YAMAHA XG250 Manuals

Manuals and User Guides for YAMAHA XG250. We have 2 YAMAHA XG250 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XG250 Service Manual

Yamaha XG250 Service Manual (278 pages)

Brand: Yamaha | Category: Motorcycle | Size: 12.16 MB

Table of Contents

Table of Contents

3
- Symbols
  4
- General Information
  6
- Identification
  7
- Important Information
  8
- Checking the Connections
  10
- Special Tools
  11
Specifications

16
- General Specifications
  17
- Engine Specifications
  18
- 1 Clutch Spring
  23
  - Chassis Specifications
    25
  - Electrical Specifications
    28
  - Tightening Torques
    30
    
    Engine Tightening Torques
    30
    
    General Tightening Torque Specifications
    30
    
    Chassis Tightening Torques
    32
  - Lubrication Points and Lubricant Types
    35
    
    Engine
    35
    
    Chassis
    36
  - Lubrication System Chart and Diagrams
    37
    
    Engine Oil Lubrication Chart
    37
    
    Lubrication Diagrams
    39
  - Cable Routing
    41
Periodic Checks and Adjustments

51
- Periodic Maintenance
  
  52
  - Introduction
    52
  - Periodic Maintenance and Lubrication Chart
    52
- Engine
  
  54
- Chassis
  
  66
- Electrical System
  
  76
Chassis

78
- General Chassis
  
  80
- Front Wheel
  
  81
- Rear Wheel
  
  88
- Front Brake
  
  92
- Rear Brake
  
  105
  - Introduction
    110
  - Checking the Rear Brake Disc
    110
  - Replacing the Rear Brake Pads
    110
  - Removing the Rear Brake Caliper
    111
  - Disassembling the Rear Brake Caliper
    111
  - Checking the Rear Brake Caliper
    112
  - Assembling the Rear Brake Caliper
    112
  - Installing the Rear Brake Caliper
    112
  - Removing the Rear Brake Master Cylinder
    114
  - Checking the Rear Brake Master Cylinder
    114
  - Assembling the Rear Brake Master Cylinder
    115
  - Installing the Rear Brake Master Cylinder
    115
- Handlebar
  
  117
  - Removing the Handlebar
    118
  - Checking the Handlebar
    118
  - Installing the Handlebar
    118
- Front Fork
  
  120
  - Removing the Front Fork Legs
    122
  - Disassembling the Front Fork Legs
    122
  - Checking the Front Fork Legs
    123
  - Assembling the Front Fork Legs
    123
  - Installing the Front Fork Legs
    126
- Steering Head
  
  127
  - Removing the Lower Bracket
    129
  - Checking the Steering Head
    129
  - Installing the Steering Head
    130
- Rear Shock Absorber Assembly
  
  131
- Swingarm
  
  134
  - Removing the Swingarm
    135
  - Checking the Swingarm
    135
  - Installing the Swingarm
    136
- Chain Drive
  
  137
  - Removing the Drive Chain
    138
  - Checking the Drive Chain
    138
  - Checking the Drive Sprocket
    139
  - Checking the Rear Wheel Sprocket
    139
  - Installing the Drive Chain
    139
Engine

141
- Engine Removal
  
  143
  - Installing the Engine
    146
- Cylinder Head
  
  147
  - Removing the Cylinder Head
    149
  - Checking the Cylinder Head
    149
  - Checking the Timing Chain Guides
    150
  - Checking the Timing Chain Tensioners
    150
  - Installing the Cylinder Head
    151
- Rocker Arm, Camshaft
  
  154
- Valves and Valve Springs
  
  160
  - Removing the Valves
    160
  - Checking the Valves and Valve Guides
    160
  - Checking the Valve Seats
    162
  - Checking the Valve Springs
    164
  - Installing the Valves
    165
- Cylinder and Piston
  
  167
  - Removing the Piston
    168
  - Checking the Cylinder and Piston
    168
  - Checking the Piston Rings
    169
  - Checking the Piston Pin
    170
  - Installing the Piston and Cylinder
    170
- Clutch
  
  172
- 2 Pressure Plate
  
  173
  - Removing the Clutch
    175
    
    Checking the Friction Plates
    175
  - Lock Washer
    175
    
    Checking the Clutch Boss
    176
    
    Checking the Clutch Housing
    176
    
    Checking the Clutch Plates
    176
    
    Checking the Clutch Springs
    176
    
    Checking the Clutch Push Rods
    177
    
    Checking the Pressure Plate
    177
    
    Checking the Primary Drive Gear
    177
    
    Installing the Clutch
    177
- Ym-91042
  
  177
  - Friction Plate
    178
- Oil Pump and Blancer Weight Gear
  
  180
  - Checking the Balancer Weight Gear
    183
  - Checking the Oil Pump
    183
  - Removing the Balancer Weight Gear and Oil Pump
    183
  - Assenbling the Balancer Drive Gear
    184
  - Installing the Balancer Weight Gear
    184
  - Installing the Oil Pump
    184
- Shift Shaft
  
  185
  - Checking the Shift Shaft
    186
  - Checking the Stopper Lever
    186
  - Installing the Shift Shaft
    186
- Electric Starter
  
  187
  - Checking the Starter Motor
    189
  - Assembling the Starter Motor
    190
- Pickup Coil Rotor and Starter Clutch
  
  191
  - Removing the Pickupcoil Rotor
    193
  - Checking the Starter Clutch
    193
  - Installing the Pickup Coil Rotor
    194
- Crankcase
  
  196
  - Disassembling the Crankcase
    198
  - Checking the Crankcase
    198
  - Assembling the Crankcase
    198
- Crankshaft Assembly
  
  201
- Transmission
  
  206
  - Removing the Transmission
    206
  - Checking the Shift Forks
    206
  - Checking the Shift Drum Assembly
    206
  - Checking the Transmission
    207
  - Installing the Shift Forks and Shift Drum Assembly
    208
Fuel System

209
- Fuel Tank
  
  210
  - Checking the Fuel Cock
    211
- Carburetor
  
  214
  - Checking the Carburetor
    214
  - Assembling the Carburetor
    215
  - Installing the Carburetor
    216
- Air Induction System
  
  218
  - Checking the Air Induction System
    221
Electrical System

223
- Ignition System
  
  224
  - Circuit Diagram
    224
  - Troubleshooting
    226
- Electric Starting System
  
  228
  - Circuit Diagram
    228
  - Starting Circuit Cut-Off System Operation
    230
  - Troubleshooting
    232
- Charging System
  
  234
  - Circuit Diagram
    234
  - Troubleshooting
    236
- Lighting System
  
  238
  - Circuit Diagram
    238
  - Troubleshooting
    240
- Signaling System
  
  242
  - Circuit Diagram
    242
  - Troubleshooting
    244
- Carburetor Heating System
  
  248
  - Circuit Diagram
    248
  - Troubleshooting
    250
- Electrical Components
  
  252
  - Checking the Switches
    256
  - Checking the Bulbs and Bulb Sockets
    259
  - Checking the Fuse
    260
  - Checking and Charging the Battery
    261
  - Checking the Relays
    264
  - Checking the Turn Signal Relay
    264
  - Checking the Diode
    265
  - Checking the Spark Plug Cap
    266
  - Checking the Ignition Coil
    266
  - Checking the Pickup Coil
    267
  - Checking the Stator Coil
    267
  - Checking the Rectifier/Regulator
    268
  - Checking the Horn
    268
  - Checking the Thermo Switch
    269
  - Checking the Carburetor Warmer
    270
Troubleshooting

271
- General Information
  272
- Starting Failures
  272
- Troubleshooting
  272
- Faulty Clutch
  273
- Faulty Gear Shifting
  273
- Incorrect Engine Idling Speed
  273
- Jumps out of Gear
  273
- Poor Medium-And-High-Speed Performance
  273
- Shift Pedal Does Not Move
  273
- Faulty Front Fork Legs
  274
- Overheating
  274
- Poor Braking Performance
  274
- Unstable Handling
  274
- Faulty Lighting or Signaling System
  275

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YAMAHA XG250 Owner's Manual

YAMAHA XG250 Owner's Manual (80 pages)

tricker 2005

Brand: YAMAHA | Category: Motorcycle | Size: 2.14 MB

Table of Contents

Important Manual Information
4
Table of Contents
6
Safety Information
8
Description
12
Left View
12
Right View
13
Controls and Instruments
14
Main Switch/Steering Lock
15
Instrument and Control Functions
15
Indicator Lights
16
Speedometer Unit
16
Handlebar Switches
17
Clutch Lever
18
Shift Pedal
18
Brake Lever
18
Brake Pedal
19
Fuel Tank Cap
19
Fuel
20
Fuel Cock
20
Starter (Choke) Knob "1
21
Seat
22
Helmet Holder
22
Storage Pouch
23
Shock Absorber
23
Sidestand
23
Ignition Circuit Cut-Off System
24
Pre-Operation Checks
26
Pre-Operation Check List
27
- Operation and Important Riding Points
  29
- Starting a Cold Engine
  29
- Starting a Warm Engine
  30
- Shifting
  30
- Tips for Reducing Fuel Consumption
  31
- Engine Break-In
  31
- Parking
  32
- Periodic Maintenance and Minor Repair
  33
- Owner's Tool Kit
  33
- Periodic Maintenance and Lubrication Chart
  34
- Removing and Installing Panels
  37
- Checking the Spark Plug
  38
- Engine Oil and Oil Filter Element
  40
Replacing the Air Filter Element and Cleaning the Check Hose
43
Adjusting the Carburetor
44
Adjusting the Engine Idling Speed
44
Checking the Throttle Cable Free Play
45
Valve Clearance
45
- Tires
  45
Tires
46
- Spoke Wheels
  47
Adjusting the Clutch Lever Free Play
48
- Adjusting the Brake Lever Free Play
  48
- Adjusting the Rear Brake Light Switch
  49
- Checking the Front and Rear Brake
  49
  - Pads
    49
  - Checking the Brake Fluid Level
    50
  - Changing the Brake Fluid
    51
  - Drive Chain Slack
    51
  - Cleaning and Lubricating the Drive
    52
    
    Chain
    52
  - Checking and Lubricating the Cables
    53
  - Checking and Lubricating the Throttle Grip and Cable
    53
  - Checking and Lubricating the Brake and Shift Pedals
    54
  - Checking and Lubricating the Brake and Clutch Levers
    54
  - Checking and Lubricating the Sidestand
    55
  - Lubricating the Rear Suspension
    55
  - Checking the Front Fork
    56
  - Checking the Steering
    56
  - Checking the Wheel Bearings
    57
  - Battery
    57
  - Replacing the Fuse
    59
  - Replacing the Headlight Bulb
    59
  - Replacing the Tail/Brake Light Bulb
    61
  - Replacing a Turn Signal Light Bulb
    61
  - Replacing the Auxiliary Light Bulb
    62
  - Supporting the Motorcycle
    63
  - Front Wheel
    63
  - Rear Wheel
    65
  - Troubleshooting
    66
  - Troubleshooting Chart
    67
  - Motorcycle Care and Storage
    68
  - Matte Black Caution
    68
  - Care
    68
  - Storage
    70
  - Specifications
    72
  - Consumer Information
    75
  - Identification Numbers
    75

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