Reassembly

Oil the points

shown

the

illustration.

not

apply the grease on the portion

X mark. For

other

parts, greasing is

unnecessary.

X Free

from

grease

Greasing

point

CAUTION:-------------------,

the

-nut

cotter

removed

for

the

greasing,

replace

with

new

one.

1980 ET25lJD

Install

the

component

parts

the

slid-

ing

sheave and the sheave cap.

NOTE:--

----

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

When

installing

the

primary

sheave cap

the

primary

sliding sheave, be sure

align

the

mark

the

sheave cap

with

that

the

spider.

Install

the

sheave subassembly

tool

and

tighten

the cap.

Tighten

the

six

primary

sheave cap

bolts

and remove

the

subassembly tool.

Tightening

torque:

1.1

m-kg (8 ft-Ib)

CAUTION:

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

Make

sure

that

the

primary sheave cap

assembly slides in

contact

with

the

fixed sheave boss.

-4-

Clean the

taper

portions

crankshaft

and fixed sheav

Fit

the

fixed sheave

the

tapered por-

tion

crankshaft.

Apply

engine oil

the

threaded

portion

primary

sheave

bolt

and its

contact

surface

with

spring washer.

h. Tighten

the

primary

sheave

mounting

bolt

using

primary

sheave cap

holding

tool.

Tightening

torque

First

tight

en the

bolt

torque

then

loosen it.

Retightened

bolt

a final torque

A.:

10m-kg

(72

ft-Ibl

: 6

m-kg

(43.5

ft-Ibl

Starter

The air

duct

longer provided because

there

will

be no

problem

overheating. Ac-

cordingly, the insert for

mounting

the

air

duct

the

starter case is

longer used.

Air

duct

. No l

onger

used

Screw

...

No longer used

3. Plain

wash

...

No longer used

Starter

case

NOTE:------

------

--------

------

.The

1979

model can also be used

without

installing

the

air

duct

ET250D

- 5 -

1980 ET250D

MAINTENANCE

INTERVALS

[PERIODIC

MAINTENANCE]

Every

Check

point

hrs.

hrs

When

Seasonally

400

800

1600

necessary

mil

(500

mil

(1000

mil

ENGINE

Tightness

bolts

and

nuts

0 0

Bends. cracks and

wear

0 0

Abnormal

noise 0 0

Loose

connection

and breaks

fuel and pulse pipes 0 0

Loose

connection

and breaks

oil

pipes

0 0

Loose

connection

and breaks

oil

delivery

pipe 0 0

Manual

ope

starter

system

0 0

Carbu

retor

• Fuel level 0 0

•

Operation

starter

jet

0 0

•

Mixing

adjuster

(pilot

screw) 0 0

•

Idling

speed

adjustment

0 0

Operation

and

adjustment

oil

pump

0 0

Ignition

timing

Cylinder

comp

ressions 0 0

Cylinder

head/exhaust

pipe decarbonize 0

Spark

plug

condition.

gap

and

cleaning

0 0

Tightening

the

cylinder

head"

DRIVE:

Tightness

bolts

and

nuts

0 0

Wear

on slide

runners

0 0

Primary

drive

system

0 0

V-belt

0 0

Secondary

drive

system

0 0

Sheave

distance

0 0

Sheave

offset

0 0

Brake pad

wear

0 0

Brake

operation

and

adjustment

0 0

Guide

wheel

rubber 0 0

Wear

drive

track

wheel

sprocket

0 0

Initial

100

Drive

track

adjustment

(60

mil

0 0

and

300

(200

mil

Breaks in drive

track

0 0

Bends

front

and rear axles 0 0

Checking

lock

washers

0 0

Drive chain

adjustment

0 0

Drive chain

oil

level 0 0

BODY

Tightness

bolts

and

nuts

0 0

Bends and cracks 0 0

Welded

riveted.

joints

0 0

Ski

adjustment

0 0

Ski runner

wear

0 0

Breaks in fuel

tank

0 0

Cleaning

fuel

tank

F,uel

filter

Loose

connection

and breaks in fuel

pipe

0 0

Breaks in

oil

tank

0 0

Oil

filter

- 6 -

1980 ET250D

Every

Check point

hrs.

hrs

When

Seasonally

400

800

1600

km necessary

(250

mil

(500

mil

(1000

mil

ELECTRICAL:

Wear

, breakage

wire

covering 0 0

Breaks in high-tension cord 0 0

Voltage regul

ator

working

voltage 0

Operation

engine

stop

switch

0 0

Operation

tether

switch

0 0

Headlight

0 0

Taillight 0 0

Brake

light

0 0

••

etight

en every

hours from the first use.

[LUBRICATION

INTERVALS]

Eve

Lubrication

point

hrs, or

hrs.

hrs, or

When

Seasonally Oil/Grease

400

1,600

necessary

8rand

name

mil

(500

mil

(1.000

mil

ENGINE:

Starter

case 0

Oil

pump

contro

box

0 0 Aeroshell grease #7A

Esso Beacon

325

grease

Pump drive cover 0 0

Oil in the oil

tank

YAMALUB

2-cycle

oil

Primary sheave

weight

0 0

and roller

pins

Molybdenum

disulf

ide

Secondary

shaft

and 0

snowmobile

grease

sliding sheave 0

Front axle

hous

ing 0 0

Shaft

1 and

shaft

2 0

Light

all-purpose grease

(Slide raill 0

Drive chain oil 0 Gear oil API "GL-

replacement

SAE#750r

BODY:

Steering

column

lower

0 0 Light all-purpose grease

bearing

Steering colu

upper

0 0

Motor

oil

bearing

Steering links 0 0

Ski

column

0 0

Ski

wear

plate 0 Light all-purpose grease

Ski

retaining

pin 0 0

Brake

wire

end

stopper

0 0 Esso

8eacon

325

grease

and brake lever

-7

1980

ET250D

SPECIFICATIONS

General

NOTE:

...

New

specification

(Compared

with

1979

ET250C)

Model:

Model

(I.B.M.

No)

ET250D

(8J5)

Frame 1.0. and

starting

number

8J5-038101

Engine 1.0. and

starting

number

S246

-0

381

Dimension:

Overall l

engt

h 2.

385

(93.9

in)

Overall

width

(std)

905

(35.6

in)

Overall

height

windshield)

965

(38.0

in)

Engine

Description:

Engine type

Fan

cooled.

two

stroke

5-port.

single

cylinder

Engine model

S246

Displacement

246

cm3

(15

cu.in)

Bore X stroke

(2.87

X 2.3 in)

Effective

compression

ratio

6.6:

Starting system Recoil hand starter

Ignition

system

C.D.1.

Lubrication system

"Autolube"

oil injection

Cylinder head

Combustion

chamber

volume

(with

spark plug)

29.6cc(1.81

cu.in)

Compression

chamber

type

Dome

+ squish

Head

gasket

thickness

0.5

(0.02

in)

Cylinder:

Material

Cast iron sleeves alu

minum

cylinder

Bore size

(2.87

in)

Taper

limit

0.05

(0.0020

in)

Out

round

limit

0.01

(0.0004

in)

Piston:

Piston

skirt

clearance

0.045

0.050

(0.00

0020

in)

(Measuring

point)

(10

from

pis

ton

skirt end)

Piston

over

size 1st

(2.88

in)

2nd

73.50

(2.89

in)

3rd

73.75

.90

in)

4th

74.00

(2.91 in)

Piston pin outside

diameter

X length

(0.71 X

2.17

in)

Piston ring:

Piston ring design (Top) Keystone

Piston ring design (2nd) Keystone

Ring end gap (Installed) (Top)

0.3

0.5

(0.012

0.020

in)

Ring end gap (Installed) (2nd)

0.3

0.5

(0.012

0.020

in)

Small end bearing:

Type Needle bearing

Big end bearing:

Type Needle bearing

Crankshaft:

Crankshaft assembly

width

(A)

+0.

0.05

(2.2 _

0.002

In)

Crankshaft

deflection

(D)

0.02

(0.

0008

in)

1980

ET250D

Connecting

rod large

end

side

clearance

(C)

0.5

(0.02

in)

Connecting

rod

small

end

def

ection

(S) 2

079

in)

r-----

D -

rrD~

cj~

116

in)

11.6 in)

I -S

Crank pin

outside

diameter

length

945

2.165

in)

Crank pin

type

Solid

shaft

Crank

bearing

type

(Left) X

q'ty

* #

6306

C3 special

treatment

x 1 pc.

Crank

bearin

type

(Right) X

q'ty

#6206

C3 X 1 pc

Crank oil seal

type

(Left) X

q'ty

* FPJ

30-72

-8

x 1 pc.

Crank oil seal

type

(Right) X

q'ty

FPJ30-48-8

X 1 pc.

Carburetor:

Type and

manufacture

quantity

CDX38-32

KEIHIN

SEIK

I X 1

I.D.

mark

8G501

Main

jet

(M.J)

#13

Slow

adjusting

screw

(Air

screw)

(

)

2.0

turns

out

Slow

jet

(SJ.)

Intermediate

jet

(I.J.) #

arter

jet (St.J.)

0.95

(004

in)

Fuel level

(F.

L.) +5 ± 3.5

(0.20

0.14

in)

Idling

engine

speed

1,300

min

Main

jet

setting

chart:

-30°C

°C -

°C O°C

°C

Altitud~

°F)

4°

114°

132°

150°

168°

#138

Sea

level .

#130

600m

12000 It)

#138

;

1200m

(4000

It)

#138

#130

1800m

16000

It) - #

138-

-#125--

#130

2400m

8000

It)

#12

5 -

125

3000m

110000

It)

or more . #

120

-Change

the

Slow jet to

#45

Change

the

slow adjusting

screw

1-1/4

- 1

-1

/ 2 turns out.

Lubrication:

Autolube

pump

Color

code

Green

Autolube

pump

Minimum

stroke

0.25

(0.008

0.01

in)

Autolube

pump

Maximum

stroke

.85

205

(0.073

0.081

in)

Autolube

pump

Reduction

ratio

Autolube

pump

Output

Min.

3.5

cc/h/l,300

r/min

(0.46

oz/h/l,300

r/min)

Autolube

pump

Output

Max.

440

cc/h/6,500

r/min

(14

oz/h/6,500

r/min)

Oil

tank

capacity

2.2

liter

(2.3 U.S.

qt)

Oil

grade

YAMALUBE

2-cycle

oil

- 9 -

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