🏷️ Basic Information Identification Make: Yamaha Model: BR250 Model Variant: BR250 Model Nickname: Yamaha BR250 Production Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 👋 Introduction Market Position Vehicle Segment: Dual-purpose motorcycle, often categorized as a street scrambler or lightweight dual-sport. Competitive Analysis Key Competitors: Honda XR250, Kawasaki KLR250, Suzuki DR250. Key Features Intended Use: Versatile machine capable of on-road commuting and light off-road excursions. Known for its simplicity and ruggedness. Manual Value Proposition: Provides owners and technicians with the essential knowledge and procedures to maintain, repair, and troubleshoot the Yamaha BR250, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive Workshop Service and Repair Page Count Estimated Page Count: 300-500 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and repair procedures for all major components including cylinder head, pistons, crankshaft, camshaft, valves, timing components. Engine Fuel System: Carburetor removal, cleaning, adjustment, and rebuilding; fuel pump inspection and service; fuel line routing and inspection. Engine Lubrication System: Oil pump service, oil filter replacement, oil cooler inspection (if applicable), lubrication points and schedules. Engine Cooling System: Radiator inspection and cleaning, thermostat service, water pump inspection and replacement, coolant specifications and flushing procedures. Ignition System: Spark plug specifications, ignition timing adjustment, coil and wiring inspection, electronic ignition system diagnosis (if applicable). Exhaust System: Muffler and pipe inspection, gasket replacement, hanger and mount checks. Transmission System: Gearbox disassembly and assembly, clutch inspection and adjustment, shift mechanism service, transmission fluid specifications and change intervals. Drivetrain System: Final drive inspection, chain and sprocket maintenance, wheel bearing service. Suspension System: Front fork service (oil change, seal replacement, spring inspection), rear shock absorber inspection and replacement, linkage lubrication. Brake System: Brake pad replacement, caliper inspection and service, master cylinder service, brake fluid specifications and bleeding procedures, drum brake adjustment (if applicable). Wheel And Tire System: Tire pressure recommendations, wheel bearing lubrication and adjustment, spoke tension checks (if applicable). Electrical System: Battery maintenance, charging system (stator, rectifier/regulator) testing and replacement, lighting system checks, starter motor service, wiring diagrams, fuse and relay identification. Frame And Bodywork: Frame inspection for damage, fairing and body panel removal and installation, seat and tank mounting. Steering System: Handlebar removal and installation, steering head bearing adjustment and replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake checks, tire pressure checks, lubrication points. Troubleshooting: Diagnostic charts and procedures for common issues, symptom-based troubleshooting guides. Major Repairs: Complete engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair. Component Disassembly Assembly: Step-by-step instructions for removing, inspecting, servicing, and reinstalling all major vehicle components. Specifications And Tolerances: Precise measurements, clearances, torque values, and tolerances for all critical engine and chassis components. Wiring Diagrams: Detailed electrical schematics illustrating the entire vehicle's wiring harness, component connections, and color coding. Technical Depth Depth Of Coverage: Expert-level, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text for quick information retrieval. Print Quality: High-resolution, suitable for printing individual pages or the entire document. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, Air-cooled Displacement: Approximately 249cc (exact displacement may vary slightly by sub-model or regional specification) Bore X Stroke: Typical: 70.0 mm x 64.0 mm (verify specific model code) Compression Ratio: Typically around 9.5:1 (verify specific model code) Performance Horsepower: Estimated 20-25 HP (at crankshaft, verify specific model code) Torque: Estimated 15-18 lb-ft (at crankshaft, verify specific model code) Fuel System Fuel Delivery: Carburetor Carburetor Model: Likely a Mikuni VM series single carburetor (e.g., VM30, VM32, or similar - verify specific model code) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed manual Clutch Type: Wet, multi-plate Features Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Typically around 2150 mm (verify specific model code) Overall Width: Typically around 850 mm (verify specific model code) Overall Height: Typically around 1180 mm (verify specific model code) Wheelbase: Typically around 1420 mm (verify specific model code) Weights Dry Weight: Approximately 120-130 kg (verify specific model code) Fuel Tank Capacity: Approximately 10-12 Liters (verify specific model code) 🛡️ Safety Features Ratings Safety Standards: Designed to meet Japanese and international motorcycle safety standards of the era. Active Features Braking System: Disc front brake, Drum rear brake (common configuration, verify specific model code for ABS if applicable, though unlikely for this era). Passive Features Lighting: Headlight, taillight, brake light, turn signals. 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance Rider Aids: N/A (No electronic rider aids common for this...