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Yamaha BR250TF, ET410TRF, VK540EF 2001 Owner's Manual PDF

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Summary of Content for Yamaha BR250TF, ET410TRF, VK540EF 2001 Owner's Manual PDF

OWNERS MANUAL

SNOWMOBILE

BR250TF ET410TRF

VK540EF

8AC-28199-17LIT-12628-02-13 PRINTED IN JAPAN 2000 8 - 0.3 1 CRPRINTED ON RECYCLED PAPER

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MACHINE IDENTIFICATION Identification numbers record

A. FRAME NUMBER:

B. ENGINE NUMBER (PRIMARY I.D.):

C. KEY NUMBER:

Record your frame number, engine number (Primary I.D.) and key number in the spaces provided, to assist you in ordering spare parts from your Yamaha dealer.

1 The frame number is the nine-digit number stamped on the frame of the machine. (See Fig. )

2 The model code number is the first three digits of the frame number. (See Fig. )

3 The engine number is stamped in the location as shown. (See Fig. )

B-a BR250T B-b ET410TR B-c VK540E

4 Key number (See Fig. )

Also, record and keep these I.D. numbers in a separate place in case your machine is stolen.

B-a

C

A

861-001

861-006

860-002

B-b

B-c

861-008

861-011

BR250TF_8AC-17_Ch00 00.10.5, 11:50 AM2

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INTRODUCTION Congratulations! Your choice of a Yamaha snowmobile assures you of the highest quality and dependability. Your Yamaha snowmobile is manufactured by a company well- known for excellence in the field of snowmobiles. The most advanced production equipment and technology have made Yamaha one of the best machine manufacturers. We are confident that this snowmobile will meet the great- est expectations of our customers. This manual is de- signed to acquaint you with the operation of this snowmo- bile and minor maintenance required for satisfactory ser- vice. Should major repairs ever be required, you are advised to consult a nearby Yamaha dealer who has the techniques, tools and parts to ensure your satisfaction. We hope that the information within this booklet will help you enjoy many hours of pleasure with your Yamaha snowmobile.

BR250TF ET410TRF VK540EF

OWNERS MANUAL 2000 by Yamaha Motor

Corporation, U.S.A. 1st Edition, August 2000

All rights reserved. Any reprinting or

unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan P/N LIT-12628-02-13

BR250TF_8AC-17_Ch00 00.10.5, 9:47 AM3

WARNING

PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE.

NOTE: Yamaha continually seeks advancements in product

design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.

This manual should be considered a permanent part of this machine and should remain with this machine when resold.

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a by- stander, or a person inspecting or repairing the machine.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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CONTENTS YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY ........................................ 1-1

YAMAHA EXTENDED SERVICE (Y.E.S.) ................................................. 1-4

LOCATION OF THE IMPORTANT LABELS ............................................... 2-1

SAFETY INFORMATION ..................... 3-1

DESCRIPTION (BR250T) ................... 4-1

DESCRIPTION (ET410TR) ................. 4-2

DESCRIPTION (VK540E) ................... 4-3

CONTROL FUNCTIONS .................... 5-1 MAIN SWITCH................................... 5-1 STARTER LEVER (CHOKE) ............. 5-1 PRIMER PUMP KNOB (BR250T) ...... 5-2 THROTTLE LEVER ........................... 5-2 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) .......................................... 5-3 ENGINE STOP SWITCH ................... 5-3 BRAKE LEVER .................................. 5-4 PARKING BRAKE BUTTON.............. 5-4 DRIVE SELECT LEVER (SHIFT LEVER) (ET410TR) .............. 5-5 DRIVE SELECT LEVER (SHIFT LEVER) (VK540E)................. 5-5 HEADLIGHT BEAM SWITCH ............ 5-6 HEADLIGHT ADJUSTING KNOB (VK540E) ........................................... 5-6 GRIP AND THUMB WARMER SWITCH (ET410TR/VK540E)............ 5-6 TRIP ODOMETER RESET KNOB (ET410TR/VK540E) ........................... 5-6 SHROUD LATCH .............................. 5-7 FUEL TANKS (BR250T) .................... 5-7 FUEL COCK LEVER (BR250T) ......... 5-8 V-BELT GUARD ................................ 5-8 V-BELT HOLDER (BR250T/ET410TR) ........................... 5-9 SPARK PLUG HOLDER (ET410TR) ......................................... 5-9

ENGINE ROOM PLATES (BR250T) ......................................... 5-10 ENGINE ROOM PLATES (ET410TR) ....................................... 5-11 ENGINE ROOM PLATES (VK540E) ......................................... 5-11 LUGGAGE BOX (VK540E) .............. 5-12 REAR CARRIER.............................. 5-12 TOW HITCH .................................... 5-12

PRE-OPERATION CHECKS .............. 6-1 FUEL (BR250T) ................................. 6-1 FUEL (ET410TR/VK540E)................. 6-2 ENGINE OIL ...................................... 6-3 THROTTLE LEVER ........................... 6-4 MANUAL STARTER .......................... 6-4 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK ............................. 6-4 BRAKE............................................... 6-5 V-BELT .............................................. 6-5 DRIVE V-BELT GUARD .................... 6-6 DRIVE TRACK................................... 6-6 SLIDE RUNNERS.............................. 6-7 SKI/SKI RUNNER .............................. 6-7 STEERING SYSTEM......................... 6-7 LIGHTS .............................................. 6-8 BATTERY (VK540E).......................... 6-8 FITTINGS/FASTENERS .................... 6-8 SERVICE TOOLS AND SPARE PARTS ............................................... 6-8

OPERATION ....................................... 7-1 STARTING THE ENGINE.................. 7-1 EMERGENCY ENGINE STARTING (BR250T/ET410TR) ........................... 7-3 EMERGENCY ENGINE STARTING (VK540E) ........................................... 7-4 BREAK-IN .......................................... 7-4 RIDING YOUR SNOWMOBILE ......... 7-5 GETTING TO KNOW YOUR SNOWMOBILE .................................. 7-5 LEARNING TO RIDE YOUR SNOWMOBILE .................................. 7-5 TO START OUT AND ACCELERATE ................................... 7-6 BRAKING........................................... 7-6 TURNING .......................................... 7-6

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RIDING UPHILL................................. 7-7 RIDING DOWNHILL .......................... 7-8 CROSSING A SLOPE (SIDE HILL) ... 7-8 ICE OR ICY SURFACE ..................... 7-9 HARD-PACKED SNOW .................... 7-9 OPERATION ON SURFACES OTHER THAN SNOW OR ICE .......... 7-9 MAXIMIZING DRIVE TRACK LIFE.. 7-10 DRIVING (BR250T) ......................... 7-11 DRIVING (ET410TR/VK540E) ......... 7-11 STOPPING THE ENGINE ............... 7-13 TRANSPORTING ............................ 7-13

PERIODIC MAINTENANCE ............... 8-1 MAINTENANCE CHART ................... 8-1 TOOL KIT .......................................... 8-4 SPARK PLUG INSPECTION ............. 8-5 ENGINE IDLE SPEED ADJUSTMENT................................... 8-6 THROTTLE CABLE ADJUSTMENT .. 8-7 OIL PUMP CABLE ADJUSTMENT.... 8-8 CARBURETOR ADJUSTMENT ........ 8-8 HIGH ALTITUDE ADJUSTMENTS .. 8-11 FAN BELT (VK540E) ....................... 8-11 DRIVE V-BELT REPLACEMENT (BR250T) ......................................... 8-12 DRIVE V-BELT REPLACEMENT (ET410TR/VK540E) ......................... 8-13 DRIVE CHAIN HOUSING ................ 8-15 BRAKE/PARKING BRAKE (BR250T) ......................................... 8-17 BRAKE/PARKING BRAKE (ET410TR) ....................................... 8-18 BRAKE/PARKING BRAKE (VK540E) ......................................... 8-19 SUSPENSION (BR250T) ................. 8-19 SUSPENSION (ET410TR) .............. 8-20 SUSPENSION (VK540E)................. 8-21 FULL RATE ADJUSTER (VK540E) ......................................... 8-22 TRACK ADJUSTMENT ................... 8-23 SKI ALIGNMENT ............................. 8-26 HANDLEBAR ADJUSTMENT (BR250T) ......................................... 8-27 HANDLEBAR ADJUSTMENT (ET410TR/VK540E) ......................... 8-28

LUBRICATION................................. 8-29 HEADLIGHT (BR250T/ET410TR) ... 8-30 HEADLIGHT (VK540E).................... 8-31 BATTERY (VK540E)........................ 8-32 FUSE REPLACEMENT (VK540E) ... 8-33

TROUBLESHOOTING ......................... 9-1

STORAGE ......................................... 10-1

SPECIFICATIONS (BR250T) ........... 11-1 DIMENSIONS .................................. 11-1 ENGINE ........................................... 11-1 CHASSIS ......................................... 11-1 ELECTRIC ....................................... 11-2

SPECIFICATIONS (ET410TR) ......... 11-3 DIMENSIONS .................................. 11-3 ENGINE ........................................... 11-3 CHASSIS ......................................... 11-4 ELECTRIC ....................................... 11-4

SPECIFICATIONS (VK540E) ........... 11-5 DIMENSIONS .................................. 11-5 ENGINE ........................................... 11-5 CHASSIS ......................................... 11-5 ELECTRIC ....................................... 11-6

WIRING DIAGRAM (BR250T) .......... 12-1

WIRING DIAGRAM (ET410TR) ........ 12-2

WIRING DIAGRAM (VK540E) .......... 12-3

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YAMAHA MOTOR CORPORATION, U.S.A. SNOWMOBILE LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha snowmobiles purchased from an autho- rized Yamaha snowmobile dealer in the continental United States will be free from defects in material and workman- ship for the period of time stated herein, subject to certain stated limitations.

WARRANTY PERIOD: 1. All Yamaha snowmobiles shall be warranted for a

term of one (1) year from the date of purchase, plus a special early-season extension (if applicable).

2. All Yamaha snowmobile clutch components are war- ranted against abnormal wear for one (1) year from the date of purchase, plus a special early-season extension (if applicable).

DURING THE PERIOD OF WARRANTY any au- thorized Yamaha snowmobile dealer will, free of charge, repair or replace, at Yamahas option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the snowmobiles warranty period. All parts replaced under warranty be- come the property of Yamaha Motor Corporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures to the machine caused by: 1. Competition, racing, or non-Yamaha authorized rental

use. 2. Operation on surfaces other than snow or ice. 3. Installation of parts or accessories that are not quali-

tatively equivalent to genuine Yamaha parts. 4. Abnormal strain, neglect, or abuse. 5. Lack of proper maintenance. 6. Accident or collision damage. 7. Modification to original parts.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance including oil, spark plugs, clutch drive belts, slide runners, and track.

THE CUSTOMERS RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the snowmobile as specified in

the appropriate Owners Manual.

2. Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten (10) days after discovery, and make the machine avail- able at that time for inspection and repairs at such dealers place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory.

WARRANTY TRANSFER: To transfer any remain- ing warranty from the original purchaser to any subse- quent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha snowmobile dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after ownership transfer. An inspection and registration fee will be charged for this service.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR- RANTIES OF MERCHANTABILITY AND FIT- NESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIM- ITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPO- RATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT AL- LOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAM- AGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LE- GAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

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SPECIAL EARLY-SEASON WARRANTY EX- TENSION A special warranty extension is available for all new Yamaha snowmobiles purchased between June 1 and December 1.

All new Yamaha snowmobiles purchased between June 1 and December 1 will have the warranty extended to November 30 of the following year.

YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period?

A. The customers responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, as well as oil, spark plugs, clutch drive belts, and slide runners.

Q. What are some examples of abnormal strain, ne- glect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include: Running the ma- chine out of oil, hitting an object submerged under snow, operation on surfaces other than snow or ice, operating the machine with a broken or damaged part which causes another part to fail, and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. May I perform any or all of the recommended main- tenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified snowmobile mechanic and follow the procedures specified in the Owners and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha snowmobile dealer.

Q. Under what conditions is the clutch not covered by warranty?

A. Clutches as well as clutch components wear with use. Normal wear is not covered under warranty such service is the customers responsibility. Abnormal wear is, however, covered for one (1) year from the date of purchase. Your Yamaha snowmobile dealer possesses criteria as to what constitutes abnormal wear.

Q. Will the warranty be void or canceled if I do not operate or maintain my new Yamaha exactly as specified in the Owners Manual?

A. No. The warranty on a new Yamaha cannot be voided or canceled. However, if a particular failure is caused by operation or maintenance other than as shown in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty?

A. Each Yamaha snowmobile dealer is expected to: 1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty

requirements to your satisfaction at the time of sale, and upon your request at any later date.

3. In addition, each Yamaha snowmobile dealer is held responsible for his setup, service and warranty repair work.

Q. Whom should I contact if I have further questions about this warranty?

A. Your Yamaha snowmobile dealer has the informa- tion and experience necessary to answer almost any questions about this warranty. If the dealer is not able to do so, he is expected to contact Yamaha Motor Corporation, U.S.A., for clarification or assistance.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha snowmobile dealer within the continental United States. Be sure to bring your warranty identification card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealer- ship. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION, U.S.A.

CUSTOMER RELATIONS DEPARTMENT P.O. Box 6555

Cypress, California 90630

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When contacting Yamaha Motor Corpora- tion, U.S.A. be sure to include the model, serial number, names, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new snowmobile, please advise us of your new address by sending a postcard listing your snowmobile model name, engine serial number, dealer number (or dealers name) as it is shown on your warranty registration identification, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

WARRANTY DEPARTMENT P.O. Box 6555

Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Ex- tended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get un- interrupted factory-backed coverage for extra peace of mind.

Y.E.S. is flexible. You choose the plan thats right for you: 12 months, 24 months, or 36 months beyond your warranty period.

Y.E.S. is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehen- sive coverage benefits. There are no mile- age limitations. Coverage isnt limited to moving parts or the drive train like many other plans. And Y.E.S. covers manu- facturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted fac- tory-backed protection can be.

You dont have to pay anything for covered repairs. Theres no deductible to pay, and repairs arent pro-rated. You dont have any out- of pocket expenses for covered repairs.

In addition, Travel and Recreation Interrup- tion Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reim- bursement per occurrence for any reason- able expenses you incur because your Yamaha needs covered service: replace- ment vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb cov- erage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your en- tire Y.E.S. plan period.

Y.E.S. coverage is honored at any autho- rized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your autho- rized Yamaha dealer to get all the facts. He can show you how easy it is to protect your invest- ment with Yamaha Extended Service.

We urge you to act now. Youll get the excel- lent benefits of TRIP coverage right away, and youll rest easy knowing youll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note:

If visiting your dealer isnt convenient, contact Yamaha with your Primary ID number (your engine number). Well be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630

(714) 761-7631

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LOCATION OF THE IMPORTANT LABELS

Please read the following labels carefully before operating this machine.

NOTE: Maintain or replace safety and instruction labels, as neces- sary.

1 BR250T

2

AVERTISSEMENT

WARNING

NE PAS FAIRE FONCTIONNER LE MOTEUR SANS COURROIE EN V OU PROTECTEUR D'EMBRAYAGE.

DO NOT OPERATE ENGINE WITHOUT V-BELT OR DRIVE GUARD.

8BD-7762-00

AVERTISSEMENT

WARNING SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING: Read the Owner's Manual and all labels before operating this vehicle. Check throttle, brake, and steering for proper operation before starting engine. Set parking brake before attempting to start engine. Never run this vehicle with the parking brake applied. To stop engine in an emergency, push the engine stop switch down. Do not operate engine without drive belt or drive guard. Make sure the fuel tank cap is closed securely after refueling. Do not operate this vehicle on public roads. You could collide with another vehicle. This vehicle is designed for operator only - no passengers. Wear an approved helmet. eye protection, and adequate clothing for snowmobiling.

AFIN D'VITER TOUT RISQUE DE BLESSURE SRIEUSE OU MME MORTELLE, VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES: Avant d'utiliser ce vhicule, lire le manuel du propritaire et toutes les tiquettes. Avant de dmarrer le moteur, vrifier l'opration du frein, de l'acclrateur et de la direction. Le frein de scurit doit tre appliqu lors du dmarrage. Ne pas rouler avec le frein de scurit actionn. En cas d'urgence, utiliser l'interrupteur d'arrt du moteur. Ne pas laisser tourner le moteur sans la courroie ou sans son garde. S'assurer que le bouchon du rservoir soit bien referm aprs le remplissage. Afin d'viter tout risque de collision, ne pas rouler sur un chemin public. Ce vhicule est conu pour un conducteur seul - aucun passeger. Toujours porter un casque approuv et un habillement de motoneigiste. Prvoir une protection pour les yeux.

87S-77761-10

BR250T

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AVERTISSEMENTWARNING

SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING: Read the Owners Manual and all labels before operating this vehicle. Check throttle, brake, and steering for proper operation before starting engine. Set parking brake before attempting to start engine. Never run this vehicle with the parking brake applied. To stop engine in an emergency, push the engine stop switch down. Do not operate engine without drive belt or drive guard. Make sure the fuel tank cap is closed securely after refueling. Do not operate this vehicle on public roads. You could collide with another vehicle. Check lever position (Forward or Reverse) before moving. Wear an approved helmet. eye protection, and adequate clothing for snowmobiling.

AFIN DVITER TOUT RISQUE DE BLESSURE SRIEUSE OU MME MORTELLE, VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES: Avant dutiliser ce vhicule, lire le manuel du propritaire et toutes les tiquettes. Avant de dmarrer le moteur, vrifier lopration du frein, de lacclrateur et de la direction. Le frein de scurit doit tre appliqu lors du dmarrage. Ne pas rouler avec le frein de scurit actionn. En cas durgence, utiliser linterrupteur darrt du moteur. Ne pas laisser tourner le moteur sans la courroie ou sans son garde. Sassurer que le bouchon du rservoir soit bien referm aprs le remplissage. Afin dviter tout risque de collision, ne pas rouler sur un chemin public. Vrifier la position du leveier (marche avant ou arrre) avant dtre en marche. Toujours porter un casque approuv et un habillement de motoneigiste. Prvoir une protection pour les yeux.

89X-77761-10YAMAHA

AVERTISSEMENT

WARNING SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING: Read the Owners Manual and all labels before operating this vehicle. Check throttle, brake, and steering for proper operation before starting engine. Set parking brake before attempting to start engine. Never run this vehicle with the parking brake applied. To stop engine in an emergency, push the engine stop switch down. Do not operate engine without drive belt or drive guard. Make sure the fuel tank cap is closed securely after refueling. Do not operate this vehicle on public roads. You could collide with another vehicle. Wear an approved helmet, eye protection, and adequate clothing for snowmobiling. Check lever position (Drive, Reverse, or Low) before moving.

AFIN DVITER TOUT RISQUE DE BLESSURE SRIEUSE OU MME MORTELLE, VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES: Avant dutiliser ce vhicule, lire le manuel du propritaire et toutes les tiquettes. Avant de dmarrer le moteur, vrifier lopration du frein, de lacclrateur et de la direction. Le frein de scurit doit tre appliqu lors du dmarrage. Ne pas rouler avec le frein de scurit actionn. En cas durgence, utiliser linterrupteur darrt du moteur. Ne pas laisser tourner le moteur sans la courroie ou sans son garde. Sassurer que le bouchon du rservoir soit bien referm aprs le remplissage. Afin dviter tout risque de collision, ne pas rouler sur un chemin public. Toujours porter un casque approuv et un habillement de motoneigiste. Prvoir une protection pour les yeux. Vrifier la position du levier (en marche, arrire ou bas) avant dtre en marche.

87R-77761-10

DRIVE SELECT LEVER

Read owners manual carefully before operating.

Before moving the drive select lever, make sure that the vehicle is at a full stop and that the throttle lever is fully released.

Low range must not be used for speeds exceeding 50 KM/H.

LEVIER DE SLECTION DE VITESSE

Lire attentivement le manuel du propritaire avant lutilisation.

Sassurer que le vhicule est compltement arrte et que le levier des gaz nest pas actionn avant de dplacer le levier de slection de vitesse.

On ne peut utiliser la position L (pettie vitesse) pour des vitesses suprieures 50 KM/H.

D LR

D LR

1 ET410TR

ET410TR

1 VK540E

VK540E

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SAFETY INFORMATION When you ride your snowmobile, you must know and use the following for your safety. Severe injury or death may result if you ignore any of the following.

Before Operating 1. Read the Owners Manual and all labels before operat-

ing this machine. Become familiar with all of the oper- ating controls and their function. Consult a Yamaha dealer about any control or function you do not under- stand.

2. This machine was not manufactured for use on public streets, roads, or highways. Such use is prohibited by law, and you could collide with another vehicle.

3. BR250T is designed to carry the OPERATOR ONLY. Passengers are prohibited. Carrying a passenger can cause loss of control.

4. Do not operate the machine after drinking alcohol or taking drugs. Your ability to operate the machine is reduced by the influence of alcohol or drugs.

5. For safety and proper care of the machine, always perform the pre-operation checks on page 6-1 ~ 6-8 before starting the engine. Check the throttle, steering and brake operation every time before starting the engine. Be sure the throttle lever moves freely and it returns to the idle position when it is released.

6. Apply the parking brake before starting the engine. Never drive the machine with the parking brake ap- plied. This may overheat the brake disc and reduce braking ability.

7. Do not allow anyone to stand behind the machine when starting, inspecting or adjusting the machine. A broken track, track fittings or debris thrown by the track could be dangerous to the operator or bystanders.

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851-004

851-006

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8. Handle fuel with care; it is highly flammable. Never add fuel when the engine is running or hot.

Allow the engine to cool for several minutes after running.

Use an approved fuel container. Fill the fuel tank outdoors with extreme care. Never

remove the fuel cap indoors. Never fill the fuel tank indoors.

Never refuel while smoking or in the vicinity of an open flame.

Make sure the fuel tank cap is closed securely after refueling. Wipe up any spilled fuel immediately.

9. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline into your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash your skin with soap and water, and change your clothes.

10. Wear protective clothing. Wear an approved helmet, and a face shield or goggles. Also, wear a good quality snowmobile suit, boots, and a pair of snowmobile gloves or mittens that will permit use of your thumbs and fingers for operation of the controls.

Operation 1. Do not run the engine indoors, except when starting the

engine to transport the machine in or out of the building. Open the outside doors; exhaust fumes are dangerous.

2. Be careful where you ride. There may be obstacles hidden beneath the snow. Stay on established trails to minimize your exposure to hazards. Ride slowly and cautiously when you ride off of established trails. Hitting a rock or stump, or running into wires could cause an accident and injury.

851-003

851-001

851-002

BR250TF_8AC-17_Ch03 00.10.5, 11:52 AM2

3-3

3. This machine is not designed for use on surfaces other than snow or ice. Use on dirt, sand, grass, rocks, or bare pavement may cause loss of control and may damage the machine.

4. Avoid operating on glare ice, or on snow which has a lot of dirt or sand mixed in. Operation under such condi- tions will damage or result in rapid wear of ski runners, drive track, slide runners and drive sprockets.

5. Always have other snowmobilers with you when going on a ride. You may need help if you run out of fuel, have an accident, or damage your snowmobile.

6. Many surfaces such as ice and hard-packed snow require much longer stopping distances. Be alert, plan ahead and begin decelerating early. The best braking method on most surfaces is to release the throttle and apply the brake gentlynot suddenly.

Maintenance and Storage 1. Modifications made to the machine not approved by

Yamaha, or the removal of original equipment may render your machine unsafe for use and may cause severe personal injury. Modifications may also make your machine illegal to use.

2. Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, open flame, spark, clothes dryers, and the like. Allow the engine to cool before storing in any enclosure.

3. Always refer to STORAGE for important details if the machine is to be stored for an extended period.

4. Maintain or replace safety and instruction labels, as necessary.

BR250TF_8AC-17_Ch03 00.10.5, 9:47 AM3

4-1

ESU00012

DESCRIPTION (BR250T)

1 Ski damper 2 Fuel cock lever 3 Windshield 4 Steering handlebar 5 Seat 6 Drive track 7 Slide rail suspension 8 Frame 9 Steering ski 0 Front baffle plate A Shroud B Headlight C Tail/brake light D Flap E Tow hitch F Speedometer G Primer pump knob H Engine stop switch I Throttle lever J Starter handle K Shroud latch L Starter lever M Main switch N Headlight beam switch O Brake lever P Parking brake button

BR250TF_8AC-17_Ch04 00.10.5, 9:47 AM1

4-2

ESU00012

DESCRIPTION (ET410TR)

1 Windshield 2 Steering handlebar 3 Seat 4 Drive track 5 Slide rail suspension 6 Frame 7 Telescopic strut suspension 8 Steering ski 9 Headlight 0 Front baffle plate A Shroud B Tow hitch C Flap D Tail/brake light E Brake lever F Parking brake button G Headlight beam switch H Odometer I Speedometer J Trip odometer K Engine stop switch L Throttle lever M Drive select lever (Shift lever) N Shroud latch O Grip warmer switch P Starter handle Q Main switch R Trip odometer reset knob S Starter lever

BR250TF_8AC-17_Ch04 00.10.5, 9:47 AM2

4-3

ESU00012

DESCRIPTION (VK540E)

1 Windshield 2 Steering handlebar 3 Seat 4 Drive track 5 Slide rail suspension 6 Frame 7 Telescopic strut suspension 8 Steering ski 9 Headlight 0 Front baffle plate A Shroud B Tail/brake light C Flap D Tow hitch E Luggage box F Headlight adjusting knob G Engine stop switch H Throttle lever I Drive select lever (Shift lever) J Main switch K Starter handle L Starter lever M Grip warmer switch N Headlight beam switch O Brake lever P Parking brake button

BR250TF_8AC-17_Ch04 00.10.5, 9:47 AM3

5-1

ESU00013

CONTROL FUNCTIONS ESU00256

MAIN SWITCH The main switch controls the following items. 1OFF: Ignition circuit is switched off. The key can be removed only in this position. 2ON: Ignition circuit is switched on. The engine can be started. 3 START (VK540E): Starting circuit is switched on. The starter motor starts.

NOTE: The lights will come on after the engine starts.

CAUTION: Release the switch immediately after the engine starts.

BR250T/ET410TR VK540E

B

A

831-001

831-004

B

A

815-030

815-001

ESU00020

STARTER LEVER (CHOKE) Use this lever when starting and warming up a cold engine.

1 Starter lever (choke) 2When starting a cold engine. 3Warming up (ET410TR/VK540E) 4When the engine is warm.

NOTE: Refer to STARTING THE ENGINE for proper operation.

BR250T ET410TR/VK540E

BR250TF_8AC-17_Ch05 00.10.5, 9:47 AM1

5-2

ESU00021

PRIMER PUMP KNOB (BR250T) Pump the knob several times in low temperatures for easier engine starting.

CAUTION: Excessive use of the primer knob may flood the engine with fuel.815-028

ESU00022

THROTTLE LEVER Once the engine is running cleanly, squeezing 2 of the throttle lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle when the thumb is released 3.

WARNING

Check throttle, brake, and steering for proper opera- tion before starting engine.

816-001

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM2

5-3

ON

OFF

RUN

OFF

OFF

STOP

Idle or

Starting

MODE Run Trouble

SWITCH

OFF

ON

RUN

Throttle switch

Carburetor switch

Engine

A B C

ESU00025

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the carburetor or throttle cable should malfunction during operation, release the throttle lever. The T.O.R.S. is de- signed to interrupt the ignition and stop the engine if the carburetor fails to return to idle when the lever is released.

WARNING

If T.O.R.S. stops the engine, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine.

Idle or starting Run Trouble 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle valve a ON b OFF

B

C

A

816-003

816-004

816-005

ESU00031

ENGINE STOP SWITCH The engine stop switch 1 is used to stall the engine in an emergency. Simply push 2 the engine stop switch, and the engine will stop. To start the engine, pull 3 the engine stop switch and see page 7-1 for more details. During the first few rides, you should practice using the switch while driving so that you can react quickly in an emergency.831-008

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM3

5-4

ESU00032

BRAKE LEVER The machine is stopped by braking the entire drive system. Squeeze the brake lever towards the handlebar to stop the machine. 1 Brake lever 2 Brake lever end 3 Handlebar end

NOTE: When the brake is operated, the brake light will illuminate.

CAUTION: Be sure the brake lever end does not project out over the handlebar end. This will help prevent brake lever damage when the machine is placed on its side for service.

818-002

ESU00034

PARKING BRAKE BUTTON When parking the machine or starting the engine, apply the parking brake. Squeeze the brake lever 1, then push down 3 the parking brake button 2 while releasing the brake lever. To release the parking brake, just squeeze the brake lever.

WARNING

Always set the parking brake before attempting to start the engine.

Never run the machine with the parking brake ap- plied. This may overheat the brake disc and reduce brak- ing ability.

818-001

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM4

5-5

817-010

817-011

ESU00036

DRIVE SELECT LEVER (SHIFT LEVER) (ET410TR) The drive select lever is used to shift your machine into forward or reverse. After coming to a complete stop, move the lever to the desired direction. 1 Drive select lever (Shift lever) 2 Push 3Move to forward 4Move to reverse

Machine movement

FWD Forward

REV Reverse

CAUTION: Do not shift from Forward to Reverse or Reverse to Forward while the machine is moving. Otherwise the drive system could be damaged.

817-003

817-005

ESU00037

DRIVE SELECT LEVER (SHIFT LEVER) (VK540E) The drive select lever is used to shift your machine into drive, low or reverse. After coming to a complete stop, squeeze the stopper underneath the lever and move the lever to the desired position. 1 Drive select lever (Shift lever) 2 Stopper

Lever position Machine movement

3 D Drive (forward)

4 R Reverse

5 L Low range (forward)

CAUTION: Do not shift from Forward to Reverse or Reverse to Forward while the machine is moving. Otherwise the drive system could be damaged.

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM5

5-6

ESU00039

HEADLIGHT BEAM SWITCH Push the switch to change the head light beam alternately to high or low.

1 Headlight beam switch 2 Push 3 High beam 4 Low beam

831-012

ESU00040

HEADLIGHT ADJUSTING KNOB (VK540E) Use the knob to adjust the headlight vertical position.

1 Up 2 Down

832-018

831-020

ESU00042

GRIP AND THUMB WARMER SWITCH (ET410TR/VK540E) This switch controls the electrically heated handlebar grips and throttle lever.

1Grip and thumb warmer switch 2ON 3OFF

833-004

ESU00046

TRIP ODOMETER RESET KNOB (ET410TR/VK540E) Use knob to reset the trip odometer.

1 Reset knob 2 Turn counterclockwise

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM6

5-7

A

845-015

ESU00048

SHROUD LATCH To open the shroud, unhook the latch, then slowly raise the shroud forward until it stops. When closing the shroud, slowly lower it to its home position, then hook the shroud latches.

1 Latch 2 Shroud

CAUTION: Be sure all cables and wires are in place when closing the shroud.

WARNING

Do not drive the machine with the shroud open or unlatched or with the shroud removed.

Keep your body and clothing away from rotating parts when servicing with the shroud open.

Do not touch the hot muffler and engine during or immediately after operation.

BR250T ET410TR VK540E

B

C

845-025

845-014

810-022

810-021

ESU00049

FUEL TANKS (BR250T) This machine is equipped with two fuel tanks; main tank 1 in the engine room and sub-tank 2 under the instrument panel. Always add fuel to each of the tanks. See page 6-1 ~ 6-2 for details.

2

1

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM7

5-8

ESU00050

FUEL COCK LEVER (BR250T) The fuel cock lever controls the fuel lines. 1OFF: With the lever in this position, fuel does not flow.

The engine can not be started. 2ON: In this position, fuel flows from the main tank to

the carburetor. The engine can be started and operated. The lever should usually be kept in the ON position while operating the machine.

3 RES: In this position, fuel flows from the sub-tank to the carburetor. The machine can be operated for a short time. If the machine runs out of fuel in the ON position, turn the lever to the RES position. Remember to fill both main and sub fuel tanks at the first opportunity. After refueling, return the lever to the ON posi- tion.

801-018

C

B

ESU00052

V-BELT GUARD The V-belt guard is designed to cover the clutch and V-belt in case parts break or come loose.

WARNING

Be sure the V-belt guard is tightened securely before operating the machine.

Never run the engine without the V-belt or with the V-belt guard removed.

BR250T ET410TR VK540E

805-078

A

805-085

805-080

BR250TF_8AC-17_Ch05 00.10.5, 9:47 AM8

5-9

805-094

ESU00255

V-BELT HOLDER (BR250T/ET410TR) Keep a spare V-belt for emergency use by putting it into the holder provided. BR250T

NOTE: Loosen the bolt 1 to remove the V-belt.

CAUTION: Be sure to tighten the bolt when installing the V-belt

in the holder. Be sure the fuel hose is not pinched and is in place

when installing the V-belt.

ET410TR

CAUTION: Be sure the V-belt is installed securely in the holder.

805-086

834-007

ESU00257

SPARK PLUG HOLDER (ET410TR) Keep spare spark plugs for emergency use by screwing them into the holder provided.

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM9

5-10

ESU00060

ENGINE ROOM PLATES (BR250T) Open the plates to cool down the engine.

CAUTION: Close the baffle plate 1, install the recoil seal 2 and

side plate 3 when operating the machine in deep powder snow.

Open the baffle plate, remove the recoil seal and side plate when the ambient temperature is above 5C (41.5F).

845-021

845-022

845-020

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM10

5-11

845-041

845-037

845-039

845-038 845-040

845-031

845-017

ESU00063

ENGINE ROOM PLATES (ET410TR) Open the plates to cool down the engine.

CAUTION: Close the plates when the machine is operated in

deep snow. Remove the louver plate 1 and belly pan plates 2

when the ambient temperature is 5C (41.5F) or higher.

ESU00064

ENGINE ROOM PLATES (VK540E) Open the plates to cool down the engine.

CAUTION: Close the plate when the machine is operated in

deep snow. Remove the belly pan plates 1 when the ambient

temperature is 5C (41.5F) or higher.

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM11

5-12

ESU00070

REAR CARRIER

Maximum load limit: 20 kg (44 lb)

849-001

846-010

847-005

ESU00071

TOW HITCH Use the tow point within the specified weight limits.

1 Tow point

Tow weight 120 kg (265 lb)

Vertical weight 15 kg (33.1 lb)

CAUTION: Avoid towing for a long time under the 10 km/h (0.6 mph) speed to prevent early wear of the drive V-belt.

ESU00069

LUGGAGE BOX (VK540E) Luggage box is located under the seat. The seat can be opened left side by unhooking the latches on the right side seat. To close the seat, slowly turn the seat right side. When it fits back to the home position, hook the latches.

BR250TF_8AC-17_Ch05 00.10.5, 11:53 AM12

6-1

ESU00072

PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the machine is used.

WARNING

The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.

ESU00073

FUEL (BR250T) Make sure there is sufficient fuel in both main and sub tanks.

Recommended fuel: Unleaded gasoline

Pump octane R+M ; 88 or higher 2

Fuel tank capacity: 1 Main tank: 15 L (3.3 Imp gal, 4.0 US gal) 2 Sub tank: 9.3 L (2.05 Imp gal, 2.46 US gal)

WARNING

Fuel is highly flammable and poisonous. Check SAFETY INFORMATION (see page 3-2) carefully before refueling.

Do not fill the fuel tank all the way to the top. When the machine is tilted, this could cause the fuel to overflow.

Make sure that the fuel tank cap is closed securely after refueling. Leaking fuel can catch fire.

CAUTION: Oxygenated fuels (gasohol) containing max. 5%

of ethanol can be used, although richer jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended.

801-019

810-020

1

810-021

2

800-021

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM1

6-2

Be sure that snow and /or ice does not enter into the fuel tank when refueling.

Do not use alcohol deicers or water absorbing additives with oxygenated fuel.

The tank should be filled with straight gasoline as specified.

801-011

801-014

800-021

801-012

A

B

ESU00074

FUEL (ET410TR/VK540E) Make sure there is sufficient fuel in the tank.

Recommended fuel: Unleaded gasoline

Pump octane R+M

; 88 or higher 2

Fuel tank capacity: ET410TR

Total: 30.6 L (6.7 Imp gal, 8.1 US gal) VK540E

Total: 31.0 L (6.8 Imp gal, 8.2 US gal)

ET410TR VK540E

WARNING

Fuel is highly flammable and poisonous. Check SAFETY INFORMATION (see page 3-2) carefully before refueling.

Do not fill the fuel tank all the way to the top. When the machine is tilted, this could cause the fuel to overflow.

Make sure that the fuel tank cap is closed securely after refueling. Leaking fuel can catch fire.

CAUTION: Oxygenated fuels (gasohol) containing max. 5%

of ethanol can be used, although richer jetting may be required to prevent engine damage. Consult a Yamaha dealer. Gasohol containing methanol is not recommended.

Be sure that snow and /or ice does not enter into the fuel tank when refueling.

Do not use alcohol deicers or water absorbing additives with oxygenated fuel.

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM2

6-3

A

ESU00084

ENGINE OIL Make sure there is sufficient oil in the oil tank.

1 Lower level 2 Upper level

Oil tank capacity: BR250T

1.8 L (1.6 Imp qt, 1.9 US qt) ET410TR

2.2 L (1.9 Imp qt, 2.3 US qt) VK540E

2.5 L (2.2 Imp qt, 2.6 US qt) Recommended oil: YAMALUBE 2-cycle oil

BR250T ET410TR VK540E

801-029

800-015

B

800-006

C

The tank should be filled with straight gasoline as specified.

BR250TF_8AC-17_Ch06 00.10.5, 9:47 AM3

6-4

1

2

3

816-025

815-006

ESU00088

MANUAL STARTER Check for proper operation. Check the rope for damage.

ESU00087

THROTTLE LEVER Check the throttle lever operation before starting the en- gine. It must open smoothly and spring back to idle when released.

ESU00089

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK

WARNING

When checking T.O.R.S.: Be sure the parking brake is applied. Be sure the throttle lever moves smoothly. Do not run the engine up to clutch engagement rpm.

Otherwise, the machine could start moving forward unexpectedly, which could cause an accident.

1. Start the engine.

NOTE: Refer to STARTING THE ENGINE.

2. Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb (above) and fore- finger (below) between the throttle lever pivot 1 and stop switch housing 2. While holding as described above, press the throttle lever 3 gradually. The engine should stop immediately.

WARNING

If the engine does not stop, stop the engine by turning the main switch to the OFF position and consult a Yamaha dealer.

818-034

816-040

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM4

6-5

ESU00092

BRAKE (See page 8-17 ~ 8-19 for more details.) Test the brake at slow speed when starting out to make sure it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear.

WARNING

Do not operate the machine if you find any problem with the brake. You could lose braking ability, which could lead to an accident.

CAUTION: Be sure the brake lever end should not project out over the handlebar end for preventing brake lever damage when the machine is placed on its side.

ESU00094

V-BELT Open the shroud and remove the V-belt guard. Check the V-belt for wear and damage. Replace if neces- sary.

Wear limit 1: BR250T/ET410TR

28.0 mm (1.10 in) VK540E

32.0 mm (1.26 in)

WARNING

Be sure the V-belt guard is tightened securely before operating the machine.

Never run the engine without the V-belt or with the V-belt guard removed.

805-001

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM5

6-6

A

ESU00097

DRIVE TRACK (See page 8-23 ~ 8-26 for more details.) Check the drive track for deflection, wear and damage. Adjust/replace if necessary.

WARNING

Do not operate the machine if you find damage to the drive track, or misadjustment. Drive track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident.

ESU00095

DRIVE V-BELT GUARD Check the drive belt guard mounts for damage, and check the tightness of the wing bolt. Make sure the drive belt guard is firmly in place.

BR250T ET410TR VK540E

805-078

820-026

B

805-085

C

805-808

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM6

6-7

ESU00098

SLIDE RUNNERS Check wear and damage. If the slide runners reach the wear limit, they should be replaced.

1 Slide runners 2Wear limit

Wear limit height: 10 mm (0.39 in)

CAUTION: Be sure to ride on the fresh snow frequently to avoid rapid wear of slide runner when operating on ice or hard packed snow.

820-001

ESU00101

SKI/SKI RUNNER Check wear and damage. Replace if necessary.

Ski runner wear limit 1: BR250T/ET410TR

4.5 mm (0.18 in) VK540E

8 mm (0.31 in)

819-054

819-003

ESU00103

STEERING SYSTEM 1. Check the following for excessive free play:

1) Push the handlebar up and down and back and forth.

2) Turn the handlebar slightly to the right and left. 2. If excessive free play is noticed, consult a Yamaha

dealer.

BR250TF_8AC-17_Ch06 00.10.5, 11:54 AM7

6-8

ESU00104

LIGHTS Check the lights. Replace any burned out bulbs.

ESU00106

BATTERY (VK540E) (See page 8-32 for more details.) Check the fluid level and top-up if necessary. Use only distilled water if refilling is necessary.

830-004

ESU00110

FITTINGS/FASTENERS Check the tightness of fittings/fasteners. Tighten in proper sequence and torque if necessary.

ESU00258

SERVICE TOOLS AND SPARE PARTS It is a good practice to carry service tools and spare parts with your machine so that minor repairs can be done by yourself. The following should be carried with you (for BR250T/ET410TR) or in the luggage box (for VK540E). Tool kit Flashlight Roll of plastic tape Steel wire Tow rope Emergency starter rope In addition to these, it is advisable to have the following spare parts: Drive belt Light bulbs Spark plugs When you start out for a long distance trip, extra fuel and oil should be carried.

BR250TF_8AC-17_Ch06 00.10.5, 9:48 AM8

7-1

ESU00112

OPERATION ESU00259

STARTING THE ENGINE

WARNING

Be sure to check SAFETY INFORMATION care- fully before starting the engine.

Be sure the parking brake is applied.

NOTE: Be sure the engine stop switch is in the ON position.

1. Fully open the starter lever (choke).

1 Starter lever (choke) 2 Fully open (cold engine starting) 3 Half-open (warm engine up)

(ET410TR/VK540E) 4 Close (warm engine starting)

NOTE: The starter lever (choke) is not required when the engine is warm. Put the starter lever in the Close position.

BR250T ET410TR/VK540E

Manual Starting Model (BR250T/ET410TR) 2. Turn the main switch to the ON position.

1 ON

3. BR250T: Pull slowly on the recoil starter until it is engaged, then pull it briskly. After the engine starts, warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position.

818-034

831-018

815-029

831-002

815-005

B

A

815-002

BR250TF_8AC-17_Ch07 00.10.5, 11:55 AM1

7-2

ET410TR: Pull slowly on the recoil starter until it is engaged, then pull it briskly. After the engine starts, put the starter lever (choke) in the Half-open position. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position.

Electric Starting Model (VK540E) 2. Turn the main switch to the START position.

After the engine starts, put the starter lever (choke) in the Half-open position. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position.

1 START

CAUTION: Release the switch immediately after the engine

starts. If the engine fails to start, release the switch, wait a

few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

815-005

831-006

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM2

7-3

ESU00260

EMERGENCY ENGINE STARTING (BR250T/ET410TR) If the recoil starter system should fail, take the emergency starter rope out of the tool kit box and proceed as follows.

NOTE: The emergency starter rope is supplied in the tool kit box at the factory.

BR250T ET410TR

1. Proceed with item 1. for the STARTING THE ENGINE and item 2. for the Manual Starting Model.

2. Tighten the emergency starter rope on the screwdriver handle.

1 Screwdriver handle

3. Mesh the rope stopper with the primary sheave edge.

1 Rope stopper 2 Primary sheave edge

4. Wind the rope 3-counterclockwise turns on the primary sheave.

5. Grasp the screwdriver handle and pull briskly.

WARNING

Do not wind the emergency starter rope around your hand.

850-009

850-001

850-002

850-003

850-004

B

A

846-023

BR250TF_8AC-17_Ch07 00.10.5, 11:56 AM3

7-4

6. BR250T: After the engine starts, warm up the engine until the engine does not stop when the starter lever is returned to Close position.

ET410TR: After the engine starts, put the starter lever (choke) in the Half-Open position. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position.

7. Install the drive guard and shroud.

WARNING

Avoid contact with the moving primary sheave.

831-005

815-006

ESU00125

BREAK-IN There is never a more important period in the life of your machine than the Break-In period. For the first 10 hours, approximately 200 km (125 mi), do not put an excessive load on the engine. Avoid prolonged full throttle operation. Also avoid lugging the engine, such as laborious operation in wet snow. If any abnormal condition is noticed, such as excessive vibration or noise, consult a Yamaha dealer.

850-005

ESU00120

EMERGENCY ENGINE STARTING (VK540E) 1. Proceed with the STARTING THE ENGINE item 1.

2. Turn the main switch to the ON position.

1 ON

3. Pull slowly on the recoil starter until it is engaged, then pull it briskly. After the engine starts, put the starter lever (choke) in the Half-open position. Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position.

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM4

7-5

ESU00273

RIDING YOUR SNOWMOBILE

GETTING TO KNOW YOUR SNOWMOBILE A snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile. Riding your snowmobile requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Riding your new snowmobile can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the snowmobile to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owners Manual completely and understand the operation of the controls. Pay particular attention to the safety information on page 3-1 ~ 3-3. Please read all warning and caution labels on your snow- mobile. Also read the Snowmobilers Safety Handbook originally supplied with your machine.

LEARNING TO RIDE YOUR SNOWMOBILE Before you ride, always perform the pre-operation checks listed on page 8-1 ~ 8-3. The short time spent checking the condition of the machine will be rewarded with added safety and a more reliable snowmobile. Always wear the proper clothing for both warmth and to help protect you from injury if an accident occurs.

Become familiar with this snowmobile at slow speeds, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the machines handling and performance characteristics.

The beginning operator should select a large, flat area to become familiar with the snowmobile. Make sure that this area is free of obstacles and other traffic. You should practice control of the throttle and brake, and master turning techniques in this area before trying more difficult terrain.

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM5

7-6

Set the parking brake and follow the instructions on page 7-1 ~ 7-2 to start the engine. Once it has warmed up, you are ready to begin riding your Snowmobile.

TO START OUT AND ACCELERATE 1. With the engine idling, release the parking brake. 2. Apply the throttle slowly and smoothly. The centrifugal

clutch will engage and you will start to accelerate.

WARNING

The operator should always keep both hands on the handlebars. Never put your feet outside the running boards. Avoid higher speeds until you have become thoroughly familiar with your Snowmobile and all of its controls.

BRAKING When slowing down or stopping, release the throttle and apply the brake gently-not suddenly.

WARNING

Many surfaces such as ice and hard packed snow require much longer stopping distances. Be alert, plan ahead and begin decelerating early. Improper use of the brake can cause the drive track to lose traction, reducing control and increasing the possibility of an accident.

TURNING For most snow surfaces, body English is the key to turning. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the running board to the inside of the turn and lean your upper body into the turn. This procedure should be practiced at slow speed many times in a large flat area with no obstacles. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Lean more as the turn gets sharper or is made at higher speeds.

852-001

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM6

7-7

Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the snow- mobile to tip. If your snowmobile begins to tip while turning, lean more into the turn to regain balance. If necessary, gradually let off on the throttle and/or steer to the outside of the turn.

Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your snowmobile.

RIDING UPHILL You should practice first on gentle slopes. Try more difficult climbs only after you have developed your skill. As you approach a hill, accelerate before you start the climb, and then reduce the throttle opening to prevent track slippage. It is also important to keep your weight on the uphill side at all times. On climbs straight up the hill this can be accom- plished by leaning forward and, on steeper inclines, stand- ing on the running boards and leaning forward over the handlebars. (Also see CROSSING A SLOPE.) Slow down as you reach the crest of the hill, and be prepared to react to obstacles, sharp drops, or other people or vehicles which may be on the other side. If you are unable to continue up a hill, do not spin the track. Stop the engine and set the parking brake. Then pull the rear of the snowmobile around to point the machine back down the hill. Do not get on the downhill side of the machine. When the snowmobile is pointed downhill, re- start the engine, release the parking brake, and descend the hill.

WARNING

Side hills and steep slopes are not recommended for a beginner or novice snowmobiler.

852-002

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM7

7-8

RIDING DOWNHILL When riding downhill, keep speed to a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow you to use engine compression to help slow the machine, and to keep the snowmobile from rolling freely down the hill. Also apply the brake frequently, with light pressure.

WARNING

Use extra caution when applying the brake during descent. Excessive braking will cause the track to lock and will cause a loss of control.

CROSSING A SLOPE (SIDE HILL)

WARNING

Side hills are not recommended for a beginner or novice snowmobiler.

Crossing the face of a slope (side hill) requires you to properly position your weight to maintain proper balance. As you travel across the slope, lean your body to position your weight towards the uphill side. A recommended riding position is to kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board. This position will make it easier for you to shift your body weight as needed. Snow and ice are slippery, so be prepared for the possibil- ity that your snow-mobile could begin to slip sideways on the slope. If this happens, steer in the direction of the slide if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. If your snowmobile starts to tip, steer down the hill to regain balance.

WARNING

If you are unable to maintain correct balance, and your snowmobile is going to tip over, dismount your snow- mobile immediately on the uphill side.

852-003

852-004

BR250TF_8AC-17_Ch07 00.10.5, 11:56 AM8

7-9

ICE OR ICY SURFACE Operating on ice or icy surfaces can be very dangerous. Traction for turning, stopping or starting is much less than that on snow.

WARNING

When you have to operate on ice or icy surfaces, drive slowly and cautiously. Avoid rapid acceleration, turn- ing or braking. Steering is minimal and uncontrolled spins are an ever-present danger.

HARD-PACKED SNOW It can be more difficult to negotiate on hard-packed snow as both skis and track do not have as much traction. Avoid rapid acceleration, turning or braking.

OPERATION ON SURFACES OTHER THAN SNOW OR ICE Operation of your snowmobile on surfaces other than ice or snow should be avoided. Operation under such condi- tions will damage or result in rapid wear of ski runners, drive track, slide runners and drive sprockets. Operation of the machine under the following conditions should be avoided at all costs: 1. Dirt 2. Sand 3. Rocks 4. Grass 5. Bare pavement

Other conditions that should be avoided for the sake of drive track and slide runner life are: 1. Glare ice surfaces 2. Snow mixed with a lot of dirt and sand All the above conditions have one thing in common in regard to drive track and slide runners; little or no lubricat- ing ability. Drive track and all slide rail systems require lubrication (snow or water) between the plastic runners and the metal track inserts. In the absence of lubrication, the plastic runners will rapidly wear and in severe cases, literally melt away, and the drive track will be subjected to damage and/or failure. Also, traction aids such as studs, cleats etc., may cause further track damage and/or failure.

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM9

7-10

WARNING

Drive track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident. Always check the drive track for damage or

misadjustment before operating the machine. Do not operate the machine if you find damage to

the drive track.

CAUTION: Be sure to ride on the fresh snow frequently to avoid rapid wear and damage of the drive track and slide runners when operating under ice or hard packed snow conditions.

ESU00251

MAXIMIZING DRIVE TRACK LIFE Recommendations

Track tension During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment fre- quently. (See pages 8-23 ~ 8-26 for adjustment proce- dures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage. Do not over- tighten the drive track, otherwise it may increase the friction between the track and the slide runners, resulting in the rapid wear of both components. Also, this may put an excessive load on the suspension components, resulting in component failure.

Marginal snow The drive track and the slide runners are lubricated and cooled by snow and water. To prevent the drive track and slide runners from overheating, avoid sustained high- speed usage in areas such as icy trails, frozen lakes and rivers that have minimal snow coverage. An overheated track will be weakened internally, which may cause failure or damage.

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM10

7-11

ESU00129

DRIVING (BR250T)

WARNING

Be sure to read SAFETY INFORMATION and RIDING YOUR SNOWMOBILE carefully before operating the machine.

NOTE: Be sure the engine is warmed up enough before riding.

1. Release the parking brake by squeezing the brake lever.

2. Press the throttle lever slowly to move the machine. 3. Turn the handlebar in the desired direction. 4. Squeeze the brake lever to stop the machine. 5. Apply parking brake squeeze the brake lever and

push down the button, then pinch it in place by releasing the brake lever.

Off-trail riding Avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a good overall base to properly cover debris, such as rocks, logs, etc. If snow coverage is not sufficient, stay on trails to avoid impact damage to the drive track.

Studded track In general, track life will be shortened when studs are installed. Drilling stud holes into the drive track will cut the internal fibers, which weakens the track. Avoid spinning the drive track. Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.

ESU00134

DRIVING (ET410TR/VK540E)

WARNING

Be sure to read SAFETY INFORMATION and RIDING YOUR SNOWMOBILE carefully before operating the machine.

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM11

7-12

NOTE: Be sure the engine is warmed up enough before riding.

1. Select the desirable shifting position by moving the shift lever.

1 FWD Forward 2 REV Reverse

ET410TR

WARNING

Be sure the throttle lever is fully released and the machine is at a full stop before shifting.

Be sure to move the shift lever to forward or reverse until it stops completely while the engine is idling.

Low range must not be used for speeds exceeding 50 km/h (30 mph). (VK540E)

Be sure the area behind is clear before reversing. Watch behind.

Reduce speed and avoid sharp turning when re- versing.

1 D Forward 2 R Reverse 3 L Forward low speed

VK540E

NOTE: The back buzzer beeps while the shift lever is in reverse.

2. Release the parking brake by squeezing the brake lever.

3. Press the throttle lever slowly to move the machine. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the machine. 6. Apply parking brake - squeeze the brake lever and push

down the button, then pinch it in place by releasing the brake lever.

817-004

B

817-012

A

A

817-013

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM12

7-13

831-046

831-021

ESU00137

STOPPING THE ENGINE 1. Turn the main switch to the OFF position to stop the

engine.

1 OFF

BR250T/ET410TR VK540E

WARNING

Push down the engine stop switch to stop the engine in an emergency.

Be sure the key is removed from the switch when- ever the operator leaves the machine, to prevent accidental starting.

A

ESU00138

TRANSPORTING When transporting your machine on a trailer or in a truck, observe the following recommendations to help protect your machine from damage: Make sure the fuel level in the fuel tank is lower than the

carburetors. Otherwise, the vibration and bumps from the road surface could make it possible for fuel to flow through the carburetor into the crankcase. This can result in hydrostatic lock, a condition where the engine cannot rotate because of fuel accumulated in the en- gine. Severe engine damage can result from hydro- static lock. When possible, the fuel tank should be empty during transportation, especially if the trip will be 30 minutes or longer.

If transporting the machine in an open trailer or truck, put a tight fitting cover on the machine. A cover specifi- cally designed for your snowmobile is best. This will help keep foreign objects out of the cooling vents in the shroud, and also help protect the machine against damage from debris on the road.

If transporting the machine in an open trailer or truck in areas where road salt is used, coat metal suspension surfaces lightly with oil or other protectant. This will help protect against corrosion. Be sure to clean the machine when you get to your destination to remove any corro- sive salts.

B

BR250TF_8AC-17_Ch07 00.10.5, 9:48 AM13

8-1

ESU00139

PERIODIC MAINTENANCE ESU00262

MAINTENANCE CHART Regular maintenance is most important for best performance and safe operation.

It is recommended that these items be serviced by a Yamaha dealer.

Page

Initial 1 month

or 800 km (500 mi) (40 hr)

Pre- operation

check (Daily)

RemarksItem

Check condition adjust the gap and clean. Replace if necessary.

Check oil level.

Air bleed the oil pump if necessary.

Check condition. Replace if necessary.

Check fuel level.

Check condition. Replace if necessary.

Check fuel hose and fuel cock for cracks or damage. Replace if necessary.

Check fuel hose for cracks or damage. Replace if necessary.

Check oil hose for cracks or damage. Replace if necessary.

Check throttle lever operation.

Adjust the jets.

Check wear and damage. Replace if necessary.

Adjust fan belt if necessary.

Check operation and rope damage. Replace if necessary.

Check operation Repair if necessary.

Spark plug

Engine oil

Oil filter

Fuel

Fuel filter

Fuel line (BR250T)

Fuel line (ET410TR/VK540E)

Oil line

Carburetor

Fan belt (VK540E)

Manual starter

Engine stop switch

Every Seasonally

or 3,200 km (2,000 mi) (160 hr)

Whenever operating condition (elevation/temperature) is changed.

8-5 ~ 8-6

6-3

6-1 ~ 6-3

5-2, 6-4, 8-7

8-11 ~ 8-12

6-4

5-3

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM1

8-2

Page

Initial 1 month

or 800 km (500 mi) (40 hr)

Pre- operation

check (Daily)

RemarksItem

Every Seasonally

or 3,200 km (2,000 mi) (160 hr)

Throttle override system

Throttle lever

Exhaust system

Decarbonization

Drive V-belt guard

Drive V-belt

Drive track/Idler wheels

Slide runners

Brake/ Parking brake

Drive chain oil (BR250T)

Drive chain oil (ET410TR/VK540E)

Drive chain (BR250T/VK540E)

Drive chain (ET410TR)

Ski/ Ski runner

Check operation. Repair if necessary.

Check operation. Repair if necessary.

Check for leakage. Retighten or replace gasket if necessary.

More frequently if necessary.

Check cracks, bends or damage. Replace if necessary.

Check wear and damage. Replace if necessary.

Check deflection, wear and damage. Adjust/replace if neces-

sary.

Check wear and damage.

Replace if necessary.

Check operation.

Adjust free play and/or replace pads if necessary.

Check oil level.

Replace.

Check oil level.

Replace.

Check deflection. Adjust if necessary.

Check deflection. Adjust if necessary.

Check wear and damage.

Replace if necessary.

5-3, 6-4

5-2, 6-4

5-8, 6-6

6-5, 8-12 ~ 8-14

6-6, 8-23 ~ 8-26

6-7

5-4, 6-5, 8-17 ~ 8-19

8-15

8-15

8-16

8-16

6-7

It is recommended that these items be serviced by a Yamaha dealer. Apply initial 1 month or 400 km (250 mi, 20 hr)

Initial at 500 km (300 mi) and every 400 km (250 mi) thereafter.

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM2

8-3

Page

Initial 1 month

or 800 km (500 mi) (40 hr)

Pre- operation

check (Daily)

RemarksItem

Every Seasonally

or 3,200 km (2,000 mi) (160 hr)

Whenever operating elevation is changed.

8-29

5-7

6-8

6-8

6-8, 8-32, 10-1 ~ 10-2

6-8, 8-30 ~ 8-31

8-29

Check operation.

Adjust toe-out if necessary.

Check operation. Replace bulbs if necessary.

Check fluid level. Add only distilled water if necessary.

Check specific gravity and breather pipe operation. Charge/Correct if neces- sary.

Check engagement and shift speed. Adjust if necessary.

Inspect sheaves for wear/ damage. Inspect weights/rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary.

Lubricate with specified grease.

Lubricate with specified grease.

Lubricate with specified grease.

Lubricate with specified grease.

Lubricate with specified grease.

Check cable damage. Replace if necessary.

Make sure the shroud latches are hooked.

Check tightness. Repair if necessary.

Check proper placement.

6-7 Steering system

Lights

Battery (VK540E)

Primary and secondary clutches

Steering column bearing

Ski and front suspension

Suspension component

Brake cable end and lever end/ Throttle cable end

Shroud latches

Fittings/Fasteners

Service tools/Spare parts

It is recommended that these items be serviced by a Yamaha dealer.

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM3

8-4

ESU00141

TOOL KIT The owners tool kit has the tools which are sufficient for most periodic maintenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts.

1 Tool kit

NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them if necessary.

BR250T ET410TR VK540E

846-015

A

B

C

846-020

846-006

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM4

8-5

ESU00144

SPARK PLUG INSPECTION The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something of the condition of the engine. Check the coloration on the white porcelain insulator around the center electrode. The ideal coloration at this point is a medium to a light tan color for a machine that is being ridden normally. If a spark plug shows a distinctly different color, there could be something wrong with the engine. For example, a very white center electrode porcelain color could indicate an intake track air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the machine to your Yamaha dealer. You should periodically remove and in- spect the spark plug because heat and deposits will cause any spark plug to slowly break down and erode. Consult your dealer before changing to a different type of spark plug.

Standard spark plug: BR250T

BR8HS (NGK) ET410TR/VK540E

BR9ES (NGK)

Spark plugs are produced in several different thread lengths. The thread length (reach) is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor performance may result. Also, if too short, carbon will form on the exposed threads resulting in combustion chamber hot spots and thread damage. Always use a spark plug with the proper reach.

Spark plug reach 1: BR250T

12.7 mm (0.50 in) ET410TR/VK540E

19.0 mm (0.75 in)

Before installing any spark plug, measure the electrode gap with a wire thickness gauge and adjust to specification.

834-001

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM5

8-6

Spark plug gap 2: BR250T

0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ET410TR/VK540E

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

When installing the plug, always clean the gasket surface. Wipe off any grime from the threads and torque the spark plug properly.

Spark plug torque: 28 Nm (2.8 mkg, 20 ftlb)

834-001

ESU00146

ENGINE IDLE SPEED ADJUSTMENT

CAUTION: Be sure this adjustment is serviced by a Yamaha

dealer. Be sure the throttle lever moves smoothly.

1. Start the engine.

NOTE: Refer to STARTING THE ENGINE.

2. Turn the throttle stop screw 1 in or out to adjust the engine idle speed.

Standard engine idle speed: BR250T

1100 100 r/min ET410TR

1900 100 r/min VK540E

1200 100 r/min

BR250T ET410TR VK540E

804-014

A

B

C

816-029

804-018

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM6

8-7

816-034

C

ESU00147

THROTTLE CABLE ADJUSTMENT

CAUTION: Be sure the engine idle speed is adjusted first.

1. Loosen the adjuster locknut. 2. Turn the adjuster in or out until proper throttle lever free

play is achieved.

Throttle lever free play 1: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)

2 Locknut 3 Adjuster

BR250T ET410TR VK540E

3. Tighten the locknut.

816-028

A

B

816-017

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM7

8-8

ESU00149

OIL PUMP CABLE ADJUSTMENT

CAUTION: Be sure the throttle cable is adjusted first.

1. Loosen the adjuster locknut. 2. Pull the oil pump outer cable and adjust the free play

between the adjuster and outer cable by turning the adjuster in or out.

Pump cable free play 1: BR250T/VK540E

25 1 mm (0.98 0.04 in) ET410TR

22 1 mm (0.87 0.04 in)

2 Locknut 3 Adjuster

BR250T ET410TR VK540E

3. Tighten the locknut.

800-011

A

816-041

B

800-008

C

ESU00152

CARBURETOR ADJUSTMENT

CAUTION: Be sure this adjustment is serviced by a Yamaha

dealer. Be sure the carburetor silencer is installed during

running to prevent engine damage.

Under some operating conditions the carburator setting may have to be changed due to air temperature changes, elevation changes, use of alcohol oxygenated fuels, etc. and should be done by an authorized Yamaha dealer.

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM8

8-9

B

CAUTION: The drive chain gears and V-belt clutch should be adjusted when operating over 900 m (3000 ft) high altitude. Consult a Yamaha dealer.

Pilot Screw Adjustment Turn the pilot screw in or out to adjust low speed tuning.

Standard pilot screw position: BR250T/VK540E

1 1/4 ET410TR

1 3/8 turns out from the seated position

804-036

Warmer weather

Higher altitude

Colder weather

Lower altitude

Pilot screw Mixture Condition

Turn in

Turn out

Leaner

Richer

BR250T ET410TR VK540E

Main Jet Replacement Replace the main jet according to the setting chart which is available at an authorized Yamaha dealer.

WARNING

Never remove the drain plug or the float chamber while the engine is hot. Fuel will flow out from the float chamber which could ignite and cause injury.

A

804-032

804-017

C

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM9

8-10

Warmer weather

Higher altitude

Colder weather

Lower altitude

Main jet Mixture Condition

Smaller No.

Larger No.

Leaner

Richer

1. Loosen the carburetor clamps and turn over the carbu- retor.

2. Pinch the fuel hose to prevent fuel flowing. 3. Remove the drain plug and install the proper main jet. 4. Assemble by reversing the removal steps.

WARNING

Be sure the throttle outer cable is firmly seated in the holder and the throttle operates smoothly after assem- bling the carburetor.

BR250T ET410TR VK540E

804-023

Place a rag under the carburetor before removing the drain plug or float chamber to catch any spilled fuel.

Handle fuel with care: it is highly flammable.

Standard main jet: BR250T

#105 ET410TR

#166 VK540E

#141.3

B

C

A

804-033

804-026

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM10

8-11

ESU00157

HIGH ALTITUDE ADJUSTMENTS Operating at high altitude reduces the performance of a gasoline engine, about 3% for every 305 m (1000 ft) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for com- bustion. Your snowmobile can be adjusted to overcome most of the problems found in high altitude riding. Carburetor adjust- ments are the most important. Less air at high altitude makes the fuel/air ratio too rich, which can cause poor performance. Common problems are hard starting, bog- ging, and plug fouling. Follow the Main Jet Setting chart which is available at an authorized Yamaha dealer care- fully. Proper carburetion adjustments will correct the fuel/ air ratio.

Remember: less air at higher altitude means there is less horsepower available, even with proper carburetion. Ex- pect acceleration and top speed to be reduced at higher altitudes. To overcome operating with less power at high altitudes, your snowmobile may also require different clutch and driveline settings to avoid poor performance and rapid wear. If you plan to operate your snowmobile at an altitude different from the area where you bought your machine, be sure to consult your Yamaha dealer. He can tell you if there are any changes necessary for the altitude where you plan to ride.

CAUTION: The drive chain gears and V-belt clutch should be adjusted when operating over 900 m (3000 ft) high altitude. Consult a Yamaha dealer.

ESU00162

FAN BELT (VK540E) Deflection check 1. Remove the fan cover.

805-074

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM11

8-12

ESU00163

DRIVE V-BELT REPLACEMENT (BR250T)

NOTE: Apply the parking brake before replacement.

1. Remove the drive V-belt guard. 2. Rotate the secondary sliding sheave clockwise 1 and

push 2 it so that it separates from the fixed sheave. 3. Pull 3 the belt up over the secondary fixed sheave. 4. Remove the belt from the secondary sheave and pri-

mary sheave.

5. Install the new belt over the primary sheave.

6. Rotate the secondary sliding sheave clockwise 4 and push 5 it so that it separates from the fixed sheave.

7. Install the belt 6 between the secondary sliding and fixed sheaves.

8. Install the drive V-belt guard.

WARNING

Never run the engine without the drive V-belt or with the drive V-belt guard removed.

805-002

805-003

805-004

805-005

805-072

2. Measure the fan belt deflection by applying 50 N {5 kg (11 lb)} of force at the center of belt.

1 Deflection 2 50 N {5 kg (11 lb)}

Standard belt deflection: 8 mm (0.31 in)/50 N {5 kg (11 lb)}

If the deflection exceeds the specification, consult a Yamaha dealer.

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM12

8-13

ESU00164

DRIVE V-BELT REPLACEMENT (ET410TR/VK540E)

WARNING

Be sure there are 2 spacers 1 between secondary fixed and sliding sheaves when installing the NEW belt. If there is no gap, the clutch engagement speed will be reduced. The machine may move unexpectedly when the engine is started.

The spacer adjustment of the secondary sheave should be serviced by a Yamaha dealer. Serious injury can occur from sudden release of spring tension during sheave disassembly.

CAUTION: To ensure proper clutch performance, the spacers in the secondary clutch must be repositioned as the V- belt wears. For this adjustment, consult a Yamaha dealer.

805-030

ET410TR 31.6 mm (1.24 in)

VK540E 35 mm (1.38 in)

2 spacers between sheaves

ET410TR 30.6 mm (1.20 in)

VK540E 34 mm (1.34 in)

1 spacer between sheaves

ET410TR 29.6 mm (1.17 in)

VK540E 33 mm (1.30 in)

No spacer between sheaves

Belt width

Spacer position

New belt width

ET410TR 31.6 mm (1.24 in)

VK540E 35 mm (1.38 in)

Belt wear limit width

ET410TR 28 mm (1.10 in)

VK540E 32 mm (1.26 in)

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM13

8-14

NOTE: Apply the parking brake before replacement.

1. Remove the drive V-belt guard. 2. Rotate the secondary sliding sheave clockwise 1 and

push 2 it so that it separates from the fixed sheave. 3. Pull 3 the belt up over the secondary fixed sheave. 4. Remove the belt from the secondary sheave and pri-

mary sheave.

5. Install the new belt over the primary sheave.

6. Rotate the secondary sliding sheave clockwise 4 and push 5 it so that it separates from the fixed sheave.

7. Install the belt 6 between the secondary sliding and fixed sheaves.

8. Install the drive V-belt guard.

WARNING

Never run the engine without the drive V-belt or with the drive V-belt guard removed.

805-002

805-003

805-004

805-005

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM14

8-15

ESU00261

DRIVE CHAIN HOUSING Oil Replenishing 1. Check the oil level by removing the level bolt and filler

cap.

Oil flowing from level bolt hole Oil level

Slight flow CORRECT

No flow Insufficient

1 Level bolt 2 Filler cap

BR250T ET410TR VK540E

2. Add chain oil until it begins to flow out from the level hole.

Drive chain oil: API GL-3 SAE 75 or 80

CAUTION: Be sure no foreign material enters the gearcase.

3. BR250T: Check the level hole bolt gasket. If damaged, replace it. ET410TR/VK540E: Check the level hole bolt gasket and filler cap O-ring. If damaged, replace it.

4. Install the level hole bolt and filler cap.

807-017

A

B

807-019

807-012

C

BR250TF_8AC-17_Ch08 00.10.5, 1:33 PM15

8-16

Chain Adjustment (BR250T/ET410TR) 1. Loosen the adjuster locknut. 2. Turn the adjuster in finger-tight.

1 Locknut 2 Adjuster

BR250T ET410TR

NOTE: Be sure the oil seal 3 is separated from the chain case 4 surface.

3. Tighten the locknut.

Chain Tension Adjustment (VK540E) 1. Remove the cap and measure the chain deflection by

pushing the chain by finger.

1 Cap

Standard chain deflection 2: 8 ~ 15 mm (0.3 ~ 0.6 in)

If the deflection exceeds specification, adjust the chain tension. 2. Loosen the locknut. 3. Turn the adjuster bolt in or out until proper chain

deflection is achieved.

3 Locknut 4 Adjuster bolt

4. Tighten the locknut. 5. Install the cap.

807-045

807-021

A

B

807-013

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM16

8-17

ESU00175

BRAKE/PARKING BRAKE (BR250T) Checking Pad Wear Check pad wear by measuring the thickness of the brake pad. If the pad reaches the wear limit, consult a Yamaha dealer for replacement.

Wear limit 1: 1.0 mm (0.04 in)

Adjustment Brake adjustment is necessary when the brake lever exceeds the proper free play.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

1. Loosen the locknut 1. 2. Turn the pad adjuster 2 in or out to adjust the clearance

between the pad 3 and disc 4.

Clearance 5: 0.2 ~ 1.0 mm (0.008 ~ 0.040 in)

3. Turn the cable adjuster 6 in or out to adjust the clearance between the pad 7 and disc 4.

Clearance 8: 0.2 ~ 1.0 mm (0.008 ~ 0.040 in)

4. Check the brake lever free play.

Brake lever free play 9: 6 ~ 7 mm (0.24 ~ 0.28 in)

Repeat steps 2, 3, and 4 until the specified clearances and free play are achieved.

5. Tighten the locknut.

818-004

818-005

818-006

818-010

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM17

8-18

ESU00178

BRAKE/PARKING BRAKE (ET410TR) Checking Pad Wear Check pad wear by measuring the thickness of the brake pad. If the pad reaches the wear limit, consult a Yamaha dealer for replacement.

Wear limit 1: 9.5 mm (0.37 in)

Adjustment Brake adjustment is necessary when the brake lever exceeds the proper free play.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

1. Loosen the locknut 1. 2. Turn the cable adjuster 2 in or out to adjust the distance

L.

Distance L: 57 mm (2.24 in)

3. Turn the pad adjuster 3 in or out to adjust the clearance between the pad 4 and disc 5.

Clearance 6: 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

CAUTION: Insert the proper feeler gauge between pad and disc to measure the clearance.

4. Check the brake lever free play.

Brake lever free play 7: 6 ~ 7 mm (0.24 ~ 0.28 in)

Repeat steps 2, 3 and 4 until the specified clearances and free play are achieved.

5. Tighten the locknut.

818-028

818-029

818-030

818-031

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM18

8-19

818-028

ESU00176

BRAKE/PARKING BRAKE (VK540E) Checking Pad Wear Check pad wear by measuring the thickness of the brake pad. If the pad reaches the wear limit, consult a Yamaha dealer for replacement.

Wear limit 1: 9.5 mm (0.37 in)

Adjustment This machine has a self-adjusting brake caliper. No adjust- ment is necessary under normal conditions. If free play at the brake lever is incorrect, consult a Yamaha dealer.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

ESU00184

SUSPENSION (BR250T) The suspension can be adjusted to suit rider preference. A softer setting, for example, may provide greater rider comfort, while a stiffer setting may allow more precise handling and control over certain types of terrain or riding conditions.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

WARNING

This shock absorber contains highly pressurized ni- trogen gas. It could explode by improper handling, causing injury or property damage. Do not tamper with or attempt to open the shock

absorber assembly. Do not subject the shock absorber assembly to

open flame or other high heat, which could cause it to explode.

Do not deform or damage the shock absorber in any way.

Do not dispose of a damaged or worn out shock absorber by yourself. Take the unit to your Yamaha dealer.

820-046

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM19

8-20

ESU00185

SUSPENSION (ET410TR) The suspension can be adjusted to suit rider preference. A softer setting, for example, may provide greater rider comfort, while a stiffer setting may allow more precise handling and control over certain types of terrain or riding conditions.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

Spring Preload Adjust the spring preload by turning the spring seat 1.

1 2 3

Harder Softer

2

Spring seat position

Preload

Standard

820-053

CAUTION: Be sure the left and right spring preload is same.

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM20

8-21

ESU00188

SUSPENSION (VK540E) The suspension can be adjusted to suit rider preference. A softer setting, for example, may provide greater rider comfort, while a stiffer setting may allow more precise handling and control over certain types of terrain or riding conditions.

WARNING

Be sure this adjustment is serviced by a Yamaha dealer.

Spring Preload The spring preload can be adjusted by turning the adjuster 1.

820-084

820-085

Extension Spring Preload Adjust the spring preload by turning the adjuster 1.

Adjuster Turn in Turn out

Preload Harder Softer

Snow condition Icy Soft

2 Standard length 16 mm (0.63 in)

CAUTION: Be sure the left and right spring preload is same.

820-049

1 2 3 4 5

Softer Harder

3

Spring adjuster position

Preload

Standard (Front)

1 2 3 4 5 6 7

Softer Harder

4

Spring adjuster position

Preload

Standard (Rear)

B

A

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM21

8-22

ESU00197

FULL RATE ADJUSTER (VK540E) The total suspension spring rate and damping character- istics can be adjusted by changing the installed position of the shock-absorber assembly.

WARNING

Be sure this adjustment is made by a Yamaha dealer.

C B A

Hard Medium Soft

A

Installation position

Spring rate and damping

Standard

820-102

820-088

820-087

NOTE: Be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile.

1. Loosen the nut 1 1/2 or 3/4 turns, while holding the adjusting bolt 2 securely with a wrench so it does not move.

CAUTION: Never allow the adjusting bolt 2 to move while loosen- ing the nut.

2. Turn the adjusting bolt 2 to the desired position.

CAUTION: Be sure the adjusting bolt ends are set at the same position on each side.

3. While holding the adjusting bolt securely, tighten the nut 1.

Nut tightening torque: 49 Nm (4.9 mkg, 35.4 ftlb)

CAUTION: Never allow the adjusting bolt to move while tighten- ing the nut.

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM22

8-23

ESU00263

TRACK ADJUSTMENT

WARNING

A broken track, track fittings, or debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions: Do not allow anyone to stand behind the machine

when the engine is running. When the rear of the machine is raised to allow the

track to spin, a suitable stand must be used to support the rear of the machine. Never allow any- one to hold the rear of the machine off the ground to allow the track to spin. Never allow anyone near a rotating track.

Inspect track condition frequently. Replace dam- aged track guide clips. Replace the track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken. Oth- erwise, track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident.

Never install studs (cleats) closer than three inches from the edge of the track.

Track Deflection Measurement 1. Lay the machine on its side. 2. Measure the track deflection with a spring scale. Pull at

the center of the track with a force of 100 N {10 kg (22 lb)}.

NOTE: Measure the gap between the slide runner and the edge of the track window. Measure both sides.

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM23

8-24

820-003

1 Deflection 2 100 N {10 kg (22 lb)}

Standard track deflection: BR250T

40 ~ 50 mm (1.57 ~ 1.97 in)/100 N {10 kg (22 lb)} ET410TR

30 ~ 35 mm (1.18 ~ 1.38 in)/100 N {10 kg (22 lb)} VK540E

35 ~ 45 mm (1.38 ~ 1.77 in)/100 N {10 kg (22 lb)}

3. If the deflection is incorrect, adjust the track.

Track Adjustment (BR250T)

WARNING

Be sure this adjustment is made by a Yamaha dealer.

Support the machine securely on a suitable stand before working underneath the machine.

Operate the engine in a well-ventilated area.

1. Lift the rear of the machine onto a suitable stand to raise the track off the ground.

2. Loosen the rear axle bolts 1. 3. Start the engine and rotate the track one or two turns.

Stop the engine.

4. Check the track alignment with the slide runner 3. If the alignment is incorrect, turn the left and right adjuster to adjust.

820-051

820-008

820-052 Turn out

Turn in

Turn in

Turn out

4 Left adjuster

5 Right adjuster

Track alignment 6 Shifted to right

7 Shifted to left

8 Slide runner 9 Track 0 Track metal AGap B Forward

820-009

6 7

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM24

8-25

820-007

Turn in

Turn in

Turn out

Turn out

4 Left adjuster

5 Right adjuster

Track deflection More than Specified

Less than Specified

NOTE: Install the box C and wrench D of the tool kit on the adjuster locknut E to turn the adjuster as follows; Set the wrench as far as space permits and turn it. Remove the wrench and turn it over F and install

wrench on the box. Repeat the above steps.

5. Adjust track deflection to the specified amount.

CAUTION: The adjusters should be turned an equal amount.

6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until proper adjustment is achieved.

7. Tighten the rear axle bolts.

Track Adjustment (ET410TR/VK540E)

WARNING

Be sure this adjustment is made by a Yamaha dealer.

Support the machine securely on a suitable stand before working underneath the machine.

Operate the engine in a well-ventilated area.

1. Lift the rear of the machine onto a suitable stand to raise the track off the ground.

2. Loosen the rear axle nut 1.

NOTE: It is not necessary to remove the cotter pin 2.

3. Start the engine and rotate the track one or two turns. Stop the engine.

4. Check the track alignment with the slide runner 3. If the alignment is incorrect, turn the left and right adjusters to adjust.

820-004

820-008

820-052

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM25

8-26

8 Slide runner 9 Track 0 Track metal AGap B Forward 5. Adjust track deflection to the specified amount.

820-005

Turn out

Turn in

Turn in

Turn out

4 Left adjuster

5 Right adjuster

Track alignment 6 Shifted to right

7 Shifted to left

Turn in

Turn in

Turn out

Turn out

4 Left adjuster

5 Right adjuster

Track deflection More than Specified

Less than Specified

820-009

6 7

CAUTION: The adjusters should be turned an equal amount.

6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until proper adjustment is achieved.

7. Tighten the rear axle nut.

Rear axle tightening torque: ET410TR

75 Nm (7.5 mkg, 55 ftlb) VK540E

80 Nm (8.0 mkg, 58 ftlb)

820-005

ESU00200

SKI ALIGNMENT 1. Turn the handlebars so the skis face straight ahead. 2. Check the following for ski alignment.

1) Ski is facing forward. 2) Ski toe-out (1 2) is within specification.

Ski toe-out (1 2): 0 ~ 15 mm (0 ~ 0.6 in)

3. If alignment is not correct, consult a Yamaha dealer.

819-001

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM26

8-27

819-041

ESU00202

HANDLEBAR ADJUSTMENT (BR250T) 1. Loosen the handlebar bolts. Move the handlebar as-

sembly up or down to adjust the handlebar height to the desired position.

2. Tighten the handlebar bolts.

Handlebar bolt tightening torque: 14 Nm (1.4 mkg, 1.0 ftlb)

CAUTION: Be sure the small gap 1 side of the holder faces forward 2.

819-040

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM27

8-28

ESU00201

HANDLEBAR ADJUSTMENT (ET410TR/VK540E) 1. Remove the handlebar cover 1. 2. Loosen the handlebar bolts. Move the handlebar

assembly up or down to adjust the handlebar height to the desired position.

3. Tighten the handlebar bolts and install the handlebar cover.

Handlebar bolt tightening torque: 15 Nm (1.5 mkg, 11 ftlb)

CAUTION: Be sure the small gap 1 side of the holder faces forward 2.

ET410TR VK540E

845-026

819-040

845-036

A

845-012

B

819-077

BR250TF_8AC-17_Ch08 00.10.5, 11:58 AM28

8-29

B

ESU00264

LUBRICATION Lubricate the following points.

Lubricant: Low-temperature grease

1 Brake/Throttle cable ends 2 Ski wear plate (BR250T) 3 Front suspension (VK540E) 4 Rear suspension (VK540E)

WARNING

Apply a dab of grease to the cable end only. Do not grease the brake/throttle cables themselves because they could become frozen, which could cause loss of control.

BR250T VK540E

819-074

A

818-026

819-075

B

820-096

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM29

8-30

832-022

832-023

832-007

A

832-026

B

ESU00207

HEADLIGHT (BR250T/ET410TR) Bulb Replacement 1. Lift up the shroud. 2. Disconnect the lead coupler. 3. Remove the bulb cover. 4. Remove the bulb holder by depressing and turning it

counterclockwise.

1 Bulb cover

5. Remove the bulb.

WARNING

Keep flammable products or your hands away from the hot bulb until it cools down.

6. Install the new bulb.

Bulb type: BR250T

12 V, 60/55 W ET410TR

12 V, 60/60 W

CAUTION: Keep oil or your hands away from the glass part of bulb or its life and illumination will be affected. If the glass is oil stained, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

BR250T ET410TR

Beam Adjustment 1. Turn the adjuster 1 in or out to adjust the headlight

beam.

832-021

BR250TF_8AC-17_Ch08 00.10.5, 11:59 AM30

8-31

ESU00211

HEADLIGHT (VK540E) Bulb Replacement 1. Lift up the shroud. 2. Disconnect the lead coupler. 3. Remove the socket cover and bulb set spring.

1 Socket cover

4. Remove the bulb.

WARNING

Keep flammable products or your hands away from the hot bulb until it cools down.

5. Install the new bulb.

Bulb type: 12 V, 60/55 W

CAUTION: Keep oil or your hands away from the glass part of bulb or its life and illumination will be affected. If the glass is oil stained, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

6. Set the spring and install the secket cover. Reconnect the bulb coupler.

Beam Adjustment 1. Turn the adjuster 1 in or out to adjust the headlight

beam.

832-009

832-007

832-017

BR250TF_8AC-17_Ch08 00.10.5, 11:59 AM31

8-32

ESU00213

BATTERY (VK540E) Replenishing the battery fluid 1. Check the fluid level. The level should be between the

upper and lower level marks.

1 UPPER LEVEL 2 LOWER LEVEL

2. Add only distilled water if necessary.

CAUTION: Normal tap water contains minerals which are harmful to a battery; therefore refill only with distilled water.

WARNING

Battery electrolyte is poisonous and dangerous. It contains sulfuric acid and can cause severe burns. Avoid contact with skin, eyes or clothing. ANTIDOTE:

EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or

milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or us- ing in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN.

830-002

830-005

BR250TF_8AC-17_Ch08 00.10.5, 9:48 AM32

8-33

ESU00214

FUSE REPLACEMENT (VK540E)

WARNING

Be sure to use specified fuse. A wrong fuse will cause electrical system damage and A FIRE HAZARD.

CAUTION: Be sure the main switch is turned off to prevent accidental short circuiting.

1. Lift up the shroud. 2. Replace the blown fuse with one of proper amperage.

NOTE: If the fuse immediately blows again, consult Yamaha dealer.

Fuse type: 10 A

835-003

BR250TF_8AC-17_Ch08 00.10.5, 11:59 AM33

9-1

816-023

WARNING

Before bypassing the T.O.R.S., be sure the throttle returns properly to the fully-closed position.

The T.O.R.S. is an important safety device; in the case of a malfunction, take the machine to a Yamaha dealer immediately for repair.

BR250T ET410TR VK540E

3. Compression Insufficient

Loose cylinder head nuts ... Tighten nuts properly.

Damaged gasket ... Replace gasket. Worn out piston and cylinder ... Consult

dealer.

B. Engine does not turn over with manual starter

1. Seized engine ... Seizure is caused by poor lubrication, inadequate fuel, or an air leak Consult dealer.

2. Hydrolock (fuel has filled crankcase when vehicle was transported) ... Re- move spark plug(s), turn engine over several times with ignition off to expel excess fuel. Consult dealer.

ESU00265

TROUBLESHOOTING A. Engine turns over but doesnt

start 1. Fuel system

No fuel supplied to combustion chamber No fuel in tanks ... Supply fuel both tanks.

(BR250T) No fuel in tank ... Supply fuel.

(ET410TR/VK540E) Clogged fuel line ... Clean fuel line. Foreign matter in fuel cock ... Clean fuel

cock. (BR250T) Clogged carburetor ... Clean carburetor.

Fuel supplied to combustion chamber. Flooded engine (too much choke) ...

Crank engine with throttle open or wipe spark plug dry.

2. Electrical system Poor or no spark

Spark plug dirty with carbon/wet ... Re- move carbon/wipe spark plug dry, or re- place spark plug.

Faulty ignition system ... Consult dealer. T.O.R.S. system malfunction ... Discon-

nect the carburetor switch connectors and connect the wire harness connectors together to bypass T.O.R.S..

B

C

A

853-001

816-022

BR250TF_8AC-17_Ch09 00.10.5, 11:59 AM1

9-2

C. Electric starter does not operate or operates slowly (VK540E)

1. Faulty wire connections ... Check con- nections or consult dealer.

2. Battery discharged ... Check battery fluid and charge battery.

3. Engine trouble ... Check B above.

D. Engine power is low 1. Faulty spark plug(s) ... Clean or replace

spark plug(s). 2. Jetting incorrect for altitude or tempera-

ture ... carburetor. Consult dealer. 3. Improper fuel flow ... See A.1. above. 4. Clutch settings not correct for altitude

and/or conditions ... Consult dealer.

E. Engine constantly backfires or mis- fires

1. Faulty spark plug(s) ... Replace spark plug(s).

2. Fuel system clogged ... See A.1. above. 3. T.O.R.S. malfunction ... See T.O.R.S. in

A.2. above.

F. Machine does not move 1. Clutch malfunction ... Consult dealer. 2. Drive track does not move ... foreign

object is caught in track, or slide runner has melted to track metal due to lack of lubrication.

3. Drive chain too tight, too loose, or broken ... Consult dealer.

G. Drive belt twists 1. Improper belt ... Replace with correct

belt. 2. Clutch offset incorrect ... Consult dealer. 3. Engine mount loose or broken ... Consult

dealer.

H. Drive belt slips or burns 1. Belt or sheave surface oily or dirty ...

clean. 2. Problem with drive line ... See F above.

I. Engine does not upshift or downshift properly/engages harshly

1. Drive belt worn ... replace belt or consult dealer.

2. Clutch settings incorrect for altitude/con- ditions ... Consult dealer.

3. Primary clutch worn or sticking ... Consult dealer.

4. Secondary clutch worn or sticking ... Consult dealer.

J. Noise or excessive vibration in drive line

1. Broken clutch components ... Consult dealer.

2. Worn or damaged bearings ... Consult dealer.

3. Drive belt damaged or worn with flat spots ...Replace.

4. Idler wheel/shaft damage ... Consult dealer.

5. Track damaged ... Consult dealer.

BR250TF_8AC-17_Ch09 00.10.5, 9:48 AM2

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ESU00252

STORAGE Long term storage, requires some preven- tive procedures to guard against deteriora- tion.

1. Cleaning Thoroughly clean the machine, inside and out, to remove the corrosive salts and acids that can accumulate. Use Yamaha Mud and Grease Release, or an equivalent, to loosen mud, grease and grime. Wash with mild soap, then rinse and dry completely.

2. Lubrication Lubricate moving parts, suspension link- age and pivot points. Use the grease or lubricant specified in the MAINTENANCE section, or Yamaha Lube-Zall general purpose lubricant. Proper lubrication fights corrosion while it reduces friction.

3. Fuel system preparation Add Yamaha Fuel Conditioner/Stabilizer, or an equivalent, to the fuel tank to help prevent fuel oxidation, gum and varnish deposits, and to inhibit corrosion in the fuel system and carburetor. In areas where oxygenated fuel (gasohol) is used, completely drain the fuel system. Consult your Yamaha dealer.

4. Engine Proper storage of the engine is essential to prevent costly rust and corrosion dam- age to internal engine components. This is more important than ever in those areas where oxygenated fuel (gasohol) is used, because the alcohol content in the fuel increases the chance for water to enter the engine. Use Yamaha Stor-Rite Fogging Oil, or an equivalent, to protect both combustion chamber and crank-

shaft from corrosion. An alternate method is to remove the airbox and squirt oil into the carburetor throats while the engine is running.

CAUTION: Do not attempt to store the machine by simply starting the engine occasionally during the storage period. This can cause more harm than good! Moisture and acids form during combustion which can actually increase the chance for corro- sion damage during the storage period.

5. Protection Apply a coat of wax, such as Yamaha Silicone Wax, to painted surfaces. Spray Yamaha Silicone Spray, or an equivalent protectant, on the exterior of the engine, on the track, and on other metal, plastic and rubber parts.

6. Battery (VK540E) Remove the battery from the snowmobile and check the fluid level. Add only dis- tilled water if necessary. (See page 8-32 the BATTERY-Replenishing the battery fluid section.) After checking the fluid level, charge the battery. Store it in a cool, dry place that is above 0C (32F), but less than 30C (90F). Check battery condition with a hydrometer monthly, and charge as necessary.

WARNING

Never smoke or make and break con- nections at the battery while charging. Sparks may ignite the battery gas.

Be sure the battery terminals are tight and that the battery vent tube is prop- erly routed and is securely attached to the battery.

BR250TF_8AC-17_Ch10 00.10.5, 9:48 AM1

10-2

CAUTION: Do not charge battery quickly. Charge for 10 hours at 1.6 amperes.

7. Track Loosen the track, and block up the chas- sis so that the track is suspended above the ground.

8. Drive belt Remove the drive belt and store sepa- rately.

9. Storage Store the machine in a dry, well-venti- lated place out of direct sunlight. Put a fabric (breathable) cover over it, prefer- ably one designed for your machine. Do not use a plastic or vinyl cover conden- sation could be trapped underneath which could increase the chance of rust- ing.

RETURN TO SERVICE AFTER STORAGE

When returning your machine to service, reinstall the drive belt and adjust the track. Reinstall the battery, and make sure the battery vent tube is properly reinstalled and is not kinked. Remove the spark plugs and clean them or replace them. Perform all other pre-opera- tion and seasonal maintenance listed in the Periodic Maintenance chart.

For peak performance, it is recommended that you have your machine checked and tuned by your Yamaha dealer. He has the experience and training to help you get the maximum performance and use from your Yamaha.

BR250TF_8AC-17_Ch10 00.10.5, 9:48 AM2

11-1

ESU00228

SPECIFICATIONS (BR250T) ESU00229

DIMENSIONS

BR250T

Overall length Overall width Overall height Dry weight Ski tread

2945 mm (115.9 in) 950 mm ( 37.4 in) 1120 mm ( 44.1 in) 175 kg ( 386 lb) 750 mm ( 29.5 in)

ESU00230

ENGINE

BR250T

Fan cooled 2-stroke, 5-port 1-cylinder 246 cm3

70.0 64.0 mm (2.76 2.52 in) 1100 100 r/min YAMALUBE 2-cycle oil KEIHIN BD32-28 1 Unleaded gasoline

Pump octane R + M

; 88 or higher 2

Manual with recoil starter

Type Cylinder arrangement Displacement Bore Stroke Idle speed Engine oil type Carburetor type Fuel

Starting system

ESU00231

CHASSIS

BR250T

Drive track and suspension: Track Width Track deflection

Length on ground Suspension type Drive sprocket

Molded rubber, fiber glass rod reinforced 381 mm (15.0 in) 40 ~ 50 mm (1.57 ~ 1.97 in)/ 100 N {(10 kg (22 lb)} 1126 mm (44.3 in) Slide rail suspension Double polyethylene, 7 teeth

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM1

11-2

BR250T

Transmission: Type

Sheave distance Sheave offset Engagement speed

Shift speed

Drive chain Reduction ratio

Fuel tank: Tank capacity

Oil tank: Tank capacity

Brake: Type Operation

Throttle: Operation

Automatic centrifugal engagement, infinitely variable 3.5:1 ~ 1:1 Approx. 266 mm (10.47 in) Approx. 11 mm (0.43 in) Approx. 3200 r/min Approx. 5900 r/min Single roller chain enclosed in oil bath 24/10 (2.40)

Main tank: 15 L (3.3 lmp gal, 4.0 US gal)

Sub tank: 9.3 L (2.05 Imp gal, 2.46 US gal)

1.8 L (1.6 lmp qt, 1.9 US qt)

Caliper type, disc brake Handle lever, left hand operated

Handle lever, right hand operated

Subject to change according to elevation settings.

ESU00232

ELECTRIC

BR250T

Ignition system Spark plug Type

Gap Headlight Bulb Quantity Tail/brake light Bulb Quantity Meter light Bulb Quantity

CDI BR8HS (NGK) 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 12 V, 60/55 W 1 12 V, 8/23 W 1 12 V, 3.4 W 1

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM2

11-3

ESU00228

SPECIFICATIONS (ET410TR) ESU00229

DIMENSIONS

ET410TR

Overall length Overall width Overall height Dry weight Ski tread

2920 mm (115.0 in) 1115 mm ( 43.9 in) 1200 mm ( 47.2 in) 217 kg ( 478 lb) 920 mm ( 36.2 in)

ESU00230

ENGINE

ET410TR

Fan cooled two-stroke, 5-port Parallel 2-cylinders 408 cm3

66.0 59.6 mm (2.598 2.346 in) 1900 100 r/min YAMALUBE 2-cycle oil TEIKEI Y26W-2 1 Unleaded gasoline

Pump octane R + M ; 88 or higher 2

Manual with recoil starter

Type Cylinder arrangement Displacement Bore Stroke Idle speed Engine oil type Carburetor type Fuel

Starting system

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM3

11-4

ESU00231

CHASSIS

ET410TR

Drive track and suspension: Track Width Track deflection

Length on ground Suspension type Drive sprocket

Transmission: Type

Sheave distance Sheave offset Engagement speed

Shift speed

Drive chain Reduction ratio

Fuel tank: Tank capacity

Oil tank: Tank capacity

Brake: Type Operation

Throttle: Operation

Molded rubber, fiber glass rod reinforced 381 mm (15.0 in) 30 ~ 35 mm (1.18 ~ 1.38 in)/ 100 N {10 kg (22 lb)} 1054 mm (41.5 in) Slide rail suspension Double polyethylene, 7 teeth

Automatic centrifugal engagement, infi- nitely variable 3.5:1 ~ 1:1 Approx. 268.5 mm (10.57 in) Approx. 11 mm (0.43 in) Approx. 3000 r/min Approx. 6500 r/min Silent chain enclosed in oil bath 38/17 (2.24)

30.6 L (6.7 lmp gal, 8.1 US gal)

2.2 L (1.9 lmp qt, 2.3 US qt)

Caliper type, disc brake Handle lever, left hand operated

Handle lever, right hand operated

Subject to change according to elevation settings.

ESU00232

ELECTRIC

ET410TR

Ignition system Spark plug Type

Gap Headlight Bulb Quantity Tail/brake light Bulb Quantity Meter light Bulb Quantity

CDI BR9ES (NGK) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 12 V, 60/60 W 1 12 V, 8/23 W 1 12 V, 3.4 W 1

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM4

11-5

ESU00228

SPECIFICATIONS (VK540E) ESU00229

DIMENSIONS

3120 mm (122.8 in) 1130 mm ( 44.5 in) 1350 mm ( 53.1 in) 291 kg ( 642 lb) 960 mm ( 37.8 in)

VK540E

Overall length Overall width Overall height Dry weight Ski tread

ESU00230

ENGINE

Type Cylinder arrangement Displacement Bore Stroke Idle speed Engine oil type Carburetor type Fuel

Starting system

VK540E

Axial fan cooled 2-stroke, 7-port Parallel 2-cylinders 535 cm3

73.0 64.0 mm (2.87 2.52 in) 1200 100 r/min YAMALUBE 2-cycle oil MIKUNI B38-34 1 Unleaded gasoline

Pump octane R + M

; 88 or higher2 Electric and manual with recoil starter

ESU00231

CHASSIS

VK540E

Molded rubber, fiber glass rod reinforced 500 mm (19.7 in) 35 ~ 45 mm (1.38 ~ 1.77 in)/ 100 N {10 kg ( 22 lb)} 1204 mm (47.4 in) Slide rail suspension Triple polyethylene, 9 teeth

Drive track and suspension: Track Width Track deflection

Length on ground Suspension type Drive sprocket

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM5

11-6

VK540E

Automatic centrifugal engagement, infinitely variable 3.8:1 ~ 0.95:1 Approx. 268.5 mm (10.57 in) Approx. 16 mm (0.63 in) Approx. 2600 r/min Approx. 6700 r/min Triple roller chain enclosed in oil bath 39/17 (2.29), Low: (28/22 28/22) (39/17) = (3.71)

31.0 L (6.8 Imp gal, 8.2 US gal)

2.5 L (2.2 Imp qt, 2.6 US qt)

Caliper type, self-adjusting mechanical disc Handle lever, left hand operated

Handle lever, right hand operated

Transmission: Type

Sheave distance Sheave offset Engagement speed

Shift speed

Drive chain Reduction ratio

Fuel tank: Tank capacity

Oil tank: Tank capacity

Brake: Type

Operation

Throttle: Operation

Subject to change according to elevation settings.

ESU00232

ELECTRIC

VK540E

Ignition system Spark plug Type

Gap Battery Capacity

Maximum charge rate Headlight Bulb Quantity Tail/brake light Bulb Quantity Meter light Bulb Quantity

CDI BR9ES (NGK) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) YB16AL-A2/12 V 16 Ah 1.6 Amperes/hr for 10 hrs 12 V, 60/55 W 1 12 V, 8/23 W 1 12V, 3.4 W 1

BR250TF_8AC-17_Ch11 00.10.5, 9:48 AM6

12-1

ESU00233

WIRING DIAGRAM (BR250T)

G

Y B

Y B G

OFF

OFF

OFF

OFF

OFF ON

ON

OFF

OFF

ON

ON

ON

B/W

B/W

B/W

B/W

ON/LIGHT

B/W B/W B/W

B/Y

B/Y

B/WB/YB/YB/W B/YB/W

B/W

B

B

B

B

B B

B B

B B B Ch

RUN B/W B

B/W

B/Y

Ch

Ch

Ch

B/Y

B/Y

Y/R

Y/R

B/Y

G/Y

G/Y

Gy

B

B

L LL L

L

L

YL

Y

L

L

B BB B

O

O

B

R

R

B

B

B

B

B

B

B

LB

R

R

Br Br

Br Br

B

B

B

B

B

B

B

BB

B BW

B

L

L

BL

G L

Y

Ch

B/W

B/W

Y/R Y/R

Y/R

Y/B

Y/B

Y/B Y/B

Y/B

W/R

W/R

W/R

W/R

W/R W/R

W/R

W/R

W/R

B/W

B/W

B/W

B/W

B/W

B/Y

B/Y

B/Y

B/Y

B/Y

G/Y G/YG/Y G/Y

Y/R

Y/R

Y/R

Y/B

Y/R Y/B

Y/B

Y/B

Y/R

Y/R

Y/B

B/Y

B/Y

HI LO L

L L L

L G G

Y

Y

L

GY

B/W

B

L

L

G Y

G/Y G/Y G/Y G/Y

1 2

3

4

5

8

9

0

A

B

C

D

E

F

G H I

7 6

COLOR CODE B ............... Black L ............... Blue G .............. Green Y ............... Yellow R............... Red O .............. Orange Br.............. Brown B/Y ........... Black/Yellow B/W .......... Black/White G/Y ........... Green/Yellow Y/B ........... Yellow/Black Y/R ........... Yellow/Red W/R .......... White/Red

1 Speedometer light 2 Carburetor switch 3 Tail/brake light 4 Spark plug 5 Ignition coil 6 CDI unit 7 CDI magneto 8 Voltage regulator 9 Brake light switch 0 Headlight beam switch A Main switch B Accel switch C Engine stop switch D Engine stop switch E Frame ground F Headlight G Thumb warmer (option) H Grip warmer (option) I Grip warmer switch (option)

BR250TF_8AC-17_Ch12 00.10.5, 9:48 AM1

12-2

G

Y B LG

BY

G

Y L B

OFF

ON/LIGHT

START

B B/W Br R R/W

Br R B

B/WR/W

L

G/Y

B

L

G/Y

B

B/W

Y/BB/Y

RB/Y Br W/RO

W/RB/W W/R

Y/BL W

B RY Br W/RW

B

R W B L

B

B/W

RUN

B

B/Y

OFF

ON

ON

B

B/Y

OFF ON

G

G/Y

OFF ON

L

G

Y

Hi Lo

B/Y B/W

B

B/W B/Y

Ch

L

G Y

L

Y G

G

G/Y

L

L L

PP

G/Y

Y/R

Y/R

Y/B

Y/B

B L BL

BL

L

B

L

G

B

Y

L

Y

B

G

L

B

G/Y

B/W

B/Y

B R/W

R/W

R

R

R

B/W

B

G/Y

B/W

R/W

R

R

RR

R/W B

B

R

R

B

L

G/Y

B

L

G/Y

B

WL B

B/W Y/B

B/Y

B/Y

Ch

Ch

W/R

W/RW/R O

O

O

O

O WY

B

Br

Y/B

Y/B

Y/B

B R

W/R B/Y

WR B L

B G

Y L

G/Y B/W

B/Y B

B/W

B/Y

Ch

B/Y

B

L

G

Y

G/Y

B/Y

B

1 2 3 4 5 6

9

7

8

C

=

A

DEF

G

BJ

I

H

K

L

M

N

O

Y/B

Y/B

Y/R

Y/R

Y/RBW B

(R) (L)

(B) Y/R B

BY/R

ON

OFF

L

P

B

P

L

B/W

B

B

L

BR

R/W B/W R R

B

B/W

Br

Br W/R B R

ESU00233

WIRING DIAGRAM (ET410TR)

1 Speedometer light 2 Tachometer light (option) 3 Thumb warmer 4 Grip warmer 5 Grip warmer switch 6 Main switch 7 Fuse (option) 8 Battery (option) 9 Starter relay (option) 0 Tail/brake light A Spark plug B Ignition coil C Starter motor (option) D CDI unit E CDI magneto F Rectifier/regulator G Frame ground H Back buzzer I Gear position switch J Brake light switch K Headlight beam switch L Carburetor switch M Accel switch N Engine stop switch O Headlight

COLOR CODE

B ............... Black Br.............. Brown Ch............. Chocolate G .............. Green L ............... Blue O .............. Orange P ............... Pink R............... Red W .............. White Y ............... Yellow B/W .......... Black/White B/Y ........... Black/Yellow G/Y ........... Green/Yellow R/W .......... Red/White W/R .......... White/Red Y/B ........... Yellow/Black Y/R ........... Yellow/Red

BR250TF_8AC-17_Ch12 00.10.5, 9:48 AM2

12-3

ESU00233

WIRING DIAGRAM (VK540E)

COLOR CODE B ............... Black Br.............. Brown Ch............. Chocolate G .............. Green L ............... Blue O .............. Orange P ............... Pink R............... Red W .............. White Y ............... Yellow B/W .......... Black/White B/Y ........... Black/Yellow G/Y ........... Green/Yellow L/W ........... Blue/White R/W .......... Red/White W/R .......... White/Red Y/B ........... Yellow/Black Y/L ............ Yellow/Blue Y/R ........... Yellow/Red

1 Back buzzer 2 Speedometer light 3 Tachometer light (option) 4 Tachometer (option) 5 Gear position switch 6 Thumb warmer 7 Grip warmer 8 Grip warmer switch 9 Main switch 0 Fuse A Rectifier B Starter relay C Battery D Tail/brake light E Spark plug F Ignition coil G Starter motor H CDI unit I CDI magneto J Voltage regulator K Frame ground L Brake light switch M Carburetor switch N Headlight beam switch O Accel switch P Engine stop switch Q Engine stop switch R Headlight

BR250TF_8AC-17_Ch12 00.10.5, 9:48 AM3

Manualsnet FAQs

If you want to find out how the BR250TF Yamaha works, you can view and download the Yamaha BR250TF, ET410TRF, VK540EF 2001 Owner's Manual on the Manualsnet website.

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