1974 Yamaha DT250A / DT360A Service Manual (207 Pages)

Complete service documentation for DT250A and DT360A models with engine specifications, clutch assembly procedures, carburetor adjustments, electrical schematics, and chassis repair instructions. Includes detailed torque specifications and maintenance intervals.

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Document Details

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Document Number / Seller:
23345 / Daniel Jackson
File Size:
165.53 MB
File Type:
PDF
Language:
English
Pages:
207
Printable:
Yes
Category:
Bike
Last updated / verified
Jan 31, 2025

Models Covered & Key Technical Specifications

Yamaha DT250A, DT360A — 1974 Mechanical Collection & Reference | DT Series Toolkit.

  • Established Component Weight: The oil tank is calibrated to 1.5 L (1.6 US qts) SAE "SE" 10W/30 lubricant requirements Standards.
  • Measured Precision Specs: For transmission operation, DT250A supports 1,000 cc plus 50 cc gearbox lubrication Threshold.
  • Operational Bolt Torques: Cylinder head fasteners are measured at 2.1–2.5 kg-m (182–217 in-lbs) securing specification Protocol.
  • Baseline Displacement Data: DT250A delivers 246 cc (15.01 cu. in.) engine cylinder volume architecture Matrix.
  • Integral Circuit Specs: Fuel capacity indicates 9.0 L (2.4 US gals) Low-Lead Gasoline tank specification Norms.
  • Specific Size Parameters: The wheelbase is specified as 1,415 mm (55.7 in.) DT250A, 1,425 mm (56.1 in.) DT360A benchmarks Range.

Professional Workshop Service Manual & Technical Specifications

Enhanced Repair Manual: Yamaha DT250A / DT360A 1974 Service Manual Specification-Guide

Model-Portfolio: Yamaha DT250A, DT360A — 1974 models // Model-Designation: Twin-stroke motorcycle engine systems, fuel delivery, and electrical circuits // Model-Designation: Comprehensive mechanical specifications, torque documentation, and assembly procedures.

Metric Technical-Path Framework
Transmission Type 5-speed constant mesh systems Complete specifications provided
Ignition Systems Magneto (DT250A) and CDI (DT360A) modules Documented in separate chapters
Carburetor Configuration Mikuni VM28SS / VM30SS fuel management See Chapter 4 carburetion section
Lubrication Module Autolube separate-feed system with stroke adjustment Documented with adjustment data
Electrical Framework 6V flywheel magneto charging and battery systems See Chapter 5 detailed documentation

Reference chapters include engine assembly and disassembly procedures, carburetion and fuel system design, electrical systems and wiring schematics, chassis suspension and brake components, and transmission shift mechanism operation, covering the complete mechanical and electrical architecture of both DT models.

Diagnostic procedures are covered for ignition timing, carburetor circuit troubleshooting, and electrical component function verification. Wiring diagrams are provided for DT250A magneto and DT360A capacitor discharge ignition configurations. Fuel system procedures are documented for petcock operation, float level adjustment, and reed valve assembly maintenance. Adjustment procedures are detailed for throttle cable synchronization, clutch engagement geometry, and brake lever freeplay. Timing procedures are documented for piston position determination and spark occurrence validation.

The manual documents torque specifications for the cylinder head fasteners to ensure proper component alignment retention. Yamaha designed these machines with emphasis on both trail-riding versatility and road performance capability. The integrated Autolube pump delivers oil directly to the intake port, eliminating the need for fuel-oil premixing. Engine disassembly requires understanding the crankcase split method and proper bearing removal procedures. Transmission shafts require precise end-play measurement before final reassembly. The two-stroke design incorporates a forward-inclined cylinder with torque induction porting, complemented by a reed valve inlet system that operates independently based on crankcase pressure dynamics.

Specifications detail the DT250A displacement at 246cc with 70×64mm bore and stroke, while the DT360A reaches 351cc with 80×70mm dimensions. Both models utilize a primary gear reduction ratio controlling drive from the crankshaft to the clutch housing. Chassis specifications include 55.7-inch (DT250A) and 56.1-inch (DT360A) wheelbase measurements, with front telescopic forks and rear swinging arm suspension. Wheel and tire systems incorporate internal expansion brake drums on both axles. The electrical system provides 6-volt charging through a dual-output magneto coil with silicon rectifier, supplying power to the 4AH battery for horn, stoplight, and signal circuits while maintaining separate alternating current paths for headlight and taillights.

FAQ

What **exact** specifications define the piston clearance assembly sequence? keyboard_arrow_down

0.040–0.045 mm nominal tolerance establishes the piston clearance mapping for both DT250A and DT360A engines during assembly to ensure proper fit within the cylinder bore.

Reference the **specific** maintenance interval parameters for transmission oil changes. keyboard_arrow_down

1,000 cc for DT250A and 1,200 cc for DT360A with SAE 10W/30 'SE' specification must be verified and replaced at each service interval to maintain proper lubrication and cooling of clutch components.

What are the **designated** torque requirements for cylinder head fastener assembly? keyboard_arrow_down

2.1–2.5 kg-m (182–217 in-lbs) securing specification defines the range for all cylinder head bolts to prevent gasket leakage and ensure combustion chamber sealing integrity on both models.

Specify the **critical** tool components required for primary drive gear service operations. keyboard_arrow_down

Clutch Holding Tool (DT1), Magneto Flywheel Puller (YG1), and Torque Wrench (0-10 Kg-m) represent the essential specialized instruments needed to safely remove and service primary drive components without damage to the crankshaft.

What is the **required** charging voltage specification for nighttime operation at 8,000 rpm? keyboard_arrow_down

8.0V established minimum ensures adequate battery charging and electrical system performance during extended high-speed riding conditions when headlight and auxiliary lighting loads are active on both DT250A and DT360A models.

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I found this manual to be incredibly helpful for maintenance and repairs. The detailed chapters made everything easy to understand. Plus, the customer support was fantastic; I got quick responses to my queries. Downloading was a breeze!
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This service manual is an absolute must-have for anyone with a Yamaha DT250A or DT360A. The diagrams are clear and the troubleshooting tips are spot on. I received my download link promptly, and the process was seamless. Highly recommended!