YAMAHA BR250TK PARTS CATALOGUE

BR250TK (8BDC) CANADA,JAPAN
A2
1D8BD-100E1
2D8BD-100E1
()
BR250TK
PARTS CATALOGUE
1st edition, May 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
A3
BR250TK
A4

FOREWORD

This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.
1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News.
2. Abbreviations The following abbreviations are used in this Parts Catalogue.
“UR” Use specified parts number. “UN” Use as many as needed. “AP” Alternate Parts “LM” Locally Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.) “O/S” Over Size
3. The number of components for assembly
• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below.
• The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.
PART NO. DESCRIPTION Q’TY REMARKS
2F5–83310–60 FRONT FLASHER LIGHT ASSY 2
115–83311–60 .BULB (6V–18W) 1
6. The asterisk (*) before a reference number indicates modified items after the first edition.
4. Applicable colours of graphics are represented in the “REMARKS” as shown below.
PART NO. DESCRIPTION Q’TY REMARKS
2N4–24110–00–X5 FUEL TANK COMP. 2 MXR
3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR
5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.
A5
FOREWORD
7. Applicable Serial No.
Engine Serial No. Frame Serial No.
8. Applicable Colour Code (The (*) mark shows Model colour.)
Abbreviation Colour Name Colour Code
DCM2(*) DARK CYAN METALLIC 2 0337
10. Applicable Starting Serial No.
Frame Serial No.
Serial No. Name Of Q’ty Column Model Code
JYE8BD0085A035899 CAN 8BDC
JPN 8BDC
9. Quantity Column Information
Column No. Name Of Q’ty Column Destination
1 CAN CANADA
2JPN JAPAN
A6

ENGINE

CYLINDER ............................................................................B2
CRANKSHAFT & PISTON ....................................................B3
AIR SHROUD & FAN ............................................................B4
OIL PUMP .............................................................................B5
PUMP DRIVE GEAR .............................................................B6
INTAKE .................................................................................B7
CARBURETOR .....................................................................B9
EXHAUST .............................................................................B11
CRANKCASE ........................................................................B12
STARTER ..............................................................................B13

DRIVE

PRIMARY SHEAVE ..............................................................B14
SECONDARY SHEAVE ........................................................ B15

BODY

ENGINE BRACKET ...............................................................C2
OIL TANK ..............................................................................C3
FRAME ..................................................................................C4
SKI .........................................................................................C6
STEERING ............................................................................C8
STEERING GATE ................................................................. C9
FUEL TANK ...........................................................................C10
FUEL TANK 2 ........................................................................C11
SEAT .....................................................................................C13
BRAKE ..................................................................................C14
CONTROL CABLE ................................................................C15
TRACK SUSPENSION 1 ....................................................... D2
TRACK SUSPENSION 2 ....................................................... D4
TRACK DRIVE 1 ...................................................................D7
TRACK DRIVE 2 ...................................................................D8
EMBLEM ...............................................................................D10
SHROUD & WINDSHIELD ....................................................D11
GUARD & LUGGAGE BOX ................................................... D13
BUMPER ...............................................................................D14
INSTRUMENT PANEL ..........................................................E2

ELECTRICAL

GENERATOR ........................................................................E3
METER ..................................................................................E4
HEADLIGHT ..........................................................................E5
CONTENTS
TAILLIGHT ............................................................................ E6
HANDLE SWITCH & LEVER ................................................ E7
ELECTRICAL 1 ..................................................................... E8
ELECTRICAL 2 ..................................................................... E9
ALTERNATE REAR VIEW MIRROR .................................... E10
ALTERNATE THUMB WARMER KIT ................................... E11
ALTERNATE REBUILD KIT .................................................. E12
ALTERNATE CLUTCH TUNE UP KIT .................................. E13
INDEX
NUMERICAL INDEX ............................................................. M1
FIG. 1 CYLINDER
REF. NO.
1
PART NO. DESCRIPTION
94702–00195
PLUG, SPARK (NGK BR8HS) 1
CAN
JPN
REMARKS
94709–00195
2
8R4–11311–02
3
8R4–11351–04
4
95827–08035
PLUG, SPARK (NGK BR8HS) 1
CYLINDER 1 1 1
GASKET, CYLINDER 1 1
BOLT, FLANGE 4 4
B
2
FIG. 2 CRANKSHAFT & PISTON
REF. NO.
1
PART NO. DESCRIPTION
8R4–11631–00–96
PISTON (STD) 1 1
CAN
JPN
REMARKS
8R4–11635–00
8R4–11636–00
2
8R4–11610–00
8R4–11610–10
8R4–11610–20
3
818–11633–00
4
93450–20026
5
93310–218A6
6
8R4–11400–00
7
8R4–11412–00
8
8R4–11422–00
9
8F3–11681–00
10
90209–24183
11
93310–424E8
12
8R4–11651–00
13
93306–30623
14
93102–30326
PISTON (0.25MM O/S) 1 1 AP
PISTON (0.50MM O/S) 1 1 AP
PISTON RING SET (STD) 1 1
PISTON RING SET (0.25MM O/S) 1 1 AP
PISTON RING SET (0.50MM O/S) 1 1 AP
PIN, PISTON 1 1
CIRCLIP 2 2
BEARING 1 1
CRANKSHAFT ASSY 1 1
.CRANK 1 1 1
.CRANK 2 1 1
.PIN, CRANK 1 1 1
.WASHER 2 2
.BEARING 1 1
.ROD, CONNECTING 1 1
BEARING 1 1
OIL SEAL 1 1
B
3
15
8R4–13178–00
16
93306–30555
17
93102–25183
18
90280–05013
19
90170–16425
20
92907–16100
GEAR, PUMP DRIVE 1 1
BEARING 1 1
OIL SEAL 1 1
KEY, WOODRUFF 1 1
NUT 1 1
WASHER 1 1
FIG. 3 AIR SHROUD & FAN
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
PART NO. DESCRIPTION
8R4–12651–03
8R4–12652–02
98507–05020
92907–05600
98507–05030
92907–05100
92907–05600
95707–05300
90119–06108
8G8–12611–01
90105–06556
90387–066K1
90465–10313
AIR SHROUD, CYLINDER 1 1 1
AIR SHROUD, CYLINDER 2 1 1
SCREW, PAN HEAD 3 3
WASHER, PLATE 3 3
SCREW, PAN HEAD 1 1
WASHER, SPRING 1 1
WASHER, PLATE 1 1
NUT, FLANGE 4 4
BOLT, WITH WASHER 2 2
FAN 1 1
BOLT, FLANGE 6 6
COLLAR 1 1
CLAMP 1 1
CAN
JPN
REMARKS
B
4
FIG. 4 OIL PUMP
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
PART NO. DESCRIPTION
81E–13101–01
90338–21075
93505–32002
90501–02217
90446–08201
353–13552–01
90468–02025
90430–04004
98907–04008
137–13138–01
137–13137–00–03
OIL PUMP ASSY 1 1
.PLUG 1 1
.BALL 1 1
.SPRING, COMPRESSION 1 1
.HOSE 1 1
.NOZZLE 1 1
.CLIP 1 1
.GASKET 1 1
.SCREW, BIND 1 1
.PLATE, ADJUSTING 1 1
.SHIM (T=0.3) 1 1 UR UN
CAN
JPN
REMARKS
137–13137–00–05
137–13137–00–10
12
92907–05100
13
95307–05600
14
8A5–13146–01
15
98507–04018
16
81E–26320–00
17
8Y0–13116–01
18
98507–05016
19
92907–05100
20
90468–02025
.SHIM (T=0.5) 1 1 UR UN
.SHIM (T=1.0) 1 1 UR UN
.WASHER, SPRING 1 1
.NUT 1 1
COVER,ADJUST PULLEY 1 1
SCREW, PAN HEAD 3 3
PUMP CABLE ASSY 1 1
GASKET, PUMP CASE 1 1
SCREW, PAN HEAD 2 2
WASHER, SPRING 2 2
CLIP 1 1
B
5
FIG. 5 PUMP DRIVE GEAR
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
8R4–15416–00
8R4–15426–00
90387–082N1
90387–062N2
93101–10001
821–13176–00
8R4–13175–00
8R4–13188–00
137–13148–00
90206–11016
90201–08624
99009–10400
93603–22028
93104–29072
98507–06020
COVER, OIL PUMP 1 1
COVER, OIL PUMP 2 1 1
.COLLAR 2 2
.COLLAR 2 2
OIL SEAL 1 1
METAL, WORM SHAFT OUTER 1 1
SHAFT, WORM 1 1
GEAR, DRIVE (59T) 1 1
PLATE, CAM THRUST 1 1
WASHER, WAVE 1 1
WASHER, PLATE 1 1
CIRCLIP 1 1
PIN, DOWEL 1 1
OIL SEAL 1 1
SCREW, PAN HEAD 2 2
CAN
JPN
REMARKS
B
6
16
92907–06100
17
92907–06600
18
91808–22019
19
95827–06030
20
95827–06025
WASHER, SPRING 2 2
WASHER, PLATE 2 2
PIN, DOWEL 2 2
BOLT, FLANGE 2 2
BOLT, FLANGE 2 2
FIG. 6 INTAKE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
8R4–13555–00
90460–64066
90460–51059
8R4–14453–00
90506–06261
90506–06262
90445–115K4
90467–11032
90445–116G8
90467–11009
90467–11032
8R4–14431–00
8R4–14441–01
98507–05025
92907–05600
MANIFOLD, INTAKE 1 1
CLAMP, HOSE 1 1
CLAMP, HOSE 1 1
JOINT, AIR CLEANER 1 1 1
SPRING, TENSION 1 1
SPRING, TENSION 1 1
HOSE (L450) 1 1
CLIP 2 2
HOSE (L135) 1 1
CLIP 1 1
CLIP 1 1
SILENCER, INTAKE 1 1 1
SILENCER, INTAKE 2 1 1
SCREW, PAN HEAD 1 1
WASHER, PLATE 1 1
CAN
JPN
REMARKS
B
7
16
95707–05300
17
97707–60510
18
90119–05071
19
8J5–26352–00
20
8A5–24410–02
21
95707–06500
22
90201–06727
23
8X8–24360–01
24
90445–083K9
25
90445–084K0
26
90467–07055
27
90468–02025
NUT, FLANGE 1 1
SCREW, TAPPING 1 1
BOLT, WITH WASHER 4 4
BOOT 1 1
FUEL PUMP ASSY 1 1
NUT, FLANGE 2 2
WASHER, PLATE 2 2
PRIMER PUMP ASSY 1
HOSE (L280) 1
HOSE (L360) 1
CLIP 2
CLIP 2
FIG. 6 INTAKE
REF. NO.
28
29
30
31
32
33
PART NO. DESCRIPTION
815–24379–00
90445–114J7
90467–11009
90467–11032
90464–16039
90465–08333
PIPE, JOINT 4 1
HOSE 1
CLIP 2
CLIP 1 1
CLAMP 1
CLAMP 1 1
CAN
JPN
REMARKS
B
8
FIG. 7 CARBURETOR
REF. NO.
1
PART NO. DESCRIPTION
80J–14101–01
CARBURETOR ASSY 1 1
CAN
JPN
REMARKS
80F–14101–01
2
80F–14131–00
3
80F–14121–00
4
371–14993–60
5
90501–08443
6
8A6–14969–00
7
8E7–14161–00
8
8A6–14977–00
9
8G6–14985–01
10
8E7–14546–00
11
663–14159–00
12
676–14548–00
13
8G6–14984–00
14
8G6–14521–00
15
90501–08214
16
98502–04040
17
92902–04100
CARBURETOR ASSY 1 1
.SPRING, THROTTLE VALVE 1 1
.SCREW, THROTTLE STOP 1 1
.PLUNGER, STARTER 1 1
.SPRING, COMPRESSION 1 1
.CAP 1 1
.NUT, CABLE ADJUSTING 1 1
.SHAFT, STARTER LEVER 1 1
.FLOAT 1 1
.VALVE, NEEDLE 1 1
.CLIP 1 1
.PIN, FLOAT ARM 1 1
.GASKET, FLOAT CHAMBER 1 1
.SCREW, ADJUST 1 1
.SPRING, COMPRESSION 1 1
.SCREW, PAN HEAD 4 4
.WASHER, SPRING 4 4
B
9
18
8R4–14994–00
19
8M7–14992–00
20
93210–19309
21
98602–04008
22
80F–14146–00
23
80F–14133–00
24
87S–8259A–00
25
80F–14137–00
26
8G6–14948–18
.PIPE 2 2
.ROD 1 1
.O-RING 1 1
.SCREW, OVAL HEAD 1 1
.PLATE 1 1
.SPRING, THROTTLE STOP 1 1
.SWITCH, CARBURETOR 1 1
.CLIP 1 1
.JET (#78) 1 1
FIG. 7 CARBURETOR
REF. NO.
27
PART NO. DESCRIPTION
8A6–14516–05
.JET, MAIN (#105) 1 1 STD
CAN
JPN
REMARKS
8A6–14515–98
8A6–14516–00
8A6–14516–02
.JET, MAIN (#98) 1 1 AP
.JET, MAIN (#100) 1 1 AP
.JET, MAIN (#102) 1 1 AP
B
10
FIG. 8 EXHAUST
REF. NO.
1
2
3
4
5
6
7
PART NO. DESCRIPTION
8R4–14613–01
8R4–14612–00
95827–08020
888–14633–00
80F–14610–00
90506–20074
90506–16494
GASKET, EXHAUST PIPE 1 1
NUT, RING 1 1
BOLT, FLANGE 2 2
RING 1 1
EXHAUST PIPE ASSY 1 1 1
SPRING, TENSION 2 2
SPRING, TENSION 2 2
CAN
JPN
REMARKS
B
11
FIG. 9 CRANKCASE
REF. NO.
1
2
3
4
5
PART NO. DESCRIPTION
8R4–15100–01
J38–11116–00
95827–08080
95827–08030
90461–06080
CRANKCASE ASSY 1 1
JOINT, BREATHER 1 1
BOLT, FLANGE 4 4
BOLT, FLANGE 4 4
CLAMP 1 1
CAN
JPN
REMARKS
B
12
FIG. 10 STARTER
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
8R4–15710–01
8R4–15711–00
8F3–15714–01
8F3–15741–01
8F3–15713–01
8F3–15715–00
8F3–15739–01
8F3–15734–00
8F3–15716–03
92901–06100
95301–06700
8F3–15758–00
8F3–15751–00
8G5–15716–00
8G5–15739–00
STARTER ASSY 1 1
.CASE, STARTER 1 1
.DRUM, SHEAVE 1 1
.PAWL, DRIVE 1 1
.SPRING, STARTER 1 1
.SPRING, FRICTION 1 1
.WASHER, THRUST 1 1
.SPRING, RETURN 1 1
.PLATE, DRIVE 1 1
.WASHER, SPRING 1 1
.NUT 1 1
.GUIDE, ROPE 1 1
.WIRE, STARTER 1 1
.COLLAR 1 1
.WASHER, THRUST 1 1
CAN
JPN
REMARKS
B
13
16
8R4–15755–00
17
8R4–15788–01
18
95807–08016
19
97007–06025
20
92907–06100
21
92907–06600
22
95307–06600
23
90176–06038
24
8R4–77118–00
25
81L–15723–00
26
95807–08012
.HANDLE, STARTER 1 1
.HOLDER, HANDLE 1 1
BOLT, FLANGE 3 3
BOLT 4 4
WASHER, SPRING 4 4
WASHER, PLATE 4 4
NUT 3 3
NUT, CROWN 1 1
STOPPER, SHROUD 1 1
PULLEY, STARTER 1 1
BOLT, FLANGE 3 3
FIG. 11 PRIMARY SHEAVE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
84J–17611–00
8V0–17621–01
8V0–17631–00
8V0–17640–02
8V0–17639–00
88X–17653–00
90387–057W5
90387–087W7
90202–08205
90201–050P9
97027–05035
95617–05100
97017–06030
92907–06600
8V0–17647–00
SHEAVE, PRIMARY FIXED 1 1
SHEAVE, PRIMARY SLIDING 1 1
CAP 1 1
SPIDER COMPLETE 1 1
STOPPER 2 2
SLIDER 3 3
COLLAR 3 3
COLLAR 3 3
WASHER, PLATE 6 6
WASHER, PLATE 6 6
BOLT 3 3
NUT, U 3 3
BOLT 6 6
WASHER, PLATE 6 6
BOLT (L=156.5MM) 1 1
CAN
JPN
REMARKS
B
14
16
90389–28032
17
93607–44190
18
90201–077F5
19
92907–16100
20
90389–40029
21
8V8–W176A–00
22
90386–07152
23
90501–554E8
24
89X–17641–00
BUSH 1 1
PIN, DOWEL 3 3
WASHER, PLATE 6 6
WASHER 1 1
BUSH 1 1
WEIGHT, WITH BUSH 3 3
.BUSH 1 1
SPRING, COMPRESSION 1 1
V-BELT 1 1
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