1988 Yamaha Terrapro Service Manual

The 1988 Yamaha Terrapro is a rugged all-terrain vehicle designed for off-road use, featuring a reliable 2-stroke engine, durable chassis, and versatile 4WD system. This service manual covers comprehensive maintenance procedures, troubleshooting guides, and technical specifications for proper upkeep and repair of your Terrapro ATV.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Fuel System 6. Electrical System 7. Drive System 8. Suspension & Steering 9. Brake System 10. Troubleshooting 11. Wiring Diagrams

General Information

This manual provides detailed service information for the 1988 Yamaha Terrapro ATV. Includes safety precautions, tool requirements, and general maintenance procedures.

Section	Description
Identification	Vehicle identification numbers and model variations
Safety First	Important safety precautions for service work
Special Tools	Required tools for proper maintenance
Maintenance Schedule	Recommended service intervals
Lubrication Points	All lubrication requirements and intervals

Specifications

Model: Yamaha Terrapro 1988
Engine Type: 2-stroke, air-cooled single cylinder
Displacement: 246cc
Bore x Stroke: 70.0mm x 64.0mm
Compression Ratio: 6.6:1
Transmission: 5-speed with reverse
Drive System: Shaft drive with selectable 2WD/4WD
Fuel Capacity: 3.7 gallons
Weight: 418 lbs

Periodic Maintenance

Regular maintenance schedule to ensure optimal performance and longevity.

Engine oil change: Every 100 hours or 6 months
Air filter cleaning: Every 50 hours
Spark plug replacement: Every 100 hours
Drive chain adjustment: Every 25 hours
Brake inspection: Every 50 hours
Wheel bearing service: Every 200 hours

WARNING! Always perform maintenance in well-ventilated area. Use proper safety equipment.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Component	Service Procedure
Cylinder Head	Torque specification: 18 ft-lbs
Piston & Rings	Clearance: 0.002-0.003 inches
Crankshaft	Runout limit: 0.002 inches
Carburetor	Float level: 0.63 inches
Ignition System	Spark plug gap: 0.024-0.028 inches

Fuel System

Carburetor service and fuel delivery system maintenance.

Remove carburetor: Disconnect fuel lines and throttle cable
Clean jets: Use compressed air and carburetor cleaner
Adjust float: Set to specified height
Fuel pump: Test pressure and flow rate
Fuel filter: Replace annually

CAUTION! Gasoline is highly flammable. No smoking during service.

Electrical System

Complete electrical system testing and repair procedures.

Battery: 12V 14Ah, maintenance required
Charging System: AC magneto with rectifier/regulator
Ignition: CDI electronic ignition
Lighting: Headlight, taillight, brake light
Starting System: Electric start with backup recoil

Drive System

Transmission, differential, and final drive service procedures.

Drain transmission fluid: Remove drain plug
Inspect gears: Check for wear and damage
4WD mechanism: Service transfer case
Drive shafts: Check CV joints and boots
Final drive: Service rear differential

Suspension & Steering

Front and rear suspension maintenance and steering system service.

Component	Specification
Front shocks	Travel: 6.3 inches
Rear shocks	Travel: 6.7 inches
Steering stem	Bearing adjustment procedure
Tire pressure	Front: 3.6 psi, Rear: 3.6 psi
Wheel alignment	Toe-in: 0-10mm

Brake System

Hydraulic disc brake service and maintenance procedures.

Brake fluid: DOT 4, change every 2 years
Brake pads: Replace when worn to 1mm
Brake discs: Minimum thickness 3.0mm
Bleeding procedure: Remove air from system
Parking brake: Adjust cable tension

WARNING! Test brakes thoroughly before riding after service.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled spark plug, stale fuel	Replace spark plug, drain old fuel
Loss of power	Clogged air filter, exhaust restriction	Clean air filter, check exhaust system
4WD not engaging	Vacuum system, shift mechanism	Check vacuum lines, service shift mechanism
Electrical failure	Battery, stator, regulator	Test charging system components
Brake drag	Stuck caliper, contaminated fluid	Service caliper, flush brake fluid

Wiring Diagrams

Complete electrical schematics for the 1988 Yamaha Terrapro. Includes color-coded wiring, connector locations, and component identification for all electrical systems.

Service Support: Contact Yamaha customer service for technical assistance or visit authorized Yamaha dealership for parts and service.