1982–2009 Yamaha Bravo BR250F, BR250T, BR250TS, and BR250TJ Snowmobile Service Manual (P/N LIT-12618-00-41)

This Yamaha service manual compilation covers the 1982–2009 Bravo BR250 series, combining BR250F base-manual material with supplementary sections for BR250TJ and BR250T/TS, including BR250TV identification data. Separate specification tables distinguish the documented configurations.

• Engine repair: Engine removal, top-end and bottom-end inspection, crankcase assembly, recoil starter service, and flywheel magneto removal and installation.

• Carburetion and Autolube: Keihin BD32-28 disassembly, float inspection, high-altitude tuning, oil pump stroke adjustment, cable adjustment, and pump bleeding.

• Clutch and chain drive: Primary and secondary sheave service, clutch tuning, V-belt inspection, sheave alignment, and chain case disassembly and gearing selection.

• Track, brakes, and chassis: Slide rail suspension removal, track drive sprocket inspection, track alignment, caliper disc brake adjustment, steering linkage, and ski service.

• Electrical diagnosis: CDI ignition troubleshooting, Throttle Override System (T.O.R.S.) switch checks, lighting tests, circuit diagrams, and wire-color references.

• Supplementary service material: BR250T/TS fuel sub-tank removal, a job instruction chart, optional warmer circuits, and BR250TJ primary-sheave repair information.

The procedures suit mechanics familiar with two-stroke snowmobiles and equipped for clutch disassembly, precision measurement, and electrical testing.

Engine Inspection and Autolube Service

The engine chapter goes beyond top-end maintenance to cover crankshaft runout, connecting-rod clearance, bearings, oil seals, and crankcase assembly. The BR250F top end uses a one-piece cylinder/head assembly; the cylinder head is not a separately removable service component.

The cylinder section warns that incorrect boring depth or unsuitable honing equipment can damage the integral combustion chamber. Piston-ring sectional sketches and exploded views support the inspection and assembly instructions.

Autolube coverage includes minimum and maximum pump-stroke checks, shim adjustment, drive-gear inspection, and bleeding after the oil system has been opened. Lubrication charts identify the specified oils and greases for shafts, pivots, and other service points.

Keihin Carburetor Tuning and Fuel-System Diagnosis

The carburetor chapter connects starting, idle, acceleration, and overflow symptoms with checks of jets, float components, fuel passages, and intake connections. Its fuel-flow chart and high-altitude tuning charts help identify which metering circuit and operating conditions apply to a running problem.

Carburetor disassembly has a specific limit: the factory-crimped throttle valve and shaft assembly is to remain assembled. The BR250T/TS supplement adds fuel sub-tank removal and hose-routing details, including layouts for configurations with and without the optional primer pump.

Sheave Repair, Track Service, and Chassis Adjustment

The powertrain sections document both clutch assemblies, with separate primary-sheave construction and service details in the BR250TJ supplement. That supplement specifies Sheave Holder YS-01880 and Sheave Puller YS-01882; spider disassembly requires the additional separator equipment identified in the procedure.

The supplement warns that poorly supported high-torque disassembly can crack the fixed sheave. Component-specific tightening tables and assembly illustrations retain the related installation notes.

Track service covers drive-axle removal, sprocket positioning, suspension wheels, slide-runner wear, and track deflection and alignment. Chassis coverage adds brake-pad inspection, caliper adjustment, ski toe-out, steering linkage assembly, and suspension settings.

Follow the manual's safety warnings for rotating clutches, preloaded springs, and fuel-system work.

CDI, T.O.R.S., and Lighting Fault Tracing

Ignition troubleshooting charts separate no-spark and weak-spark faults into coil, connection, switch, and CDI checks. The T.O.R.S. block diagram and switch-state tables help distinguish a throttle or carburetor switch fault from an ignition-component problem.

The electrical sections distinguish F8R4 and F85L magneto configurations. Wiring diagrams, lighting circuit schematics, and cable-routing views show component connections and optional equipment, including grip and thumb warmers. Match the model-specific electrical table to the machine before selecting test specifications.

A Preview of Cylinder Dimensions and Pickup-Coil Data

These examples are a small selection of the inspection dimensions and electrical test data contained in the manual.

For BR250T/TS engines, the maintenance tables specify a standard cylinder bore of 70.00–70.02 mm and piston-to-cylinder clearance of 0.045–0.050 mm. The cylinder section also supplies separate taper and out-of-round limits.

For the BR250T/TS F85L magneto, pickup-coil resistance is 20 ohms ±20% at 20°C (68°F), between the White/Red and Black leads. The other configurations have their own electrical specifications.

PDF Navigation, Diagram Detail, and Included Sections

Search, bookmarks, and diagram detail: PDF text search is unavailable. Embedded bookmarks navigate the main chapters and supplements, although the “How to use this Manual” entry has no destination. Small wiring labels require zooming, and some fine lines are faint. The spark-plug comparison photographs are reproduced in grayscale.

One printable, 181-page PDF contains the BR250T/TS supplement (33 pages), BR250TJ supplement (41 pages), and BR250F section (107 pages). The total includes the contents pages, the incorporated revised top-end page, and one unnumbered spark-plug comparison page.