Yamaha YFM250XL Manuals

Manuals and User Guides for Yamaha YFM250XL. We have 1 Yamaha YFM250XL manual available for free PDF download: Service Manual

Yamaha YFM250XL Service Manual

Yamaha YFM250XL Service Manual (398 pages)

YFM250XL(C) Yamaha

Brand: Yamaha | Category: Offroad Vehicle | Size: 16.83 MB

Table of Contents

Chapter Titles

7
- Important Information
  3
- Table of Contents
  7
- Carburetion
  11
- Chapter 1. General Information
  
  15
  - Machine Identification
    15
    
    Vehicle Identification Number
    15
    
    Model Label
    15
  - Important Information
    16
    
    Preparation for Removal Procedures
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking of Connections
    18
  - Special Tools
    19
- Chapter 2. Specifications
  
  25
  - General Specifications
    25
  - Maintenance Specifications
    28
    
    Engine
    28
    
    Chassis
    38
    
    Electrical
    42
  - How to Use the Conversion Table
    44
  - General Torque Specifications
    44
  - Lubrication Points and Lubricant Types
    45
    
    Engine
    45
    
    Chassis
    46
  - Lubrication Diagrams
    47
  - Cable Routing
    49
- Chapter 3. Periodic Inspections and Adjustments
  
  55
  - Introduction
    55
  - Periodic Maintenance/Lubrication
    55
  - Fender and Fuel Tank
    57
    
    Front Fender
    57
    
    Rear Fender
    59
    
    Fuel Tank
    62
  - Engine
    64
    
    Valve Clearance Adjustment
    64
    
    Insp Adj
    64
    
    Timing Chain Tensioner Adjustment
    66
    
    Idle Speed Adjustment
    67
    
    Throttle Cable Free Play Adjustment
    68
    
    Speed Limiter Adjustment
    69
    
    Spark Plug Inspection
    69
    
    Ignition Timing Check
    71
    
    Compression Pressure Measurement
    72
    
    Engine Oil Level Inspection
    73
    
    Engine Oil Replacement
    74
    
    Clutch Adjustment
    77
    
    Air Filter Cleaning
    78
  - Chassis
    80
    
    Front and Rear Brake Lining Inspection
    80
    
    Front Brake Adjustment
    80
    
    Rear Brake Lever and Pedal Adjustment
    81
    
    Drive Select Lever Position Adjustment
    83
    
    Final Drive Gear Oil Level Inspection
    83
    
    Final Drive Gear Oil Replacement
    84
    
    Drive Shaft Dust Boot Inspection
    85
    
    Steering System Inspection
    86
    
    Toe-In Adjustment
    86
    
    Front and Rear Shock Absorbers Inspection
    88
    
    Rear Shock Absorber Adjustment
    88
    
    Tire Inspection
    89
    
    Wheel Inspection
    91
  - Electrical
    92
    
    Battery Inspection
    92
    
    Fuse Inspection
    95
    
    Headlight Beam Adjustment
    96
    
    Headlight Bulb Replacement
    96
- Chapter 4. Engine Overhaul
  
  99
  - Engine Removal
    99
    
    Preparation for Removal
    99
    
    Front Fender and Rear Fender
    99
    
    Engine Oil
    100
    
    Exhaust Pipe and Muffler
    100
    
    Carburetor
    100
    
    Starter Motor
    101
    
    Rear Brake Cables and Footrest
    101
    
    Wirings and Hoses
    101
    
    Rear Wheel Drive Assembly and Swingarm
    102
    
    Engine Removal
    102
  - Engine Disassembly
    103
    
    Cylinder Head Assembly, Cylinder and Piston
    103
    
    Starter Pulley CDI Magneto
    106
    
    Middle Driven Pinion Gear
    108
    
    Primary and Secondary Clutches
    109
    
    Oil Pump and Shifter
    111
    
    Balancer Driven Gear
    112
    
    Crankcase (Left)
    113
    
    Balancer Shaft, Transmission and Crankshaft
    114
    
    Cylinder Head
    115
    
    Valve
    116
    
    Recoil Starter
    117
  - Inspection and Repair
    118
    
    Cylinder Head
    118
    
    Intake and Exhaust Valve
    118
    
    Valve Guide
    119
    
    Valve Seat
    120
    
    Valve Spring
    123
    
    Valve Installation
    124
    
    Cam Shaft
    125
    
    Rocker Arm and Rocker Arm Shaft
    126
    
    Timing Chain
    128
    
    Cam Sprocket and Cam Drive Sprocket
    129
    
    Timing Chain Guide
    129
    
    Timing Chain Tensioner
    129
    
    Tappet Cover and Cam Sprocket Cover
    130
    
    Cylinder and Piston
    130
    
    Piston Ring and Piston Pin
    131
    
    Crankshaft
    134
    
    Balancer Drive Gear and Driven Gears
    135
    
    Primary Gears and Starter
    135
    
    Secondary Clutch
    136
    
    Oil Pump
    138
    
    Transmission and Shifter
    139
    
    Middle Gear
    141
    
    Bearings and Oil Seals
    141
    
    Circlips and Washers
    141
    
    Crankcase
    141
    
    Recoil Starter
    142
  - Engine Assembly and Adjustment
    143
    
    Recoil Starter
    143
    
    Crankshaft/Balancer
    145
    
    Transmission
    146
    
    Shifter
    147
    
    Crankshaft, Transmission and Balancer Shaft
    148
    
    Crankcase (Left)
    149
    
    Balancer Driven and Drive Gears
    149
    
    Shift Shaft/Oil Pump
    151
    
    Shifter and Oil Pump
    152
    
    Clutch
    154
    
    Primary and Secondary Clutches
    155
    
    Middle Driven Pinion Gear
    159
    
    Starter Pulley (Except for Usa)/CDI Magneto
    160
    
    Starter Pulley (Except for Usa) and CDI Magneto
    161
    
    Cylinder and Cylinder Head Assembly
    163
    
    Piston, Camshaft and Timing Chain
    164
    
    Cylinder Head Assembly, Cylinder and Piston
    165
    
    Remounting Engine
    170
  - Carburetor
    177
    
    Removal
    178
    
    Disassembly
    178
    
    Inspection
    180
    
    Installation
    184
    
    Fuel Level Adjustment
    185
- Chapter 5. Carburetion
  
  177
- Chapter 6. Drive Train
  
  187
  - Middle Gear Service
    187
    
    Middle Gear
    187
    
    Middle Gear Shims
    188
    
    Removal
    189
    
    Disassembly
    191
    
    Inspection
    193
    
    Middle Gear Shim Selection
    195
    
    Assembly
    202
    
    Middle Gear Lash Adjustment
    207
    
    Installation
    208
  - Final Drive Gear and Drive Shaft
    210
    
    Troubleshooting
    211
    
    Removal
    214
    
    Disassembly
    215
    
    Inspection
    217
    
    Final Drive Pinion Gear and Ring Gear Shim Selection
    218
    
    Assembly
    221
    
    Final Gear Gear Lash Measurement and Adjustment
    223
    
    Installation
    226
- Chapter 7. Chassis
  
  229
  - Front Wheels and Front Brake
    229
    
    Removal
    230
    
    Inspection
    231
    
    Installation
    234
  - Rear Wheels/Rear Brake and Rear Axle
    237
    
    Removal
    239
    
    Inspection
    241
    
    Installation
    244
  - Steering System
    248
    
    Removal
    249
    
    Inspection
    251
    
    Installation
    252
  - Front Shock Absorber and Front Arm
    256
    
    Removal
    257
    
    Inspection
    259
    
    Installation
    260
  - Rear Shock Absorber and Swingarm
    263
    
    Removal
    264
    
    Inspection
    266
    
    Installation
    268
- Chapter 8
  
  271
  - Electrical
    271
  - Electrical Components
    271
    
    Switch Inspection
    272
    
    Inspecting a Switch Shown in the Manual
    272
    
    Switch Continuity Inspection
    273
  - Elec
    273
  - Checking of Bulbs (for Headlight)
    276
    
    Checking Bulbs Condition
    276
  - Ignition System
    277
    
    Circuit Diagram
    277
    
    Troubleshooting
    278
  - Electric Starting System
    282
    
    Circuit Diagram
    282
    
    Starting Circuit Operation
    283
    
    Troubleshooting
    284
    
    Starter Motor
    284
    
    Starter Motor Inspection
    288
    
    Starter Motor Assembly
    289
  - Charging System
    291
    
    Circuit Diagram
    291
    
    Troubleshooting
    292
  - Lighting System
    294
    
    Circuit Diagram
    294
    
    Troubleshooting
    295
    
    Lighting System Check
    295
  - Signal System
    299
    
    Circuit Diagram
    299
    
    Troubleshooting
    300
    
    Signal System Check
    300
- Chapter 9. Troubleshooting
  
  305
  - Starting Failure/Hard Starting
    305
    
    Fuel System
    305
    
    Electrical System
    305
    
    Compression System
    306
  - Poor Idle Speed Performance
    306
  - Poor Medium and High-Speed Performance
    306
  - Faulty Drive Train
    307
  - Faulty Gear Shifting
    308
    
    Hard Shifting
    308
    
    Jumps out of Gear
    308
    
    Clutch Slipping
    308
    
    Clutch Dragging
    308
    
    Overheating
    309
  - Faulty Brake
    309
  - Poor Braking Effect
    309
  - Shock Absorber Malfunction
    309
    
    Malfunction
    309
    
    Unstable Handling
    310
  - Lighting System
    310
    
    Headlight Dark
    310
    
    Bulb Burnt out
    310
Table of Contents

318
- General Information
  320
  - Machine Identification
    320
    
    Vehicle Identification Number
    320
    
    Model Label
    320
- Specifications
  321
  - General Specifications
    321
  - Maintenance Specifications
    322
    
    Engine
    322
    
    Chassis
    323
    
    Electrical
    325
  - Cable Routing
    326
- Periodic Inspections and Adjustments
  333
  - Introduction
    333
  - Periodic Maintenance/Lubrication
    333
  - Engine
    335
    
    Spark Arrester Cleaning
    335
  - Chassis
    336
    
    Front Brake Fluid Level Inspection
    336
    
    Front Brake Pad Inspection
    336
    
    Brake Hose Inspection
    337
    
    Air Bleeding (Hydraulic Brake System)
    337
- Chassis
  339
  - Front Wheel
    339
    
    Removal
    340
    
    Inspection
    341
  - Front Brake
    342
    
    Brake Pad Replacement
    343
    
    Caliper Disassembly
    345
    
    Master Cylinder Disassembly
    346
    
    Inspection and Repair
    347
    
    Caliper Assembly
    350
    
    Master Cylinder Assembly
    353
  - Rear Wheels/Rear Brake and Rear Axle
    356
  - Front Shock Absorber and Front Arm
    357
  - Rear Shock Absorber and Swingarm
    358
- Electrical
  359
  - Electrical Components
    359
  - Ignition System
    360
    
    Troubleshooting
    361
  - Electric Starting System
    366
    
    Circuit Diagram
    366
    
    Starting Circuit Operation
    367
    
    Troubleshooting
    368
- Yfm250Xn Wiring Diagram
  373
Table of Contents

379
- Specifications
  380
  - General Specifications
    380
  - Maintenance Specification
    381
    
    Engine
    381
    
    Chassis
    382
    
    Electrical
    382
  - Cable Routing
    383
- Periodic Checks and Adjustments
  391
  - Introduction
    391
  - Periodic Maintenance/Lubrication Intervals
    391
  - Chassis
    393
    
    Adjusting the Front Brake
    393
    
    Adjusting the Rear Brake Light Swith
    393
- Electrical
  394
  - Checking the Switch
    394
    
    Checking a Switch Shown in the Manual
    394
  - Signal System
    395
    
    Circuit Diagram
    395
    
    Checking the Signal System
    396
- Yfm250Xp Wiring Diagram
  398

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