Yamaha 2008 Raptor 250 Manuals

Manuals and User Guides for Yamaha 2008 Raptor 250. We have 1 Yamaha 2008 Raptor 250 manual available for free PDF download: Service Manual

Yamaha 2008 Raptor 250 Service Manual (311 pages)

Raptor 250

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.36 MB

Specifications

5
- Table of Contents
  7
Periodic Checks and Adjustments

5
Engine

10
Carburetor

12
Chassis

12
Electrical

13
Troubleshooting

14
Machine Identification

16
- Vehicle Identification Number
  16
- Model Label
  16
Chapter 1 General Information

16
Gen Info

16
Important Information

17
- Preparation for Removal and Disassembly
  17
- Replacement Parts
  17
- Gaskets, Oil Seals and O-Rings
  17
- Lock Washers/Plates and Cotter Pins
  17
- Bearings and Oil Seals
  18
- Circlips
  18
- Checking the Connections
  19
Special Tools

20
Chapter 2 Specifications

24
Spec

24
General Specifications

24
Engine Specifications

27
Chassis Specifications

34
Electrical Specifications

36
Tightening Torques

38
- Engine Tightening Torques
  38
- Chassis Tightening Torques
  40
How to Use the Conversion Table

42
General Tightening Torque Specifications

42
Lubrication Points and Lubricant Types

43
- Engine
  43
Oil Flow Diagrams

45
Cable Routing

48
Chapter 3 Periodic Checks and Adjustments

62
Introduction

62
Periodic Maintenance Chart for the Emission Control

62
System

62
Chk Adj

62
General Maintenance and Lubrication Chart

63
Seat, Fenders and Fuel Tank

65
Engine

70
Chassis

87
Electrical System

106
- Checking and Charging the Battery
  106
- Checking the Fuses
  113
- Adjusting the Headlight Beam
  114
- Replacing a Headlight Bulb
  115
Chapter 4

117
- Muffler and Exhaust Pipe
  117
- Installing the Exhaust Pipe and Muffler
  118
- Leads, Cables and Hoses
  119
- Engine Mounting Bolts
  121
- Installing the Engine
  122
Engine Removal

117
Eng

117
Cylinder Head

123
- Removing the Cylinder Head
  125
- Checking the Cylinder Head
  126
- Checking the Timing Chain Guides
  127
- Checking the Timing Chain Tensioners
  127
- Installing the Cylinder Head
  128
Rocker Arm, Camshaft

131
- Removing the Rocker Arms and Camshaft
  132
- Checking the Camshaft
  133
- Checking the Rocker Arms and Rocker Arm
  134
- Shafts
  134
- Installing the Camshaft and Rocker Arms
  135
Valves and Valve Springs

137
- Removing the Valves
  138
- Checking the Valves and Valve Guides
  139
- Checking the Valve Seats
  141
- Checking the Valve Springs
  144
- Installing the Valves
  145
Cylinder and Piston

147
- Removing the Piston
  148
- Checking the Cylinder and Piston
  148
- Checking the Piston Rings
  150
- Checking the Piston Pin
  152
- Installing the Piston and Cylinder
  153
Clutch

155
- Removing the Clutch
  159
- Checking the Friction Plates
  160
- Checking the Clutch Plates
  160
- Checking the Clutch Springs
  161
- Checking the Clutch Housing
  161
- Checking the Clutch Boss
  161
- Checking the Pressure Plate
  161
- Checking the Clutch Push Rods
  162
- Checking the Primary Drive Gear
  162
- Installing the Clutch
  162
Oil Pump and Blancer Weight Gear

166
- Removing the Balancer Weight Gear and Oil Pump
  169
- Checking the Oil Pump
  169
- Checking the Balancer Weight Gear
  170
- Assenbling the Balancer Drive Gear
  171
- Installing the Oil Pump
  171
- Installing the Balancer Weight Gear
  172
Shift Shaft

173
- Checking the Shift Shaft
  174
- Checking the Stopper Lever
  174
- Installing the Shift Shaft
  174
Pickup Coil Rotor and Starter Clutch

176
- Removing the Pickupcoil Rotor
  178
- Checking the Starter Clutch
  179
- Installing the Pickup Coil Rotor
  180
Crankcase

182
- Disassembling the Crankcase
  185
- Checking the Crankcase
  186
- Assembling the Crankcase
  186
Crankshaft Assembly

188
Transmission

193
- Removing the Transmission
  196
- Checking the Shift Forks
  196
- Checking the Shift Drum Assembly
  197
- Checking the Transmission
  197
- Assembly
  197
Carburetor

199
Carb

199
Chapter 5

202
- Checking the Carburetor
  202
- Assembling the Carburetor
  204
- Installing the Carburetor Joint
  205
- Installing the Carburetor
  205
Chapter 6

206
- Front Wheels
  206
- Rear Wheels
  208
- Checking the Wheels
  209
- Checking the Wheel Hubs
  209
- Checking the Brake Discs
  210
- Installing the Front Wheel Hub Bearings
  211
- Installing the Front Brake Discs
  211
- Installing the Front Wheels
  211
- Installing the Wheel Hubs
  212
Front and Rear Wheels

206
Chas

206
Rear Axle and Rear Axle Hub

213
- Removing the Rear Axle
  215
- Checking the Rear Axle
  216
- Checking the Driven Sprocket
  216
- Checking the Brake Disc
  216
- Installing the Driven Sprocket
  216
- Installing the Rear Axle
  216
Front and Rear Brakes

218
- Front Brake Pads
  218
- Rear Brake Pads
  219
- Replacing the Front Brake Pads
  220
- Replacing the Rear Brake Pads
  222
- Front Brake Master Cylinder
  224
- Rear Brake Master Cylinder
  226
- Checking the Master Cylinders
  229
- Assembling the Front Brake Master Cylinder
  230
- Assembling the Rear Brake Master Cylinder
  230
- Installing the Front Brake Master Cylinder
  231
- Installing the Rear Brake Master Cylinder
  233
- Front Brake Calipers
  235
- Rear Brake Caliper
  237
- Removing the Parking Brake Cable
  239
- Disassembling the Front and Rear Brake Calipers
  239
- Checking the Front and Rear Brake Calipers
  240
- Assembling the Front Brake Calipers
  241
- Assembling the Rear Brake Caliper
  241
- Installing the Front Brake Calipers
  243
- Installing the Rear Brake Caliper
  245
Steering System

247
- Handlebar
  247
- Removing the Clutch Switch
  249
- Removing the Handlebar Grips
  249
- Checking the Handlebar
  249
- Installing the Handlebar
  250
- Installing the Handlebar Grips
  250
- Installing the Clutch Lever
  251
- Installing the Brake Master Cylinder
  251
- Steering Stem
  252
- Checking the Steering Stem
  253
- Installing the Steering Stem
  253
- Installing the Lock Washer
  253
- Tie-Rods and Steering Knuckles
  254
- Removing the Steering Knuckles
  255
- Checking the Tie-Rods
  255
- Checking the Steering Knuckles
  255
- Installing the Tie-Rods
  255
Front Arms and Front Shock Absorber Assemblies

256
- Removing the Front Arms
  258
- Checking the Front Arms
  258
- Checking the Front Shock Absorbers
  258
- Checking the Ball Joints
  259
- Installing the Front Arms
  259
Rear Shock Absorber, Swingarm and Drive Chain

260
- Handling the Rear Shock Absorber
  262
- Disposing of a Rear Shock Absorber
  262
- Removing the Rear Shock Absorber
  263
- Checking the Rear Shock Absorber
  263
- Removing the Swingarm
  263
- Checking the Swingarm
  264
- Checking the Drive Chain
  265
- Installing the Swingarm
  267
- Installing the Drive Sprocket
  267
Chapter 7

268
Elec

268
Electrical Components

268
Checking Switch Continuity

269
Checking the Switches

270
Checking the Bulbs and Bulb Sockets

272
Ignition System

275
- Circuit Diagram
  275
- Troubleshooting
  276
Electric Starting System

280
- Circuit Diagram
  280
- Starting Circuit Cut-Off System Operation
  281
- Troubleshooting
  282
Starter Motor

286
- Checking the Starter Motor
  288
- Assembling the Starter Motor
  290
Charging System

291
- Circuit Diagram
  291
- Troubleshooting
  292
Lighting System

294
- Circuit Diagram
  294
- Troubleshooting
  295
- Checking the Lighting System
  296
Signal System

298
- Circuit Diagram
  298
- Troubleshooting
  299
- Checking the Signaling System
  300
Chapter 8

303
- Fuel System
  303
- Electrical System
  303
Starting Failure/Hard Starting

303
Trbl Shtg

304
- Compression System
  304
Poor Idle Speed Performance

304
Poor Medium and High-Speed Performance

304
Clutch Slipping/Dragging

305
- Clutch Slipping
  305
- Clutch Dragging
  305
Faulty Gear Shifting

305
- Hard Shifting
  305
- Shift Pedal Does Not Move
  305
- Jumps out Gear
  305
Overheating

306
Faulty Brake

306
- Poor Braking Effect
  306
Shock Absorber Malfunction

306
- Malfunction
  306
Unstable Handling

307
Lighting System

307
- Headlight Does Not Come on
  307
- Tail/Brake Light Does Not Light
  307
- Bulb Burnt out
  307
- Tail/Brake Light Bulb Burnt out
  307

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Yamaha 2008 Raptor 250 Manuals

Yamaha 2008 Raptor 250 Service Manual (311 pages)

Table of Contents

Specifications

Periodic Checks and Adjustments

Engine

Carburetor

Chassis

Electrical

Troubleshooting

Machine Identification

Chapter 1 General Information

Gen Info

Important Information

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

How to Use the Conversion Table

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control

System

Chk Adj

General Maintenance and Lubrication Chart

Seat, Fenders and Fuel Tank

Engine

Chassis

Electrical System

Chapter 4

Engine Removal

Eng

Cylinder Head

Rocker Arm, Camshaft

Valves and Valve Springs

Cylinder and Piston

Clutch

Oil Pump and Blancer Weight Gear

Shift Shaft

Pickup Coil Rotor and Starter Clutch

Crankcase

Crankshaft Assembly

Transmission

Carburetor

Carb

Chapter 5

Chapter 6

Front and Rear Wheels

Chas

Rear Axle and Rear Axle Hub

Front and Rear Brakes

Steering System

Front Arms and Front Shock Absorber Assemblies

Rear Shock Absorber, Swingarm and Drive Chain

Chapter 7

Elec

Electrical Components

Checking Switch Continuity

Checking the Switches

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Starter Motor

Charging System

Lighting System

Signal System

Chapter 8

Starting Failure/Hard Starting

Trbl Shtg

Poor Idle Speed Performance

Poor Medium and High-Speed Performance

Clutch Slipping/Dragging