YAMAHA BR250TY 2009 PARTS CATALOGUE 09

0 (0)

BR250TY

(8BDH) CANADA

(8BDJ) RUS,JAPAN

1H8BD-100E1

( )

BR250TY

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in Japan.

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

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.

6. The asterisk (*) before a reference number indicates modified items after the first edition.

FOREWORD

7. Applicable Serial No.			10. Applicable Starting Serial No.
	Engine Serial No.	Frame Serial No.		Frame Serial No.

				Serial No.	Name Of Q’ty Column	Model Code
				Serial No.	Name Of Q’ty Column	Model Code

				JYE8BD0099A044343	CAN	8BDH

				JYE8BD0099A044343	RUS	8BDJ

				JYE8BD0099A044343	JPN	8BDJ

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation	Colour Name	Colour Code

DCM2(*)	DARK CYAN METALLIC 2	0337

9. Quantity Column Information

Column No.	Name Of Q’ty Column	Destination

1	CAN	CANADA

2	RUS	RUS

3	JPN	JAPAN

	ENGINE
CYLINDER ............................................................................	1
CRANKSHAFT & PISTON	.................................................... 2
AIR SHROUD & FAN ............................................................	3
OIL PUMP .............................................................................	4
PUMP DRIVE GEAR .............................................................	5
INTAKE .................................................................................	6
CARBURETOR .....................................................................	8
EXHAUST .............................................................................	10
CRANKCASE ........................................................................	11
STARTER ..............................................................................	12
	DRIVE
PRIMARY SHEAVE ..............................................................	13
SECONDARY SHEAVE ........................................................	14
	BODY
ENGINE BRACKET ...............................................................	15
OIL TANK ..............................................................................	16
FRAME ..................................................................................	17
SKI .........................................................................................	19
STEERING ............................................................................	21
STEERING GATE .................................................................	22
FUEL TANK ...........................................................................	23
FUEL TANK 2 ........................................................................	24
FUEL TANK 3 ........................................................................	25
FUEL TANK 4 ........................................................................	26
SEAT .....................................................................................	28
BRAKE ..................................................................................	29
CONTROL CABLE ................................................................	30
TRACK SUSPENSION 1 .......................................................	31
TRACK SUSPENSION 2 .......................................................	33
TRACK DRIVE 1 ...................................................................	36
TRACK DRIVE 2 ...................................................................	37
EMBLEM ...............................................................................	39
SHROUD & WINDSHIELD	.................................................... 40
GUARD & LUGGAGE BOX	................................................... 42
BUMPER ...............................................................................	43
INSTRUMENT PANEL ..........................................................	45
	ELECTRICAL
GENERATOR ........................................................................	46

CONTENTS
METER .................................................................................	47
HEADLIGHT .........................................................................	48
TAILLIGHT ............................................................................	49
HANDLE SWITCH & LEVER ................................................	50
ELECTRICAL 1 .....................................................................	51
ELECTRICAL 2 .....................................................................	52
ALTERNATE REAR VIEW MIRROR ....................................	53
ALTERNATE THUMB WARMER KIT ...................................	54
ALTERNATE REBUILD KIT ..................................................	55
ALTERNATE CLUTCH TUNE UP KIT ..................................	56
INDEX
NUMERICAL INDEX .............................................................	57

FIG.

1 CYLINDER

REF.

PART NO.

DESCRIPTION

CAN

RUS

JPN

REMARKS

NO.

94702–00195

PLUG, SPARK (NGK BR8HS)

94709–00195

PLUG, SPARK (NGK BR8HS)

8R4–11311–02

CYLINDER 1

8R4–11351–04

GASKET, CYLINDER

95827–08035

BOLT, FLANGE

FIG. 2 CRANKSHAFT & PISTON

REF.		PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS
NO.		PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS

1	8R4–11631–00–96		PISTON (STD)		1	1		1
	8R4–11635–00		PISTON (0.25MM O/S)		1	1		1		AP
	8R4–11636–00		PISTON (0.50MM O/S)		1	1		1		AP
2	8R4–11610–00		PISTON RING SET (STD)		1	1		1
	8R4–11610–10		PISTON RING SET (0.25MM O/S)		1	1		1		AP

	8R4–11610–20		PISTON RING SET (0.50MM O/S)		1	1		1		AP
3	818–11633–00		PIN, PISTON		1	1		1
4	93450–20026		CIRCLIP		2	2		2
5	93310–218A6		BEARING		1	1		1
6	8R4–11400–00		CRANKSHAFT ASSY		1	1		1

7	8R4–11412–00		.CRANK 1		1	1		1
8	8R4–11422–00		.CRANK 2		1	1		1
9	8F3–11681–00		.PIN, CRANK 1		1	1		1
10	90209–24183		.WASHER		2	2		2
11	93310–424E8		.BEARING		1	1		1

12	8R4–11651–00		.ROD, CONNECTING		1	1		1
13	93306–30623		BEARING		1	1		1
14	93102–30326		OIL SEAL		1	1		1
15	8R4–13178–00		GEAR, PUMP DRIVE		1	1		1
16	93306–30555		BEARING		1	1		1

17	93102–25183		OIL SEAL		1	1		1
18	90280–05013		KEY, WOODRUFF		1	1		1
19	90170–16425		NUT		1	1		1
20	92907–16100		WASHER		1	1		1

FIG. 3 AIR SHROUD & FAN

REF.		PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.		PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–12651–03		AIR SHROUD, CYLINDER 1		1	1		1
2	8R4–12652–02		AIR SHROUD, CYLINDER 2		1	1		1
3	98507–05020		SCREW, PAN HEAD		3	3		3
4	92907–05600		WASHER, PLATE		3	3		3
5	98507–05030		SCREW, PAN HEAD		1	1		1

6	92907–05100		WASHER, SPRING		1	1		1
7	92907–05600		WASHER, PLATE		1	1		1
8	95707–05300		NUT, FLANGE		4	4		4
9	90119–06108		BOLT, WITH WASHER		2	2		2
10	8G8–12611–01		FAN		1	1		1

11	90105–06556		BOLT, FLANGE		6	6		6
12	90387–066K1		COLLAR		1	1		1
13	90465–10313		CLAMP		1	1		1

FIG.		4 OIL PUMP

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS

1	81E–13101–01			OIL PUMP ASSY		1	1		1
2	90338–21075			.PLUG		1	1		1
3	93505–32002			.BALL		1	1		1
4	90501–02217			.SPRING, COMPRESSION		1	1		1
5	90446–08201			.HOSE		1	1		1

6	353–13552–01			.NOZZLE		1	1		1
7	90468–02025			.CLIP		1	1		1
8	90430–04004			.GASKET		1	1		1
9	98907–04008			.SCREW, BIND		1	1		1
10	137–13138–01			.PLATE, ADJUSTING		1	1		1

11	137–13137–00–03			.SHIM (T=0.3)		1	1		1		UR UN
	137–13137–00–05			.SHIM (T=0.5)		1	1		1		UR UN
	137–13137–00–10			.SHIM(T=0.1MM)		1	1		1		UR UN
12	92907–05100			.WASHER, SPRING		1	1		1
13	95307–05600			.NUT		1	1		1

14	8A5–13146–01			COVER,ADJUST PULLEY		1	1		1
15	98507–04018			SCREW, PAN HEAD		3	3		3
16	81E–26320–00			PUMP CABLE ASSY		1	1		1
17	8Y0–13116–01			GASKET, PUMP CASE		1	1		1
18	98507–05016			SCREW, PAN HEAD		2	2		2

19	92907–05100			WASHER, SPRING		2	2		2
20	90468–02025			CLIP		1	1		1

FIG. 5 PUMP DRIVE GEAR

REF.		PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.		PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–15416–00		COVER, OIL PUMP		1	1		1
2	8R4–15426–00		COVER, OIL PUMP 2		1	1		1
3	90387–082N1		.COLLAR		2	2		2
4	90387–062N2		.COLLAR		2	2		2
5	93101–10001		OIL SEAL		1	1		1

6	821–13176–00		METAL, WORM SHAFT OUTER		1	1		1
7	8R4–13175–00		SHAFT, WORM		1	1		1
8	8R4–13188–00		GEAR, DRIVE (59T)		1	1		1
9	137–13148–00		PLATE, CAM THRUST		1	1		1
10	90206–11016		WASHER, WAVE		1	1		1

11	90201–08624		WASHER, PLATE		1	1		1
12	99009–10400		CIRCLIP		1	1		1
13	93603–22028		PIN, DOWEL		1	1		1
14	93104–29072		OIL SEAL		1	1		1
15	98507–06020		SCREW, PAN HEAD		2	2		2

16	92907–06100		WASHER, SPRING		2	2		2
17	92907–06600		WASHER, PLATE		2	2		2
18	91808–22019		PIN, DOWEL		2	2		2
19	95827–06030		BOLT, FLANGE		2	2		2
20	95827–06025		BOLT, FLANGE		2	2		2

FIG.		6 INTAKE

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–13555–00			MANIFOLD, INTAKE		1	1		1
2	90460–64066			CLAMP, HOSE		1	1		1
3	90460–51059			CLAMP, HOSE		1	1		1
4	8R4–14453–00			JOINT, AIR CLEANER 1		1	1		1
5	90506–06261			SPRING, TENSION		1	1		1

6	90506–06262			SPRING, TENSION		1	1		1
7	90445–11046			HOSE		1
	90445–115K4			HOSE (L450)			1		1
8	90467–11032			CLIP		2	2		2
9	8BD–14298–00			PIPE		1

	90445–116G8			HOSE (L135)			1		1
10	90467–11009			CLIP		1	1		1
11	90467–11032			CLIP		1	1		1
12	8R4–14431–00			SILENCER, INTAKE 1		1	1		1
13	8R4–14441–01			SILENCER, INTAKE 2		1	1		1

14	98507–05025			SCREW, PAN HEAD		1	1		1
15	92907–05600			WASHER, PLATE		1	1		1
16	95707–05300			NUT, FLANGE		1	1		1
17	97707–60510			SCREW, TAPPING		1	1		1
18	90119–05071			BOLT, WITH WASHER		4	4		4

19	8J5–26352–00			BOOT		1	1		1
20	8A5–24410–02			FUEL PUMP ASSY		1	1		1
21	95707–06500			NUT, FLANGE		2	2		2
22	90201–06727			WASHER, PLATE		2	2		2
23	8X8–24360–01			PRIMER PUMP ASSY		1	1

24	90445–08031			HOSE		1
	90445–083K9			HOSE (L280)			1

FIG.		6 INTAKE

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

25	90445–08032			HOSE		1
	90445–084K0			HOSE (L360)			1
26	90467–07055			CLIP		2	2
27	90468–02025			CLIP		2	2
28	815–24379–00			PIPE, JOINT 4		1	1

29	8BD–14294–00			HOSE		1
	90445–114J7			HOSE			1
30	90467–11009			CLIP		2	2
31	90467–11032			CLIP		1	1		1
32	90464–16039			CLAMP		2	1

33	90465–08333			CLAMP		1	1		1

FIG.		7 CARBURETOR

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	80J–14101–03			CARBURETOR ASSY 1		1	1
	80F–14101–03			CARBURETOR ASSY 1					1
2	80F–14131–00			.SPRING, THROTTLE VALVE		1	1		1
3	80F–14121–00			.SCREW, THROTTLE STOP		1	1		1
4	371–14993–60			.PLUNGER, STARTER		1	1		1

5	90501–08443			.SPRING, COMPRESSION		1	1		1
6	8A6–14969–00			.CAP		1	1		1
7	8E7–14161–00			.NUT, CABLE ADJUSTING		1	1		1
8	8A6–14977–00			.SHAFT, STARTER LEVER		1	1		1
9	8G6–14985–01			.FLOAT		1	1		1

10	8E7–14546–00			.VALVE, NEEDLE		1	1
	8E7–14546–01			.VALVE, NEEDLE					1
11	663–14159–00			.CLIP		1	1		1
12	676–14548–00			.PIN, FLOAT ARM		1	1		1
13	8G6–14984–00			.GASKET, FLOAT CHAMBER		1	1		1

14	8G6–14521–00			.SCREW, ADJUST		1	1		1
15	90501–08214			.SPRING, COMPRESSION		1	1		1
16	98502–04040			.SCREW, PAN HEAD		4	4		4
17	92902–04100			.WASHER, SPRING		4	4		4
18	8R4–14994–00			.PIPE		2	2		2

19	8M7–14992–00			.ROD		1	1		1
20	93210–19309			.O-RING		1	1		1
21	98602–04008			.SCREW, OVAL HEAD		1	1		1
22	80F–14146–00			.PLATE		1	1		1
23	80F–14133–00			.SPRING, THROTTLE STOP		1	1		1

24	87S–8259A–01			.SWITCH, CARBURETOR		1	1		1
25	80F–14137–01			.CLIP		1	1		1

FIG.

7 CARBURETOR

REF.

PART NO.

DESCRIPTION

CAN

RUS

JPN

REMARKS

NO.

8G6–14948–18

.JET (#78)

8A6–14516–05

.JET, MAIN (#105)

STD

8A6–14515–98

.JET, MAIN (#98)

8A6–14516–00

.JET, MAIN (#100)

8A6–14516–02

.JET, MAIN (#102)

FIG.		8 EXHAUST

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–14613–01			GASKET, EXHAUST PIPE		1	1		1
2	8R4–14612–01			NUT, RING		1	1		1
3	95827–08020			BOLT, FLANGE		2	2		2
4	888–14633–00			RING		1	1		1
5	80F–14610–10			EXHAUST PIPE ASSY 1		1	1		1

6	90506–20074			SPRING, TENSION		2	2		2
7	90506–16494			SPRING, TENSION		2	2		2

FIG.		9 CRANKCASE

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–15100–01			CRANKCASE ASSY		1	1		1
2	J38–11116–00			JOINT, BREATHER		1	1		1
3	95827–08080			BOLT, FLANGE		4	4		4
4	95827–08030			BOLT, FLANGE		4	4		4
5	90461–06080			CLAMP		1	1		1

FIG.		10 STARTER

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–15710–01			STARTER ASSY		1	1		1
2	8R4–15711–00			.CASE, STARTER		1	1		1
3	8F3–15714–01			.DRUM, SHEAVE		1	1		1
4	8F3–15741–01			.PAWL, DRIVE		1	1		1
5	8F3–15713–01			.SPRING, STARTER		1	1		1

6	8F3–15715–00			.SPRING, FRICTION		1	1		1
7	8F3–15739–01			.WASHER, THRUST		1	1		1
8	8F3–15734–00			.SPRING, RETURN		1	1		1
9	8F3–15716–03			.PLATE, DRIVE		1	1		1
10	92901–06100			.WASHER, SPRING		1	1		1

11	95301–06700			.NUT		1	1		1
12	8F3–15758–00			.GUIDE, ROPE		1	1		1
13	8F3–15751–00			.WIRE, STARTER		1	1		1
14	8G5–15716–00			.COLLAR		1	1		1
15	8G5–15739–00			.WASHER, THRUST		1	1		1

16	8R4–15755–00			.HANDLE, STARTER		1	1		1
17	8R4–15788–01			.HOLDER, HANDLE		1	1		1
18	95807–08016			BOLT, FLANGE		3	3		3
19	97007–06025			BOLT		4	4		4
20	92907–06100			WASHER, SPRING		4	4		4

21	92907–06600			WASHER, PLATE		4	4		4
22	95307–06600			NUT		3	3		3
23	90176–06038			NUT, CROWN		1	1		1
24	8R4–77118–00			STOPPER, SHROUD		1	1		1
25	81L–15723–00			PULLEY, STARTER		1	1		1

26	95807–08012			BOLT, FLANGE		3	3		3

FIG.		11 PRIMARY SHEAVE

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	84J–17611–00			SHEAVE, PRIMARY FIXED		1	1		1
2	8V0–17621–01			SHEAVE, PRIMARY SLIDING		1	1		1
3	8V0–17631–00			CAP		1	1		1
4	8V0–17640–02			SPIDER COMPLETE		1	1		1
5	8V0–17639–00			STOPPER		2	2		2

6	88X–17653–00			SLIDER		3	3		3
7	90387–057W5			COLLAR		3	3		3
8	90387–087W7			COLLAR		3	3		3
9	90202–08205			WASHER, PLATE		6	6		6
10	90201–050P9			WASHER, PLATE		6	6		6

11	97027–05035			BOLT, HEXAGON		3	3		3
12	95617–05100			NUT, U		3	3		3
13	97017–06030			BOLT		6	6		6
14	92907–06600			WASHER, PLATE		6	6		6
15	8V0–17647–00			BOLT (L=156.5MM)		1	1		1

16	90389–28032			BUSH		1	1		1
17	93607–44190			PIN, DOWEL		3	3		3
18	90201–077F5			WASHER, PLATE		6	6		6
19	92907–16100			WASHER		1	1		1
20	90389–40029			BUSH		1	1		1

21	8V8–W176A–00			WEIGHT, WITH BUSH		3	3		3
22	90386–07152			.BUSH		1	1		1
23	90501–554E8			SPRING, COMPRESSION		1	1		1
24	89X–17641–01			V-BELT		1	1		1

FIG.		12 SECONDARY SHEAVE

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN	REMARKS

1	8R4–17660–00			SECONDARY FIXED SHEAVE COMP.		1	1		1
2	8R4–17670–01			SECONDARY SLIDING SHEAVE		1	1		1
3	8R4–17688–00			.SHOE, RAMP		3	3		3
4	8R4–17681–01			SHAFT, SECONDARY		1	1		1
5	8R4–17684–00			SEAT, SECONDARY SPRING		1	1		1

6	93440–25100			CIRCLIP		1	1		1
7	90508–40080			SPRING, TORSION		1	1		1
8	90387–260W3			COLLAR		1	1		1
9	90201–122H1			WASHER, PLATE		1	1		1
10	90185–12061			NUT, SELF-LOCKING		1	1		1

11	90282–05047			KEY, STRAIGHT		1	1		1
12	93306–20582			BEARING		1	1		1
13	8R4–47631–00			HOUSING, BEARING		1	1		1
14	97027–08016			BOLT, HEXAGON		3	3		3
15	92907–08600			WASHER, PLATE		3	3		3

FIG.		13 ENGINE BRACKET

REF.			PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS
NO.			PART NO.		DESCRIPTION	CAN		RUS		JPN		REMARKS

1	8R4–21411–00			BRACKET, ENGINE 1		1	1		1
2	8R4–21485–00			DAMPER, RUBBER 1		1	1		1
3	95807–10014			BOLT, FLANGE		1	1		1
4	90201–10321			WASHER, PLATE		2	2		2
5	8V7–21486–00			DAMPER 2		1	1		1

6	8R4–21488–01			DAMPER		1	1		1
7	95707–08500			NUT, FLANGE		1	1		1
8	92907–08200			WASHER		1	1		1
9	8F3–21486–00			DAMPER 2		1	1		1
10	90179–10279			NUT		1	1		1

11	86A–21419–00			BRACKET, ENGINE 2		1	1		1		AP
12	8F3–21486–00			DAMPER 2		1	1		1		AP
13	95807–10020			BOLT, FLANGE		1	1		1		AP
14	95707–10500			NUT, FLANGE		2	2		2		AP

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