Yamaha DT250 DT400 Full Service & Repair Manual 1977-1979
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🏷️ Basic Information Identification Make: Yamaha Model: DT250 / DT400 Product Type: Full Service & Repair Workshop Manual Applicable Years: 1977, 1978, 1979 👋 Introduction Market Position Target Audience: Yamaha DT250/DT400 owners, mechanics, enthusiasts Value Proposition: Provides professional-level repair and maintenance information for DIY and professional use. Competitive Analysis Advantage: Comprehensive factory data, lifetime access, no extra fees. Key Features Accuracy: Factory-level accuracy and detail for all procedures. Completeness: Full manual without limitations or trial periods. 📋 Manual Details Coverage Areas General Coverage: All repairs, servicing, and troubleshooting procedures Page Count Estimated Page Count: Hundreds (as stated in description) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English (assumed based on product description) Format Format: Digital (PDF, downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, inspection, repair, assembly, tuning Fuel System: Carburetor service, adjustment, fuel lines, fuel tank Ignition System: CDI system, spark plugs, timing, troubleshooting Transmission: Gearbox disassembly, inspection, repair, clutch service Chassis Suspension: Front forks, rear shock absorbers, swingarm, bearings Brakes: Front and rear brake system service, adjustment, component replacement Electrical System: Wiring diagrams, lighting, charging system, battery, switches Wheels Tires: Wheel bearing service, spoke tension, tire replacement Bodywork Frame: Frame inspection, body panel removal/installation, seating Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication Troubleshooting: Diagnostic procedures for common and uncommon faults Engine Rebuild: Complete engine overhaul procedures Carburetor Tuning: Jetting, float level, idle speed adjustments Clutch Service: Clutch plate replacement, adjustment Suspension Service: Fork seal replacement, fluid changes, shock absorber servicing Electrical Diagnostics: Fault finding using wiring diagrams and test procedures Technical Depth Depth: Comprehensive (covering all repair and servicing) Diagrams: Hundreds of detailed photos and exploded diagrams Instructions: Step-by-step instructions for all procedures 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable (single page or entire manual) Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) Compatibility Operating Systems: Windows and MAC compatible Licensing License Type: Lifetime use, no expiry, no renewal fees Installation: Installable on multiple computers/devices ⚙️ Engine Specifications Primary Engine Type: Two-stroke, piston-ported (typical for DT series) Configuration: Single cylinder Cooling: Air-cooled Displacement Dt250: 247cc (approximate, specific model variations may exist) Displacement Dt400: 397cc (approximate, specific model variations may exist) Performance Horsepower Dt250: Typically around 20-25 HP (varies by year and tune) Horsepower Dt400: Typically around 26-30 HP (varies by year and tune) Fuel System Carburetor Type: Single Mikuni VM series (e.g., VM30 for DT250, VM34 for DT400 - specific sizes may vary) Fuel Type: Unleaded gasoline mixed with two-stroke oil (specific ratio provided in manual) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Type: Constant mesh, 5-speed Features Clutch Type: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Weights Dry Weight Dt250: Approx. 260-280 lbs (118-127 kg) (varies by year) Dry Weight Dt400: Approx. 280-300 lbs (127-136 kg) (varies by year) Wheels Tires Front Wheel Size: Typically 21-inch Rear Wheel Size: Typically 18-inch Front Tire Size: Commonly 3.00-21 or 80/100-21 Rear Tire Size: Commonly 4.00-18 or 110/100-18 🛡️ Safety Features Ratings Safety Certification: Not applicable for this era/type of vehicle documentation Active Features Braking System: Drum brakes front and rear (some later models may have introduced disc brakes, manual will specify) 💡 Technology Features Infotainment Features: Not applicable (pre-digital era motorcycle) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific recommendations based on usage (typically every few hundred to thousand miles) Spark Plug Service: Regular inspection and cleaning/replacement as per manual, critical for two-strokes. Chain Lubrication Adjustment: Frequent checks and lubrication, especially for off-road use. Fluid Specifications Two Stroke Oil: Yamaha branded 2-stroke oil or equivalent high-quality JASO FD certified oil (specific type and ratio in manual) Transmission Oil: Yamalube Gear Oil or equivalent SAE 80W/90 API GL-4 (specific viscosity and capacity in manual) Fork Oil: Yamaha Fork Oil or equivalent SAE 10W (specific type and quantity per leg in manual) Known Issues Common Wear Items: Piston rings, clutch plates, swingarm bushings, crank seals, carburetor jets due to age and fuel variability. Carburetor Fouling: Can be prone to clogging if fuel is not fresh or if bike sits for extended periods. Electrical Corrosion: Wire connectors and grounds can corrode over time, leading to intermittent electrical issues. 📚 Vehicle History Brand Heritage Heritage Focus: Yamaha's extensive history in motorcycle design and performance, particularly in off-road and dual-sport segments. Model Evolution Dt Series Significance: The DT series was a groundbreaking line of dual-sport motorcycles known for their reliability and off-road capability, making them popular for trail riding and commuting. Evolution 77-79: Models from 1977-1979 likely saw refinements in suspension, engine tuning, and chassis components based on earlier DT models. 🏆 Awards & Recognition Recognitions Model Popularity: The DT series was highly popular and influential in its class, often recognized for its...
Diagnostic procedures for common and uncommon faults
Engine Rebuild:
Complete engine overhaul procedures
Carburetor Tuning:
Jetting, float level, idle speed adjustments
Clutch Service:
Clutch plate replacement, adjustment
Suspension Service:
Fork seal replacement, fluid changes, shock absorber servicing
Electrical Diagnostics:
Fault finding using wiring diagrams and test procedures
Technical Depth
Depth:
Comprehensive (covering all repair and servicing)
Diagrams:
Hundreds of detailed photos and exploded diagrams
Instructions:
Step-by-step instructions for all procedures
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable (single page or entire manual)
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
Compatibility
Operating Systems:
Windows and MAC compatible
Licensing
License Type:
Lifetime use, no expiry, no renewal fees
Installation:
Installable on multiple computers/devices
⚙️ Engine Specifications
Primary Engine
Type:
Two-stroke, piston-ported (typical for DT series)
Configuration:
Single cylinder
Cooling:
Air-cooled
Displacement Dt250:
247cc (approximate, specific model variations may exist)
Displacement Dt400:
397cc (approximate, specific model variations may exist)
Performance
Horsepower Dt250:
Typically around 20-25 HP (varies by year and tune)
Horsepower Dt400:
Typically around 26-30 HP (varies by year and tune)
Fuel System
Carburetor Type:
Single Mikuni VM series (e.g., VM30 for DT250, VM34 for DT400 - specific sizes may vary)
Fuel Type:
Unleaded gasoline mixed with two-stroke oil (specific ratio provided in manual)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Type:
Constant mesh, 5-speed
Features
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
📐 Dimensions
Weights
Dry Weight Dt250:
Approx. 260-280 lbs (118-127 kg) (varies by year)
Dry Weight Dt400:
Approx. 280-300 lbs (127-136 kg) (varies by year)
Wheels Tires
Front Wheel Size:
Typically 21-inch
Rear Wheel Size:
Typically 18-inch
Front Tire Size:
Commonly 3.00-21 or 80/100-21
Rear Tire Size:
Commonly 4.00-18 or 110/100-18
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable for this era/type of vehicle documentation
Active Features
Braking System:
Drum brakes front and rear (some later models may have introduced disc brakes, manual will specify)
💡 Technology Features
Infotainment
Features:
Not applicable (pre-digital era motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific recommendations based on usage (typically every few hundred to thousand miles)
Spark Plug Service:
Regular inspection and cleaning/replacement as per manual, critical for two-strokes.
Chain Lubrication Adjustment:
Frequent checks and lubrication, especially for off-road use.
Fluid Specifications
Two Stroke Oil:
Yamaha branded 2-stroke oil or equivalent high-quality JASO FD certified oil (specific type and ratio in manual)
Transmission Oil:
Yamalube Gear Oil or equivalent SAE 80W/90 API GL-4 (specific viscosity and capacity in manual)
Fork Oil:
Yamaha Fork Oil or equivalent SAE 10W (specific type and quantity per leg in manual)
Known Issues
Common Wear Items:
Piston rings, clutch plates, swingarm bushings, crank seals, carburetor jets due to age and fuel variability.
Carburetor Fouling:
Can be prone to clogging if fuel is not fresh or if bike sits for extended periods.
Electrical Corrosion:
Wire connectors and grounds can corrode over time, leading to intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Yamaha's extensive history in motorcycle design and performance, particularly in off-road and dual-sport segments.
Model Evolution
Dt Series Significance:
The DT series was a groundbreaking line of dual-sport motorcycles known for their reliability and off-road capability, making them popular for trail riding and commuting.
Evolution 77-79:
Models from 1977-1979 likely saw refinements in suspension, engine tuning, and chassis components based on earlier DT models.
🏆 Awards & Recognition
Recognitions
Model Popularity:
The DT series was highly popular and influential in its class, often recognized for its durability and off-road prowess.