The 1980-1985 Yamaha YT60, YT125, YT175, YTM200, YTM225, YTZ250 ATV repair manual by Haynes, covers 3- and 4-wheelers manufactured by Yamaha, with 2- and 4-stroke engines, including:
Book Excerpt: 1980-1985 Yamaha YT60, YT125, YT175, YTM200, YTM225, YTZ250 Repair Manual
- Yamaha YT60L, YT60N
- Yamaha YT125G, YT125H, YT125J, YT125K, YT125L, YT125N
- Yamaha YT175J, YT175K
- Yamaha YTM200K, YTM200L, YTM200EK, YTM200EL, YTM200N, YTM200ERN
- Yamaha YFM200N
- Yamaha YTM225DXK, YTM225DXL, YTM225DXN
- Yamaha YTZ250N
CHAPTER 2 | PART A | TWO-STROKE ENGINES
ENGINE-REMOVAL AND INSTALLATION
CHAPTER 4 | IGNITION SYSTEM
- Go to the beginning of this book and read the Sections on maintenance techniques, tools and working facilities and Safety first.
Note especially that your working area throughout the entire teardown, overhaul and reassembly procedure must be spotlessly clean.
This includes the machine and the engine itself, which should be cleaned as thoroughly as possible before beginning any operations in this manual.
- Engine removal should be done with the aid of an assistant to avoid damage if the engine falls or is dropped.
- Remove the seat and rear fender assembly. Store it out of the way until the end of the procedure you are performing. On YT125/175 models remove the fuel tank cover bolts and detach the cover.
- On YTZ250 models refer to Chapter 1 and drain the coolant, then separate the hoses from the water pump and radiator. Remove the right side footrest assembly. The YEIS chamber hose must be disconnected as well.
- Refer to Chapter 1 and drain the transmission oil. While the oil is draining you can perform other removal procedures.
- Remove the spark plug lead and loop it around the frame to keep it out of the way.
- On YTZ 250 models detach the cylinder head-to-frame brackets and remove the hose fitting.
- Disconnect the electrical connectors for the ignition system and lighting coil and separate the wires from the frame so that they won't hang up when the engine is removed.
- Trace the clutch cable (YTZ 250 only) to the lever on the left crankcase cover and detach it from the lever and crankcase mount. Detach the vacuum hose that leads to the fuel pump at the crankcase.
- On YTZ 250 models only detach the rear brake reservoir from the frame.
- Remove the exhaust pipe and muffler assembly. Some are held in place by nuts/bolts (photos), while others are held in place with a combination of springs, nuts and bolts.
- Remove the drive chain by referring to Chapter 1.
- Remove the Auto lube pump cover, disconnect the cable and pull the cable out of the crankcase (photos) wrap it around the frame, out of the way.
- The transmission oil should now be completely drained . Replace the drain plug and wipe up any spills.
- Disconnect the Auto lube hose from the fitting on the crankcase or carburetor and plug the end with a bolt (photo).
- Separate the shift lever from the engine shaft (photo).
- On models so equipped, remove the Allen head bolt that attaches the chain tensioner to the engine case (photo).
- Refer to Chapter 3 and remove the carburetor. Detach the vent hoses from the crankcase fittings (there may be several, so mark them to ensure correct reinstallation).
- On YT 125/175 models detach the brake cable and return spring from the rear brake pedal. Remove the engine mounting bolts/nuts and pull the engine up and out of the right side of the frame.
- On YTZ 250 models support the machine under the engine with a jack or blocks of wood, then remove the engine mounting bolts and lift out the engine.
IGNITION COIL-REMOVAL AND INSTALLATION
- On 125 and 175 models the ignition coil is attached to the frame under the seat. On all other models the ignition coil is mounted under the gas tank on the upper frame section. It is held in place by two bolts.
The easiest way to locate the coil is to trace the spark plug wire from the plug to the coil.
- Remove the spark plug cap from the spark plug.
- Disconnect the primary wire(s) at the connector near the coil.
- Remove the two mounting screws (photo) and separate the coil from the frame.
- Installation is the reverse of removal.
CDI UNIT-REMOVAL AND INSTALLATION
- The CDI unit is usually mounted near the ignition coil and is held in place by a rubber mount. Trace the primary wires from the coil to locate the CDI unit.
- To remove the CDI unit, unplug the wires and pull them out of the way. Peel back the rubber strap from the frame bracket and pull the CDI unit and strap off the frame mount (photo).
- Check that all the terminals in the CDI unit and the wire connectors are clean and free of corrosion. Check the rubber retaining strap for cracks and other damage. Replace it with a new one if necessary.
- Installation of the CDI is the reverse of the removal procedure. Be sure that the electrical connections are clean and tight.
Because of the need for special test equipment and expertise, the CDI unit cannot be checked by the home mechanic. Take it to an authorized dealer service department where the checks can be made quickly and accurately.
It should be noted that CDI control units seldom fail, so check the remaining ignition system components carefully before blaming the CDI unit for ignition failure.
Subject: 1980, 1981, 1982, 1983, 1984, 1985 Yamaha YT60, YT125, YT175, YTM200, YTM225, YTZ250 service, maintenance, repair. ISBN-10: 185010154X | ISBN-13: 9781850101543 | Haynes 1154