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

(

1.

NEW SERVICE PROCEDURE

..

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

...

.

.....

.

...

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

2. MAINTENANCE INTERVALS

.....

....

..

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

...

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

...

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

..

6

3. SPECiFiCATIONS

.....

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

..

....

...

..........

..

........

....

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

4. SPECIAL TOOLS

..

.........

.. ..

......

....

..

.

......

..

...

.

........

....

..

....

...........

....

...

......

13

5.

WIRING

DIAGRAM

...

.

...

.

...

..

.

..

.

..

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

..

.......

...

....

.

...

14

( 6. WIRE ROUTING

DIAGRAM/PIPING

AND

CONTROL

CABLE

DIAGRAM

...

........

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

.... ..

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

...

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

....

15

1.

NEW

SERVICE

PROCEDURE

(N

ew service procedure applied

to

the

1980

ET250D)

c A.

Primary

sheave

For better clutch operation and durability, a

new

clutch has been adopped.

2

1.

Primary fixed sheave

C

2_

Primary sliding sheave

3 _ Bushing (Large)

4_ Cap

5_ Bushing (Small)

6_

Bolt

7_

Bolt

8_

Spring

washer

20

9 _ Spider

10_

Sl

ider

11.

with

hole

4

12

_ Plate

washer

C

13

_

Weight

14_

Collar

15_

Collar

16_

Bolt

17_

Plate

washer

18_

Cotter

19_

Compr

ession spring

5

20_

Cam

21.

Hexagon

bolt

C

22_

U-

nut

23_

Plate

washer

24_

Plate

washer

-

1-

1980

ET250D

1.

Removal

a.

Remove the

primary

sheave

mounting

bolt

using

the

sheave holder.

Tool name Tool No.

Sheave holder

90890-01880

1.

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

(M

18

Pl.5)

1.

Primary fixed sheave

puller

bolt

2. Disassembly

Tool No.

90890

-

01881

a.

Separate

the

sliding sheave assembly

from

the

fixed sheave by

rotating

the

sliding sheave counterclockwise.

-

2-

b.

Install

the

sheave sub-assembly

tool

to

the

primary

sheave.

Tool name Tool No.

Sheave sub-assembly

tool

90890-01879

1 Sheave sub-assembly

tool

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

of

the

crank-

shaft and

primary

fixed sheave for

scratches. If scratched unduly, replac

e.

If scratches are minor, burnish

with

emery

cloth.

b.

Check the

primary

sheave cap bushing

and sliding sheave

bushing

for

wear.

If

beyond tolerance, replace

the

bushing.

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)

)

r

c

(

c

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

If

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

c.

Check the compression spring for free

length.

If

excessively fatigued, rep!ace.

d.

Check the spider and roller

for

smooth

movement

and wear.

e.

Check both sheaves

for

warping.

If

warped, replace.

4. Reassembly

a.

Oil the points

shown

in

the

illustration.

Do

not

apply the grease on the portion

of

X mark. For

other

parts, greasing is

unnecessary.

+-

X Free

from

grease

+-

Greasing

point

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

If

the

U

-nut

or

cotter

is

removed

for

the

greasing,

replace

it

with

new

one.

1980 ET25lJD

b.

Install

the

component

parts

to

the

slid-

ing

sheave and the sheave cap.

NOTE:--

----

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

--

When

installing

the

primary

sheave cap

to

the

primary

sliding sheave, be sure

to

align

the

X

mark

on

the

sheave cap

with

that

on

the

spider.

c.

Install

the

sheave subassembly

tool

and

tighten

the cap.

d.

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-

e.

Clean the

taper

ed

portions

of

crankshaft

and fixed sheav

e.

f.

Fit

the

fixed sheave

to

the

tapered por-

tion

of

crankshaft.

g.

Apply

engine oil

to

the

threaded

portion

of

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

to

a

torque

of

A

then

loosen it.

Retightened

bolt

to

a final torque

of

B.

A.:

10m-kg

(72

.5

ft-Ibl

B.

: 6

m-kg

(43.5

ft-Ibl

B.

Starter

The air

duct

is

no

longer provided because

there

will

be no

problem

of

overheating. Ac-

cordingly, the insert for

mounting

of

the

air

duct

on

the

starter case is

no

longer used.

1.

Air

duct

..

. No l

onger

used

2.

Screw

...

No longer used

3. Plain

wash

er

...

No longer used

4.

Starter

case

NOTE:------

------

--------

------

.The

1979

model can also be used

without

installing

the

air

duct

.

19

80

ET250D

- 5 -

1980 ET250D

2.

MAINTENANCE

INTERVALS

[PERIODIC

MAINTENANCE]

Every

Check

point

20

hrs.

or

40

hrs.

or

80

hrs

or

When

Seasonally

400

km

800

km

1600

km

necessary

(2

50

mil

(500

mil

(1000

mil

ENGINE

Tightness

of

bolts

and

nuts

0 0

Bends. cracks and

wear

0 0

Abnormal

noise 0 0

Loose

connection

and breaks

of

fuel and pulse pipes 0 0

Loose

connection

and breaks

of

oil

pipes

0 0

Loose

connection

and breaks

of

oil

delivery

pipe 0 0

Manual

r

ope

starter

system

0 0

Carbu

retor

• Fuel level 0 0

•

Operation

of

starter

jet

0 0

•

Mixing

adjuster

(pilot

screw) 0 0

•

Idling

speed

adjustment

0 0

Operation

and

adjustment

of

oil

pump

0 0

Ignition

timing

0

Cylinder

comp

ressions 0 0

Cylinder

head/exhaust

pipe decarbonize 0

Spark

plug

condition.

gap

and

cleaning

0 0

Tightening

of

the

cylinder

head"

0

DRIVE:

Tightness

of

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

of

drive

track

wheel

sprocket

0 0

Initial

100

km

Drive

track

adjustment

(60

mil

0 0

and

300

km

(200

mil

Breaks in drive

track

0 0

Bends

in

front

and rear axles 0 0

Checking

of

lock

washers

0 0

"-

Drive chain

adjustment

0 0

Drive chain

oil

level 0 0

BODY

Tightness

of

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

of

fuel

tank

0

F,uel

filter

0

Loose

connection

and breaks in fuel

pipe

0 0

Breaks in

oil

tank

0 0

Oil

filter

0

- 6 -

1980 ET250D

Every

Check point

20

hrs.

or

40

hrs.

or

80

hrs

or

When

Seasonally

400

km

800

km

1600

km necessary

(250

mil

(500

mil

(1000

mil

ELECTRICAL:

Wear

, breakage

of

wire

covering 0 0

Breaks in high-tension cord 0 0

Voltage regul

ator

working

voltage 0

Operation

of

engine

stop

switch

0 0

Operation

of

tether

switch

0 0

Headlight

0 0

Taillight 0 0

Brake

light

0 0

••

R

etight

en every

10

hours from the first use.

[LUBRICATION

INTERVALS]

Eve

ry

Lubrication

point

20

hrs, or

40

hrs.

or

80

hrs, or

When

Seasonally Oil/Grease

400

km

8

00

km

1,600

km

necessary

8rand

name

(2

50

mil

(500

mil

(1.000

mil

ENGINE:

Starter

case 0

Oil

pump

contro

l

box

0 0 Aeroshell grease #7A

or

Esso Beacon

325

grease

Pump drive cover 0 0

Oil in the oil

tank

0

YAMALUB

E

2-cycle

oil

DR

I

VE

:

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-

3"

replacement

0

SAE#750r

#

80

BODY:

Steering

column

lower

0 0 Light all-purpose grease

bearing

Steering colu

mn

upper

0 0

Motor

oil

bearing

Steering links 0 0

Ski

column

0 0

Ski

wear

plate 0 Light all-purpose grease

0

Ski

retaining

pin 0 0

Brake

wire

end

stopper

0 0 Esso

8eacon

325

grease

and brake lever

-7

-

1980

ET250D

3.

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

01

Dimension:

Overall l

engt

h 2.

385

mm

(93.9

in)

Overall

width

(std)

905

mm

(35.6

in)

Overall

height

(w

/

windshield)

965

mm

(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

73

X

59

mm

(2.87

X 2.3 in)

Effective

compression

ratio

6.6:

1

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

mm

(0.02

in)

Cylinder:

Material

Cast iron sleeves alu

minum

cylinder

Bore size

73

mm

(2.87

in)

Taper

limit

0.05

mm

(0.0020

in)

Out

of

round

limit

0.01

mm

(0.0004

in)

Piston:

Piston

skirt

clearance

0.045

~

0.050

mm

(0.00

18

~

0.

0020

in)

(Measuring

point)

(10

mm

from

pis

ton

skirt end)

Piston

over

size 1st

73

.

25

mm

(2.88

in)

2nd

73.50

mm

(2.89

in)

3rd

73.75

mm

(2

.90

in)

4th

74.00

mm

(2.91 in)

Piston pin outside

diameter

X length

18

X

55

mm

(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

mm

(0.012

~

0.020

in)

Ring end gap (Installed) (2nd)

0.3

~

0.5

mm

(0.012

~

0.020

in)

Small end bearing:

Type Needle bearing

Big end bearing:

Type Needle bearing

Crankshaft:

Crankshaft assembly

width

(A)

+0

+0.

56

_

0.05

mm

(2.2 _

0.002

In)

Crankshaft

deflection

(D)

0.02

mm

(0.

0008

in)

-

8-

1980

ET250D

Connecting

rod large

end

side

clearance

(C)

0.5

mm

(0.02

in)

Connecting

rod

small

end

def

l

ection

(S) 2

mm

(0

.

079

in)

A

r-----

D -

rrD~

cj~

40

mm

116

in)

40

mm

11.6 in)

I -S

Crank pin

outside

diameter

X

length

24

X

55

mm

(0

.

945

X

2.165

in)

Crank pin

type

Solid

shaft

Crank

bearing

type

(Left) X

q'ty

* #

6306

C3 special

treatment

x 1 pc.

Crank

bearin

g

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

8

Slow

adjusting

screw

(Air

screw)

(

SA

)

2.0

turns

out

Slow

jet

(SJ.)

#

50

Intermediate

jet

(I.J.) #

38

St

arter

jet (St.J.)

0.95

mm

(004

in)

Fuel level

(F.

L.) +5 ± 3.5

mm

(0.20

±

0.14

in)

Idling

engine

speed

1,300

r/

min

Main

jet

setting

chart:

~

-30°C

-

20

°C -

10

°C O°C

10

°C

20

°C

Altitud~

.

1-

22

°F)

1-

4°

F)

114°

F)

132°

F)

150°

F)

168°

F)

#138

Sea

level .

#130

!

-

600m

12000 It)

#138

.

#1

30

;

-

1200m

(4000

It)

#138

.

#130

-

1800m

16000

It) - #

138-

-#125--

#130

#1

30

-

2400m

1

8000

It)

#12

5 -

#

125

-

3000m

110000

It)

or more . #

120

-

-Change

the

Slow jet to

#45

Change

the

slow adjusting

screw

to

1-1/4

- 1

-1

/ 2 turns out.

Lubrication:

Autolube

pump

-

Color

code

Green

Autolube

pump

-

Minimum

stroke

0.

20

~

0.25

mm

(0.008

~

0.01

in)

Autolube

pump

-

Maximum

stroke

1

.85

~

205

mm

(0.073

~

0.081

in)

Autolube

pump

-

Reduction

ratio

1/

40

Autolube

pump

-

Output

Min.

1

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

.9

oz/h/6,500

r/min)

Oil

tank

capacity

2.2

liter

(2.3 U.S.

qt)

Oil

grade

YAMALUBE

2-cycle

oil

- 9 -

1980

ET250D

Drive and track suspension

Transmission:

Type

Drive ratio

Engagement

rpm

Primary spring Part No.

Primary spring Color code

Secondary spring Part No.

Secondary spring

Color

code

Secondary spring pre-load (Twist)

Sheave distance

Sheave

off

-set

V-belt

width

and

outer

line

length

V-belt

wear

limit

Track suspension:

Type

Damper

type

Slide runner

wear

limit

Track

width

Track

deflection

Length on

ground

Wheel

sprocket

material and

number

of

teeth

Secondary drive:

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

Chassis

Frame:

Frame design and 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 (Steering

column)

Right

Lock

to

lock

angle (Steering

column)

Left

Lock

to

lock angle (Ski)

Right

Lock

to

lock

angle (Ski) Left

Front suspension:

Type

Damper

type

Fuel tank:

Capacity

Fuel grade

V-belt

automatic

centrifugal

engagement

3.5:

1

~

1 : 1

*

3.400

r/ min

*

90501-55559

* Blue

90508

-

40080

Not

painted

160

°

*

266

± 2

mm

(10.47

±

0.08

in)

11

± 1

mm

(0.43

±

0.04

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

10

mm

(0.4

in)

381

mm

(15

in)

25

~

30

mm/l

0 kg

(098

~

1.18

in/

22

Ib)

650

mm

(25

.6 in)

* Polyethylene

11

T

Chain

(#40K-1)

22

/

13

(1692)

12

.7

mm

(0.5 in) X

60

pcs.

1

0

~

mm

(0.4

~

~08

in)

450

cc (15.21 oz)

Gear oil API

"GL

-

3"

SAE

#75

or

#80

Disc brake

7.3

mm

(029

in)

1

mm

(0.04

in)

0.2

~

1.0

mm

(0008

~

0.039

in)

Aluminum

and steel

25

°

0°

980

x

120

x 1.6

mm

(38.6

x 4.7 x

0.06

in)

750

mm

(38.6

in)

o

~

6

mm

(024

in)

Tie-rod

55

°

15

'

55

°

15'

Right hand ski

24.9

°, Left hand ski

27

.6°

Right hand ski

27

.6°, L

eft

hand ski

24

.9°

Leaf spring X 3

Oil

damper

18

Liter (4.8 US gal)

Regular gasoline

-

10-

19S0

ET250D

Electrical

Ignition

system:

Type-flywheel

magneto

(C.D.I. Type)

MOdel/manufacturer

F3T355/MITSUBISHI

Voltage

lZV

Pulser coil

re

sistance

9.0n

at

20

°C

(68

°

F)

(White/Red-Black)

Charging coil resistance

350n

at

20

°C (6S0

F)

(Brown

-Black)

15

.

0n

at

20

°C

(68

°

F)

(Blue-Black)

Ignition

timing:

B.T.D.C. 1.2 ± 0.1

mm

(0.05

±

0.004

in)

Ignition

coil:

Model

:

Manuf

acturer

F6T411/MITSUBISHI

Spark gap 9

mm

(0.35

in)/300

r/

min

11

mm

(0.43

in)/3,000

r/min

Primary

winding

resistance

1.0n

at

20

°C

(68

°

F)

Secondary

winding

resistance 5.

9kn

at

20

°C (6S 0

F)

Diode (Yes or No) No

Spark plug:

Type and

quantity

NGK

B-SHS X 1 pc.

Spark plug gap

0.5

~

0.6

mm

(0.020

~

0.024

in)

Spark plug cap:

Type Rubber type

with

noise suppressor

Noise suppressor resistance 5 kn

at

20

°C

(68

°

F)

C.D.I. unit:

Model/manufacturer

8H4

-

20/MITSUBISHI

Lighting system:

Lighting

output

12V-l00W

Lighting coil resistance

0.19n

at

20

°C

(68

°

F)

(Yellow-Black)

Head

light

type Semi shield

Bulb

wattage/q'ty

12V-60/60W

X 1 pc.

Tail/brake

light

wattage

12V

-

8W/23W

A.C. regulator:

Model/manufactu

rer TRIZ-

24B

HITACHI

Voltage

13

.S ±

0.5V

Tightening

torque

Part

to

be

tightened

Thread size Tightening torque Remarks

[Engine]

Spark plug

M14Pl.25

2.S

m-kg

(20

ft-Ib)

Cylinder head

MS

Pl.25

First:

2.0

m-

kg

(14

.5

ft

-Ib)

Final:

2.5

m-kg

(18

ft

-Ib)

Flywheel

magneto

M16

Pl.0

7.3

m-kg

(53

ft

-Ib)

Fand and

flywheel

magneto

M6

Pl

.0

1.0

m-kg

(7

ft

-Ib) Use LOCK-TITE

Pully and

flywheel

magneto

M8

Pl.25

1.6 m-kg

(11.5

ft-Ib)

Flywheel base

M6

Pl

.0 0.7

m-kg

(5 ft-Ib)

-11-

1980 ET250D

Part

to

be

tightened

Crankcase left and right

Tightening sequence

1

Crankcase and engine bracket

Cylinder and ring

nut

Pump drive cover and crankcase

Starter

case and crankcase

Cylinder head and air shroud

Crankcase and air shroud

Air

shroud 1 and 2

Pump drive cover 1 and 2

Silencer 1 and 2

Startercase and

duct

[Drive

and

track

suspension

)

* Primary sliding sheave and cap

* Installation

of

primary

sheave

Chaincase housing and frame

Front axle housing and frame

Front axle

(R

.H.)

Chain drive sprocket

Chain driven sprocket

Housing cap

Chain tensioner adjusting lock

nut

Sprocket

whee

l and

front

axle

Shaft 1 and frame

.Pivot arm 1 and sliding frame 1

Suspension

wheel

Spring

hook

Sliding frame 1

Rear guide

wheel

Sliding runner 1

Sliding runner 2

Stopper

[Chassis]

Engine

mounting

bolt

(nut)

Ski runner

Steering

column

and gate

Steering relay rod adjusting

nut

Universal

joint

Outside arm and ski

column

Steering relay ass'y

Steering

lower

bracket

Steering

column

1 and 2

Steering gate

Thread size

M6

P1.0

M10P1.25

M8

P1.25

M8

P1.25

M6

P1

.0

M6

P1.0

M6

P1.0

M6

P1

.0

M6

P1.0

M6

P1.0

M5

P.0.8

M5

PO.8

M6

P1.0

UNF 1/

2"

M8

P1.25

M8

P1.25

M20

P1.0

M12P1.25

M8

P1.25

M8

P1.25

M10P1.25

M12

P1.25

M8

P1.25

M8

P1.25

M8

P1.25

M6

P1.0

M6

P1.0

M6

P1.0

M10P1

.

25

M8

P1.25

M8

P1

.

25

M10P1.25

M8

P1.25

M8

P1.25

M8

P1.25

-12-

Tightening torque

0.7

m-kg

(5

ft

-Ib)

3.0

m-kg

(22

ft-Ib)

2.3

m-kg

(16.5

ft

-Ib)

2.3 m-kg

(16.5

ft-Ib)

1.0

m-kg (7

ft

-Ib)

1.0

m-kg

(7

ft

-Ib)

0.7

m-kg (5 ft-Ib)

0.7

m-kg (5 ft-Ib)

0.7 m-kg (5

ft

-Ib)

0.7

m-kg

(5 ft-Ib)

0.5

m-kg (3.5 ft-Ib)

0.5

m-kg

(3.5

ft-Ib)

1.1

m-

kg

(8

ft

-Ib)

Initial:

10m-kg

(72.5

ft

-I

b)

Loosen once and retighten:

6.0

m-kg

(43

.5 ft-Ib)

2.5

m-kg

(18

ft

-Ib)

2.5

m-kg

(18

ft

-Ib)

8.0 m-kg

(58

ft

-Ib)

4.0

m-kg

(29

ft

-Ib)

2.5

m-kg

(18

ft-Ib)

1.5 m-kg (11

ft-

I

b)

3.3

m-kg

(24

ft-Ib)

0.5

m-kg (3.5

ft

-Ib)

5.5 m-kg

(40

ft-Ib)

4.0

m-kg

(29

ft-Ib)

8.0

m-kg

(58

ft-Ib)

2.5

m-kg

(18

ft

-Ib)

2.5

m-kg

(18

ft-Ib)

2.5

m-kg

(18

ft-Ib)

0.25

m-kg

(2

ft

-Ib)

0.6

m-kg (4.5 ft-Ib)

0.4

m-kg

(3

ft

-Ib)

3.0 m-kg

(22

ft

-Ib)

1.4

m-kg

(10

ft

-Ib)

2.0

m-kg

(14.5

ft

-Ib)

3.0 m-kg

(22

ft-Ib)

3.0

m-kg

(22

ft-Ib)

3.0

m-kg

(22

ft-Ib)

3.0 m-kg

(22

ft-Ib)

2.0

m-kg

(14.5

ft

-Ib)

1.4

m-kg

(10

ft

-Ib)

1.4

m-kg

(10

ft-Ib)

Remarks

Use LOCK-TITE

Use

motor

oil

Use

cotter

Use LOCK-TITE

4.

(

l-a_

l -

b_

l-c.

r

2-a.

(

( 2-c.

r No.

1-a

1-b

1-c

2-a

2-b

2-c

2-d

2-e

3

4

5-a

5-b

SPECIAL

TOOLS

(For

1980

ET250D)

2-d_

2-e.

3.

4.

5-b.

Description

Dial gauge

Dial gauge stand

No.2

Needle

(56

mm)

Flywheel puller

bolt

Flywheel puller

attachment

Flywheel puller

screw

Drive handle

Flywheel puller

body

crankcase separating tool

Spacer

(<1>80

X

55

mm)

Crank installer

bolt

Crank installer

bolt

adaptor

(M16)

(for Right)

1980 ET250D

5-c.

6. 12.

7.

13.

-

--'"

14.

9.

Tool No. No. Description Tool No.

90890-03097

90890-01195

5-c Crank installer

bolt

adaptor

90890-01279

(M 12) (for Left)

90890-03098

5-d Crank installer

pot

90890-01274

90890-01803

6 Rotor holding

tool

90890-01235

90890-01804

7 Sheave holder

90890-01880

90890

-

01806

8 Primary fixed sheave puller

(M18)

90890-01881

90890

-

01817

9 Sheave sub-assembly tool

90890-01879

90890-01848

10

Bushing tool

90890-01877

90890

-

01135

11

Sheave gauge

90890-01875

90890

-

01818

12

Main

switch

ring

nut

tool

90890-01857

90890-01275

13

Pocket tester

90890

-

03104

14

Electro tester

90890-03021

90890

-

01280

15

A.C. Regulator checker

90890-03090

-13-

-"

~

I

Main

switch

Tailli

ght/b

rake light

(12V

8!23W)

Head light

(h

(12V60

!60

W)

~

L

~

GI

11111

l

III

,I

G~'

I I)

~~

Brake light switch

: GI yI

Gyi

~

I L

Y

G"

I I I I I01

il

I

1

To""

.wi"h

L

B/W

I ", B

w

o

Igniti

on

co

il

Eo,

i"

"'"'

.w

i

"h

D=rn

:G

y

Gy

o L L

~

Gy

0 :

--l

r

COl

magneto

CO

l un

it

Color Code

G ................Green

B ................Black

q

,

_J

Beam

sw

itch Y .

....

...........

Yeliow

L . .

.........

Blue

o

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

Orange

~

Gy ..............Gray

Voltage regulator Br ..............Brown

B! W ..........Black/White

W! R ..........White/

Red

U1

~

:l'J

-

2

G)

C

-

»

G)

:l'J

»

S

<.0

co

o

m

--l

N

(J1

o

6.

Wire

routing

diagram

r

c

1. Ground

to

body

10.

2. To

ignition

coil 11.

3. To C.D.I.

magneto

12.

4. To oil

pump

13.

5. To oil

tank

14.

6.

Clamp

lead

wire

with

oil pipe

7.

C.D.I.

unit

15.

8. Put lead

wire

into

connector

after

connecting

16.

9.

Taillight

lead

wire

17.

o

A

B

Ground lead

wire

18.

To C.D.

I.

magneto

19.

To

headlight

20

.

Instrument

panel

grommet

Hook

band 21

(Tighten

hook

with

coupler

holder) 22.

Main

switch

lead

wire

Tether

switch

lead

wire

Engine

stop

switch

lead

wire

-

15-

/

I

\

....

Headlight

beam

switch

lead

wire

Brake

light

switch

lead

wire

Clamp

1980 ET250D

,

I

(Tighten

clamp

with

silencer bracket)

Engine cover

Pass

through

inside

of

gate

bracket.

1980 ET25

0D

Piping and control cable diagram

®

(j)

---

-~

@

®

@

®~

----

-

-tH~;.\.l

Fuel cock lever

2. Fuel level hose

3. To vertical

position

(To indicate

fuellevell

4.

To

instrument

panel

5.

Fuel

cock

assembly

6.

Fuel pipe

7. The pipe

protector

(coil spring)

must

be

so

positioned

that

its

bot-

tom

end overlaps (at lease one

turn

of

the

winding)

the

end

of

fuel

filter

nozzle and

that

its

smaller

end

diameter

end faces

upward.

8. Clip

9. the pipe

protector

(coil spring)

must

be so

positioned

that

its

both

end overlap (at least one

turn

or

the

winding)

the

nozzle

of

the carbure-

tor

and fuel

cock

nozzle.

10. Clip

-16-

11.

To oil

pump

12. Clip

13. Oil

filter

14.

Clip

15. Pipe

protector

must

be

touched

fuel tank

clamp

16.

Clip

17. Route

the

decompressor

wire

so

it

is

as

much

straight

as possible.

18. To fuel

cock

19.

Starter

wire

20. Fuel cock

wire

21. Clip

22. Decompressor

wire

23.

Throttle

wire

24. Clip

25. Brake

wire

26. To brake caliper

27.

To brake lever

28.

To

throttle

lever

Yamaha ET250D Manual

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