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Yamaha BR250 2008 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: BR250 Year: 2008 Vehicle Type: Motorcycle Codes Chassis Code Prefix: BR250 👋 Introduction Market Position Market Segment: Compact Dual-Sport / Enduro Motorcycle Target...
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
BR250
Year:
2008
Vehicle Type:
Motorcycle
Codes
Chassis Code Prefix:
BR250
👋 Introduction
Market Position
Market Segment:
Compact Dual-Sport / Enduro Motorcycle
Target Audience:
Off-road enthusiasts, trail riders, dual-sport riders seeking a lightweight and capable machine.
Competitive Analysis
Key Competitors:
Honda CRF250X, Kawasaki KLX250S, Suzuki DR-Z250, KTM 250 EXC.
Key Features
Engine Type:
Lightweight, torquey single-cylinder engine designed for versatility.
Suspension:
Robust suspension system capable of handling varied terrain.
Durability:
Yamaha's reputation for building reliable and durable off-road machinery.
Accessibility:
Likely designed for ease of maintenance and repair for the average owner.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Rebuilding, Refurbishing, Restoration
Page Count
Estimated Page Count:
Extensive (typically 500+ pages for a full service manual)
Manual Type
Manual Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, and reassembly of engine components (cylinder head, piston, crankshaft, connecting rods, valves, camshafts).
Engine Fuel System:
Carburetor(s) tuning, cleaning, and rebuilding; fuel pump inspection and testing; fuel filter replacement.
Engine Lubrication:
Oil pump inspection, oil filter replacement, oil change procedures, oil specifications.
Engine Cooling:
Radiator maintenance, coolant specifications, fan operation, thermostat testing (if applicable).
Ignition System:
Spark plug specifications, ignition timing adjustment, coil testing, CDI unit diagnostics.
Transmission Drivetrain:
Clutch operation, inspection, and adjustment; gearbox disassembly and reassembly; chain and sprocket maintenance; gear oil specifications.
Brakes System:
Brake pad replacement, caliper servicing, brake fluid specifications and bleeding procedures, master cylinder inspection.
Suspension Steering:
Front fork disassembly, seal replacement, oil specifications, rear shock absorber inspection and replacement, steering head bearing adjustment.
Electrical System:
Battery maintenance and testing, charging system (stator, regulator/rectifier) troubleshooting, lighting system diagnostics, wiring diagrams.
Body Frame:
Panel removal and installation, seat maintenance, fender replacement, chassis inspection.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire pressure checks.
Troubleshooting Diagnostics:
Systematic approaches to identify and resolve common and uncommon faults, diagnostic charts, symptom-based guides.
Engine Rebuild:
Complete engine overhaul procedures, including bore honing, piston ring installation, valve lapping, gasket replacement.
Carburetor Tuning:
Detailed steps for adjusting idle speed, air/fuel mixture, and jetting for optimal performance.
Suspension Overhaul:
Front fork seal replacement, damping rod adjustments, rear shock absorber rebuilds.
Electrical Component Testing:
Using multimeters to test stators, regulators, ignition coils, and sensors.
Brake System Bleeding:
Proper techniques for purging air from hydraulic brake lines.
Wheel Bearing Replacement:
Steps for removing and installing wheel bearings.
Wiring Diagram Interpretation:
Understanding and using electrical schematics for fault finding.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to complete engine and component rebuilds.
Torque Specifications:
All critical fastener torque values provided for engine, chassis, and suspension components.
Clearances Tolerances:
Precise specifications for piston-to-cylinder wall, ring gap, valve lash, bearing clearances, etc.
Diagnostic Charts:
Flowcharts and tables to aid in diagnosing electrical and mechanical issues.
Special Tool Requirements:
Identification of specific tools needed for certain procedures.
Illustration Diagrams:
Detailed exploded views and diagrams illustrating assembly and disassembly sequences.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, suitable for digital viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, liquid-cooled single cylinder
Displacement:
Approximately 249cc (Exact specification may vary slightly by market or specific sub-model).
Bore X Stroke:
Standard specifications for this class of engine (e.g., 74mm x 58mm common for similar displacements).
Compression Ratio:
Typical for performance-oriented dual-sports (e.g., 10.5:1 to 12.0:1).
Performance
Horsepower:
Estimated 20-25 HP (Power figures are often quoted at the crank and can vary).
Torque:
Designed for tractable low-to-mid range torque for off-road use.
Fuel System
Fuel Delivery:
Carburetor (likely a Mikuni VM or similar).
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Typical for dual-sports, around 2.5-3.5 gallons.
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet, multi-plate
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific ratios detailed in the manual.
Transmission Fluid Type:
Yamaha Genuine Gear Oil or equivalent SAE 10W-40 or SAE 20W-40 motorcycle oil.
📐 Dimensions
Exterior
Overall Length:
Standard dimensions for a 250cc dual-sport, likely around 80-85 inches.
Overall Width:
Standard dimensions, typically 30-35 inches.
Overall Height:
Standard dimensions, typically 45-50 inches.
Wheelbase:
Around 55-57 inches for stability on and off-road.
Ground Clearance:
Designed for off-road use, typically 10-12 inches.
Seat Height:
Likely between 34-36 inches, common for dual-sports.
Weights
Dry Weight:
Typically around 240-260 lbs for a 250cc dual-sport.
Wet Weight:
Will increase with fluids, approximately 260-280 lbs.
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned NHTSA or IIHS crash test ratings. Safety is dependent on rider skill and adherence to traffic laws.
Active Features
Braking System:
Disc brakes front and rear for effective stopping power.
Lighting:
Headlight, tail light, brake light, turn signals for visibility.
Passive Features
Frame Construction:
Sturdy frame designed to withstand off-road stress.
Ergonomics:
Designed for rider control and comfort over varied terrain.
💡 Technology Features
Infotainment
Infotainment System:
None (typical for a 2008 dual-sport motorcycle).
Driver Assistance
Driver Assistance Features:
None (typical for a 2008 dual-sport motorcycle).
Connectivity
Connectivity Options:
None (typical for a 2008 dual-sport motorcycle).
Instrumentation
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km (1,865 miles) or 6 months, whichever comes first (typical for this type of motorcycle).
Air Filter Cleaning:
Every 1,000 km (620 miles) or as needed depending on riding conditions.
Chain Maintenance:
Lubricate and adjust chain every 500 km (310 miles).
Valve Clearance Check:
Every 6,000 km (3,730 miles) or 12 months.
Fluid Specifications
Engine Oil Type:
Yamalube 4-stroke Motorcycle Oil SAE 10W-40 or SAE 20W-40 API SG or higher.
Engine Oil Capacity:
Approximately 1.5 - 1.8 liters (1.6 - 1.9 US qt) with filter change.
Coolant Type:
Yamaha's recommended permanent type antifreeze coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Common Wear Items:
Clutch plates, brake pads, sprockets, chain, fork seals, wheel bearings due to off-road use.
Carburetor Clogging:
Can occur if fuel is left in the carburetor for extended periods without use; requires regular cleaning/stabilizing.
Electrical Connector Corrosion:
Can happen in wet or dirty environments; requires regular inspection and dielectric grease application.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha's long-standing reputation for innovation, performance, and reliability in motorcycles, particularly in off-road disciplines.
Model Evolution
Br250 Lineage:
Part of Yamaha's lineage of capable 250cc off-road and dual-sport motorcycles, building on previous models like the XT and WR series.
Production
Production Years:
The BR250 model has been in production for several years, with the 2008 model being a specific iteration.
Manufacturing Location:
Typically manufactured in Japan or other Yamaha global facilities.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
Specific awards for the BR250 model in 2008 are not widely documented. However, Yamaha motorcycles consistently receive praise for reliability and performance in their respective classes.
Ratings
Reliability Reputation:
Yamaha generally holds a strong reputation for long-term reliability and durability, especially in its off-road focused models.