Yamaha 1994 YZ250/LC Manuals

Manuals and User Guides for Yamaha 1994 YZ250/LC. We have 1 Yamaha 1994 YZ250/LC manual available for free PDF download: Owner's Service Manual

Yamaha 1994 YZ250/LC Owner's Service Manual (580 pages)

Brand: Yamaha | Category: Motorcycle | Size: 16.26 MB

Important Notice: Safety Information
6
F.I.M Machine Weights
10
How to Use this Manual: How to Read Descriptions
14
Illustrated Symbols
16
Index
18
Contents
20
General Information
45
Motorcycle Description
46
Vehicle Identification Number
48
Frame Serial Number
48
Engine Serial Number
48
Preparation for Removal and Disassembly
50
All Replacement Parts
52
Gaskets, Oil Seals and O-Rings
52
Lock Washers/Plates and Cotter Pins
52
Bearing and Oil Seals
52
Circlips
54
Special Tools: for Tune up
54
Special Tools: for Engine Service
54
Special Tools: for Chassis Service
58
Special Tools: for Electrical Service
60
Control Functions: Engine Stop Button
62
Control Functions: Clutch Lever
62
Control Functions: Shift Pedal
62
Control Functions: Kick Starter
62
Control Functions: Throttle Grip
64
Control Functions: Front Brake Lever
64
Control Functions: Rear Brake Lever
64
Control Functions: Fuel Cock
64
Control Functions: Starter Knob (Choke)
66
Control Functions: Detachable Sidestand
66
Control Functions: Valve Joint
66
Fuel and Engine Mixing Oil
68
Pre-Operation Check List
70
Starting a Cold Engine
74
Starting a Warm Engine
74
Break-In Procedures
76
Torque-Check Points
80
Cleaning
86
Storage
88
Specifications
91
Maintenance Specifications: Engine
95
Specifications: Chassis
98
Specifications: Electrical
102
General Torque Specifications
103
Definition of Units
103
Cable Routing Diagram
128
Setting Parts: Front Fork
134
Setting Parts: Rear Shock Absorber
134
Regular Inspection and Adjustments
137
Maintenance Intervals
138
Coolant Level Inspection
146
Coolant Replacement
146
Radiator Cap Inspection
150
Radiator Cap Opening Pressure Inspection
152
Cooling System Inspection
152
Clutch Adjustment
154
Throttle Cable Adjustment
156
Air Filter Cleaning
156
Transmission Oil Level Check
160
Transmission Oil Replacement
162
Pilot Air Screw Adjustment
164
Idle Speed Adjustment
164
Brake System Air Bleeding
166
Front Brake Adjustment
168
Front Brake Pad Inspection and Replacement
168
Rear Brake Pad Inspection and Replacement
170
Brake Fluid Level Inspection
174
Rear Brake Adjustment
174
Sprockets Inspection
176
Drive Chain Inspection
176
Drive Chain Slack Adjustment
178
Front Fork Inspection
182
Front Fork Oil Seal and Dust Seal Cleaning
182
Front Fork Rebound Damping Force Adjustment
182
Front Fork Compression Damping Force Adjustment
184
Rear Shock Absorber Inspection
186
Rear Shock Absorber Spring Preload Adjustment
188
Rear Shock Absorber Rebound Damping Force Adjustment
190
Rear Shock Absorber Compression Damping Force Adjustment
192
Tire Pressure Check
194
Spokes Inspection and Tightening
194
Wheel Inspection
194
Steering Head Inspection and Adjustment
196
Silencer Fiber Replacement
200
Lubrication
202
Spark Plug Inspection
204
Ignition Timing Check
206
Engine
211
Seat, Fuel Tank, Side Covers, Exhaust Pipe and Silencer Preparation for Removal
212
Radiator and Water Pump: Preparation for Removal
214
Radiator and Water Pump: Note on Removal and Reassembly
215
Radiator and Water Pump: Removal Points
220
Radiator and Water Pump: Inspection
222
Radiator and Water Pump: Assembly and Installation
224
Carburetor and Reed Valve: Preparation for Removal
230
Carburetor and Reed Valve: Specifications
230
Carburetor and Reed Valve: Note on Removal and Reassembly
231
Carburetor and Reed Valve: Removal Points
231
Carburetor and Reed Valve: Inspection
236
Carburetor and Reed Valve: Assembly and Installation
240
Cylinder Head, Cylinder and Piston: Preparation for Removal
248
Cylinder Head, Cylinder and Piston: Note on Removal and Reassembly
249
Cylinder Head, Cylinder and Piston: Removal Points
249
Cylinder Head, Cylinder and Piston: Piston and Piston Ring
254
Cylinder Head: Inspection
256
Cylinder: Inspection
258
Piston: Inspection
260
Piston Pin and Small End Bearing
260
Piston Ring: Inspection
262
Piston Clearance
264
Combination of Piston and Cylinder
266
Cylinder Head, Cylinder and Piston: Power Valve
268
Cylinder Head, Cylinder and Piston: Power Valve Hole on Cylinder
268
Cylinder Head, Cylinder and Piston: Assembly and Installation
268
Clutch and Primary Driven Gear: Preparation for Removal
278
Clutch and Primary Driven Gear: Note on Removal and Reassembly
279
Clutch and Primary Driven Gear: Removal Points
279
Clutch and Primary Driven Gear: Inspection
284
Clutch and Primary Driven Gear: Assembly and Installation
286
Kick Axle, Shift Shaft and Primary Drive Gear: Preparation for Removal
292
Kick Axle, Shift Shaft and Primary Drive Gear: Note on Removal and Reassembly
293
Kick Axle, Shift Shaft and Primary Drive Gear: Removal Points
293
Kick Axle Assembly
298
Shift Guide and Shift Lever Assembly
298
Stopper Lever
298
Kick Axle, Shift Shaft and Primary Drive Gear: Inspection
298
Kick Axle, Shift Shaft and Primary Drive Gear: Assembly and Installation
302
YPVS Governor: Preparation for Removal
310
YPVS Governor: Note on Removal and Reassembly
311
YPVS Governor: Removal Points
311
YPVS Governor: Inspection
311
YPVS Governor: Assembly and Installation
316
CDI Magneto: Preparation for Removal
320
CDI Magneto: Note on Removal and Reassembly
321
CDI Magneto: Removal Points
321
CDI Magneto: Inspection
321
CDI Magneto: Assembly and Installation
326
Engine Removal: Preparation for Removal
332
Engine Removal: Note on Removal and Reassembly
333
Engine Removal: Removal Points
333
Engine Removal: Assembly and Installation
338
Crankcase and Crankshaft: Preparation for Removal
344
Crankcase and Crankshaft: Note on Removal and Reassembly
345
Crankcase and Crankshaft: Removal Points
345
Crankcase and Crankshaft: Inspection
350
Crankcase and Crankshaft: Assembly and Installation
352
Transmission, Shift Cam and Shift Fork: Preparation for Removal
358
Transmission, Shift Cam and Shift Fork: Note on Removal and Reassembly
359
Transmission, Shift Cam and Shift Fork: Removal Points
359
Transmission, Shift Cam and Shift Fork: Inspection
359
Transmission, Shift Cam and Shift Fork: Assembly and Installation
366
Chassis
373
Front Wheel: Preparation for Removal
374
Front Wheel: Removal Points
376
Front Wheel: Inspection
376
Front Wheel: Assembly and Installation
378
Rear Wheel: Preparation for Removal
382
Rear Wheel: Removal Points
384
Rear Wheel: Inspection
384
Rear Wheel: Assembly and Installation
386
Front Brake: Preparation for Removal
392
Front Brake: Note on Removal and Reassembly
393
Front Brake: Removal Points
398
Front Brake: Inspection
400
Front Brake: Assembly and Installation
402
Rear Brake: Preparation for Removal
414
Rear Brake: Note on Removal and Reassembly
415
Rear Brake: Removal Points
415
Rear Brake: Caliper Piston
420
Rear Brake: Piston Seal Kit
420
Rear Brake: Brake Pedal
422
Rear Brake: Master Cylinder Kit
422
Rear Brake: Inspection
422
Rear Brake: Assembly and Installation
424
Front Fork: Preparation for Removal
436
Front Fork: Handling Note
437
Front Fork: Removal Points
442
Front Fork: Assembly
448
Front Fork: Installation and Adjustment
460
Steering: Preparation for Removal
464
Steering: Removal Points
466
Steering: Inspection
466
Steering: Steering Shaft
468
Steering: Assembly and Installation
468
Steering: Handlebar
474
Swingarm: Preparation for Removal
476
Swingarm: Note on Removal and Reassembly
477
Swingarm: Removal Points
477
Swingarm: Inspection
482
Swingarm: Connecting Rod and Relay Arm
482
Swingarm: Assembly and Installation
486
Rear Shock Absorber: Preparation for Removal
492
Rear Shock Absorber: Notes on Disposal
496
Rear Shock Absorber: Removal Points
496
Rear Shock Absorber: Inspection
498
Rear Shock Absorber: Assembly and Installation
498
Electrical
505
Electrical Components
506
Wiring Diagram
506
Ignition System: Inspection Steps
508
Ignition System: Spark Gap Test
512
Ignition System: Couplers and Leads Connection Inspection
512
Ignition System: 'Engine Stop' Button Inspection
512
Ignition System: Ignition Coil Inspection
514
Ignition System: CDI Magneto Inspection
516
Ignition System: CDI Unit Inspection
518
Tuning
521
Carburetor Tuning: Carburetor Setting
522
Carburetor Tuning: Test Run
524
Carburetor Tuning: Improper Throttle Valve Setting
524
Carburetor Tuning: Main Jet Adjustment
526
Carburetor Tuning: Air Screw Adjustment
526
Carburetor Tuning: Idling Adjustment
526
Carburetor Tuning: Jet Needle Groove Position Adjustment
528
Carburetor Tuning: Jet Needle Adjustment
528
Carburetor Tuning: Relationship with Throttle Opening
530
Carburetor Tuning: Relationship between the Jet Needle Diameter and Clip Position
530
Carburetor Tuning: Road Condition and Examples of Carburetor Setting
532
Carburetor Tuning: Examples of Carburetor Setting Depending on Symptom
532
Spark Plug: Change of the Heat Range
538
Spark Plug: Heat Range
540
Gearing: Selection of the Secondary Reduction Ratio
542
Suspension Tuning
546
Front Fork: Fork Oil Level
550
Front Fork: Rebound Damping
550
Front Fork: Compression Damping
552
Front Fork: Fork Spring
552
Front Fork: Fork Clamp Position
552
Rear Shock: Spring Preload
554
Rear Shock: Adjustment Steps
554
Rear Shock: Spring Replacement
556
Rear Shock: Rebound Damping
556
Rear Shock: Compression Damping
558
Troubleshooting: Symptoms of the Front Forks
560
Troubleshooting: Symptoms of the Rear Shock
562
Troubleshooting: Readjustment of the Suspension
564
Troubleshooting: Front and Rear Compatibility
566
Troubleshooting: General Symptoms and Remedy
566
Setting Record Table
576

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Yamaha 1994 YZ250/LC Owner's Service Manual (580 pages)

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