1980-1982 Yamaha RD250 LC RD350 LC Motorcycle Service & Repair Manual

I \6maha RD250&350 1C Owners \A/orkshop Manual by Pete Shoemark Models covered RD250 LC.247cc. RD350 LC. 347cc. lntroduced May l ggO lntroduced June {9gO rsBN O 85696 803 x @ Haynes Publishing Group 1g90 Haynes Publishing Group Sparkford Nr yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA ABCOE All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, elecrroni" o, rn""r,rni"ir,lictuding photocopying, recording or by any information storage or ratii"u"r lvr,"r. without permission in writing from the copyright holder. Printed in Engtand (SO3 _ 7p6)

Acknowledgements Our thanks are due to Fran Ridewood and Co of Wells, who supplied the RD2sO LC featured ttrrougtout ihiJriaiual ana to Mits.ui Machinery Sates (UK) r-tj;il;;h,.J iil'n""""..r, service information and oave permissio" ii-r"pr.J"." many of the line drawings used. - The Avon Rubber Company supplied information and tech_ nical assistance on tvre care and fitiing, ana NtCitpart etugs (uK.) Ltd provided iniormation on ;d;;iil";J"tand "t"c_ trode conditions. Renold Lrd advised ""., "f,.i" ,.i"ilnance and renewal. About this manual The purpose of this manual is to present the owner with a 1onci19 and gra.phic guide which witr'enalie r,i,i io t".rru .nv operation from basic routine mainten.n"" io ; ;4", overhaul. It has been assumed that any work will be undertaken without the tuxury of a weil-equippea worrsiil;;il range of manufacturer's service tools. _ To this end, the machine featured in the manual was stripped and rebuilt in our own workshop, Uy a-ie-am'comprising a, mechanic, a photographer ana tne- auih;;.;;" resutting photographic sequence depicts "u"nt" ." ti.t"l'toot prace, ttre hands shown being those br tne arrtoianoii"lil.n.ni". .lh9 us9 of speciatised, .na "*p"nriu"l 5.g;# toots was a_voided unless their use was considered to'Ue-ess-e--ntlat Oue to :1,:1^P_:rl.se or injury. There is ,"r.ilv-""r.; way of rmprovtstng a method of removing a stubborn ;omponent, provided that a suitable degree of "ir" i" "r"r"i."Ol _ The author learnt his motorcycle rn""f,ani"a,ou"r a number of years, faced with the same'diffi;uti;; a-nduling simirar facitities to those encounrered by ;;.1-;;;"il.'iiiTi,op"o ,r,", this practicat experience c"n u" pa"slJ;;;h;;,i{i" pases of this manual. \ Where possible, a well_used example of the m\chine is chosen for a workshoo Droject, ", ir,iJ r,igilliii","""ny "r"u" which might be particuiariy prone to giving rise to problems. ln this way, any such difficutiies ,r" ;;;"i;;J#;;tu;; before the text is written, and rhe te"f,niqre" ,-siji" o"'.'i*ti\i them can be incorporated_ in the relevant Section. Armed with a workins knowtedse of the machine,ih;;;;;;;;derrakes a considerable amount of research in order tf,.iif," maximum amount of data can be included in ttre manuat. -"' . Ert Chapter is divided into "rrf"i"j-sections. Within these .Sections are numbe*a p"r"Ji.ph"l l"rl"l r."t"r"n." throughout the manuat is quite -straig-h?o1*"'rj-ino rogicar. when reference is made .sd se;ti-o';?;;l ;;;": section 6, paragraph 10 in the same. chapter. rt anoth"r-th-apter were intended, the reference would reJd, for "^i'"ioi",'.s1" Section 2, Section. 6.10'. Al the photosrap;" ;;"';;;rio-n"ed with a, section/paragraph number to which ttrev refer inj are relevant to the Chapter text adjacent. Figures (usually line illustrations) appear in a logical but numerical order, within a given Chapter. Fi-g i. f 'tf,"r"fore refers to the first figure in Chpaier l. ., . Left-hand and right_hand descriptions of the machines and their components refer to the teft ";J ;di;i';siv;n macnine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations ."J ir,""", irr,"n notified, are incorporated into our manuals "t th; ;;;li;iop"po.tunitv. _. . Whilst every care is taken to ensure that the information in this ma.nuat is correct no tiabitity "";il;;;;i;;'uy"it" ur*,o' or publishers for loss, damage or injury ""r"-JJ Ov-anv errors in or omissions from the information Siu"n.

ntents Section Page Section Page sections Acknowledgements About this manual lntroduction to the Yamaha RD25O and RD35O LC models Dimensions and weights Operations with unit in frame Unit dismantling - general Examination and renovation: General Engine 2 2 Ordering spare parts Safety first! Working conditions and tools Fault diagnosis Routine maintenance Castrol lubricants 7 8 9 10-19 20-31 32 1 Engine, 6 j 35 40 47 58 lGearbox components Clutch Engine reassembly - general Starting and running the rebuilt engine 60 63 63 85 and gearbox 2 Cooling Draining the cooling system Radiator and cap Hoses 88 89 91 Water pump Water temperature gauge 92 92 3 Fuel system Petrol tank Petrol cap Carburettors Exhaust system 96 96 97,98,1 02,1 03 103 Air cleaner Lubrication - general description Oil pump Reed valve induction system 105 105 107 110 lSrication 4 lgnition 5 Frame and Testing electronic ignition system Wiring - checking Coils - testing 114 lgnition timing 114 Spark plugs 116 '117 117 Front forks Steering head assembly Steering head bearings Steering lock Frame - examination and renovation 1 19,123 Rear suspension assemblY 121 Rear sub frame 126 Centre stand 126 Prop stand Footrests 127 Speedometer and tachometer 128,133 't28 134 134 134 134 is6 tro6 Wheels, brakes Front wheel Disc brake Front disc brake master cylinder Bleeding brakes Rear wheel Front wheel bearings 137 Rear wheel bearings 137 Cush drive Rear wheel sprocket 14O Final drive chain 143 Tyres 146 Wheel balancing 149 149 153 154 156 156 157 ---- 162 165 166 7 Electrical Charging system Battery Alternator - resistance tests Regulator/rectifier unit Fuses 159 Headlamp 159 Flashing indicator circuit 160 lnstrument head 160 Switches 161 Wiring diagram 169.170 172 General description and specifications are given in each Chapter immediately after the list of Contents 173 - 176

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1980-1982 Yamaha RD250 LC RD350 LC Motorcycle Service & Repair Manual

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