Yamaha SR250G User manual

Table of contents

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.

@

YAMAHA

«

|

SR250G

Service

Manual

ud

(a

&

CHAPTER

1.

MOTORCYCLE

IDENTIFICATION

EXTERNAL

VIEW...

SPTCIAL

TOOLS

GENERAL

INFORMATION

seed

12

1-2

CHAPTER

1.

GENERAL

INFORMATION

MOTORCYCLE

IDENTIFICATION

The

freie

sera!

aunber

-s

located

07

the

right--and

side

of

te

head

pive

The

frst

these

digi:s

identity

the

model.

“his

5

fo

-

lowina

by

a

dass.

fhe

remaining

digits

identify

the

production

number

of

ee

unit.

The

engine

serial

number

is

locates

on

a

raised

hess

on

the

.pner

reas.

nght-hand

side

of

the

engire

Engine

idenzfication

follows

the

some

code

as

‘rsme

iden:

fication.

Starting

Sarlal

Number

YE

OI

Large

seat

sume

EXTERNAL

VIEW

VEHICLE

EMISSION

CONTRO

BATTERY

CAUTION

LABEL

iy

SPECIAL

TOQLS

Mo.

vowwe

08112

20)

No.

90890-0302

1-5¢)

"

(P/Na,

90892-03007-00)

liegt

(Pec.

90890-01238.00)

(Pith,

80380.01°89-06)

Lutes

natane

toot

mts,

at

wou

a

a2

vd

Crankcase

separating

“oct

|P/Na.

9080-01

136-20)

Tappa

sd

wsting

al

790,

99880-2131

1.00)

Front

fork

evinder

co-malte

hotder

(n/Mes

90690.073

04.20

‘Thype

hard

@(P/Me

30590-01301-09)

ing

mt

wrench

(P/N

90890-07266-00)

‘Spoke wienen

(P/Mo,

90899-0808

7.00),

NFORMATION

LAREL

PLATE

SC

“4

preg

compressor

(#/No.

80890-01263.00)

wwe

(P/No.

80090-21227-00)

Pir.

WuEED-

21.

Aches

mc

suet

oiler

we

9%

Pmt.

90820.

MAINTENANCE

AND

LUBRICATION

CHART

ENGINE

CHASSIS

CHAPTER

2.

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

Introduction

Maintenance

Interval

Charts

Periadic

Maintenance

Emission

Control

System

General

Maintenance/Lubrication.

Carburetor.

iG

Air

Fiter

Engine

Oil

Engine

Oil

and

Oil

Filtor

Replacement

Clutch

Adjustment

Froe

Play

Adjustment

Cam

Chain

Adjustment

Valve

Clearance

Adjustment

Fue!

Petcock

Front

Brake

and

Wheel

Front

Brake

Adjustment

Spoke

Adjustment

and

Torque...

Front

Axle

Tire

Pressure

r

Roar

Brake

and

Wheel

Hear

Brake

Adjustmer

Brake

Lining

Inspection...

Spoke

Adjustment

anc

Tension.

Rezr

Axle

Tire

Pressure

Drive

Chain

Tension

Check

Drive

Chain

Tension

Acjustment.

Drive

Chany

Lubri¢ation

Front

Fork

Oil

Change

: :

Suspension,

Steering

and

Swing

Arm......

Reet

y

Rear

Shock

Ahsarher

Cable

Inspection

and

Lubricat

Throttle

Cables

and

Grip

Lutri

Lubrication

of

Levers.

Pedals,

etc.

ation

ELECTRICAL...

erent

Ignition

Timing

Spar<

Plug

CHAPTER

2.

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

MAINTENANCE

AND

LUBRICATION

CHART

Introduction

This

cheptor

includes

all

information

neces-

sary

to

perform

recommended

inspection

end

adjustments.

These

preventative

main-

tenerce

procedures,

if

followed.

will

insure

more

reliable

vehicle

operation

and

2

longer

service

life

The

need

for

costly

overhaul

work

will

be

greatly

“aduced.

This

informa-

tion

applies

not

only

to

vehicles

already

in

service,

but

also

to

new

vehicles

thst

are

being

propered

for

salo.

Any

sorvico

tech

ncian

performing

preparation

work

should

he

familiar

with

th's

entire

chantor

Periodic

Maintenance

Maintenance

Intervals

Charts

Proper

periodic

maintenance

is

important

Especially

important

are

the

maintenance

services

related

to

emissions

control,

The:

controls

not

only

function

to

ensure

cleaner

ait

bul

ary

also

vita!

to

proper

engine

opera

tion

and

maximum

performance.

in

the

fol-

lowing

tables

of

periodic

maintenance.

the

services

related

to

emissions

control

are

grouped

seperately.

Emission

Control

System

forere

Treveater

voy

200

km

000

bn

©2500

m)

|

Cars

chain

‘Drax

caustcha

cn

Valve

clearence

woreneas

ne

RGUEVEve

Cena

ca

wha

Spubeky

Crankease

ventiaticr

Root

mereary

Check

a

sine

Re

yim

{ebace

aint

nese

‘aoe

fo

hoe

or

ercke

cr

image

eee

ee

7

‘heck

ad

eds

magia

le

sowed

aks’

cab

x

pay

Wneaeary

1

‘Teievecommenced

hat

hase

arma

oe

sunvccd

bya

Yarwha

Seas

or

2the

Cuan

2

General

Maintenance/

Lubrication

‘

Thisvecammenced

sat

shave

have

mawcud

bya

Vorane

dese

0

hw"

T

‘Thereaher

evary

|

ion

=

Zo0cke

|

£000km

|

15002

ww

Be

ies

evome

|

HoCEm)

|

(9

500m)

aréments

[ort2

mons

or

tami

il

1

[Werwmore

|

aman

Rat

2

o ©

foe

ar

faorsze

rows

[petormaanee

|

Sre"SE

motan

ot

z

Tes

wer

1

he

eB

2

|Olemoner

_

|

iemantandcaen

=

2 ¢

e

Wet

format

”

tewaiedes

|

Yemebe

acre

|

«

2

Syeaon

vase

femal

esi

ay

=

°

Ca

ee

PT

=

0

<

3

IE

ee

Varaha

chan

ane

5

|

Drvecnon

APY

CRANE

|

Seno

cr

bab

hock

nai

ncn

a

bs

oer

800

hm

(300

wg

JONV/30

moter

Yarrana

cra

mane

7

depycdankbe

|

Meubeciiar

|

© « °

Fiesta

{TUN/30

motor

3

py

nemn

qi

|

Lar

8996

30

c

Acumen

i

MO

a

Yarana

cana

[Saiecedal

—Acpychsnkbe

|Site

tees

Bae

©

e

Tow

30

mat

Yoreha

oe

none

Araalewen

—Acpychainhin|

]

10

{ete

be

cr

SAE

c ¢

feoreivatshahs

eee

Nicci

ama

Depjauanise

|

Yorabecren

sx!

11

[Emre

sony

smaniube

|

tla

ube

or

EAE

Ca

[bw

somnor

=

4

Dan

swan

12+

|

roncion

ot

Retin

c

[rennet

seciaten

}

Tek

traree

]

Simenng

a

|

gem

1ae

[Seated

Seseme”

|

Mat

pores

|

«

<

we

m=

‘every

16.0008m

|

"8"

|

5

2

NOTE:

The

air

filter

should

be

cleaned

moro

often

than

spes

fied

inzervals

if

the

motorcycle

is

operated

in

extremely

dusty

area.

22

ENGINE

Carburetor

Idle

speed

setting

procedure

Start

the

engine

2nd

warm

it

uo

for

a

few

minutes.

Set

the

2ngire

idle

speed

to

specified

r/min,

by

turning

the

thro:

tle

stop

screwy

in

te

increase

the

engine

speed

and

tack

off

the

screw

to

de-

1

thie

engine

specd

@

tachometer

for

checking

justing

the

engine

speed

Idle

speed

1.200

2.

ole

mixture

The

idle

mixture

is

set

2:

the

factory

by

the

use

of

special

equipmem

Nat

attampt

should

9¢

made

by

the

dealer

ty

change

this

adjustment

3.

Throvtle

cable

adjustment

NOTE:

cle

speed

should

be

set

before

making

this

adjustment

The

thrattle

grip

should

have

s

play

of

2

~

5

mm

(0.08

~

02

in)

in

the

wrning

direction

at

the

grip

flange,

If

the

play

is

net

this

range,

take

the

fellowing

step

for

adjustment

Loosen

the

adjuster

fuck

nut

on

the

throttle

cable.

and

tum

the

adjuste

or

out

So

the

play

|S

corrcet.

A’

avjustmant,

bg)

les

tie

ock

nut

23

Air

Filter

The

air

filter

protects

the

engine

from

dirt

which

can

enter

with

the

intake

sir

and

cause

rend

engine

wear

This

dirt

is

filterad

from

the

air

dy

the

air

filter

element.

This

mode!

uses

a

cartridge

type

air

filter

element

which

consists

of

foam

ruboer

moistened

with

oil

When

his

filter

element

becomes

dirty

it

should

be

cleaned

Remove

the

seat

and

che

side

cover

Held)

Remove

the

air

fikter

element

from

its

aase,

romove

olement

from)

guide

and

ivan

with

solvent.

After

clesning,

re~

move

the

remaining

solvent

by

squacz

ing

the

element

Then

apply

equivalent

to

squeez®

out

the

excess

cil

should

be

wet

but

not

dripping

When

installing

the

air

filter

elem

75

case,

be

sure

its

sealing

surface

hatches

purfecty

the

sealing

surface

the

case

s0

"167

's

not

air

leaksge

ube

2-cycle

cil

or

and

Element

the

entire

sur

in

The

air

filter

element

should

be

cleaned

at

the

specifec

intervals

It

should

be

cleaned

more

often

if

the

motercycle

is

cperated

in

custy

or

wet

areas

CAUTION

The

engine

should

never

be

run

without

the

air

cleaner

element

installed:

ex-

cessive

piston

and/or

cylinder

wear

may

result.

1

Ot

1.

Oillevel

measuremem

uanght

position.

Warm

several

T)nutes

NOTE:

HH

___________

Be

sure

the

motorcycle

1s

positioned

straight

up

when

checking

the

oil

level:

a

slignt

tit

(ower

the

sive

can

produce

false

readings.

b

With

the

engine

stopped,

check

the

nil

evel

through

78

level

wincow

located

at

the

lower

ert

of

the

right

side

orankeas®

caver

Nore:

————_____

Wait

a

“ew

minutes

until

the

oil

ievel

settles

before

checking

Level

wedow

2

Misimam

srk

2

Oil

capacity

Afzer

angine

evertaul

1.6

it

(1.7

US

qd)

Aftor

ol!

filter

replace:

1.311

(1.4

US

qd

Engine

Oil

and

Oil

Fitter

Replacement

;-CAUTION

After

replacement

of

engine

oil,

be

sure

to

check

the

oil

pressure

in

the

follow-

ing

procedure.

1

Remove

the

air

bleed

screw

from

oil

filter

cover,

and

loosen

the

check

bolt

in

the

cylindar

head.

2

Start

the

engine

and

keep

it

idle

running

til!

oi!

flows

out

of

the

bleed

hole.

and

at

the

check

bolt

(see

the

following

photo).

The

check

bolt

has

a

slit

for

checking

oil

Ifo

oil

comes

out

even

after

a

lapse

|

‘of

over

one

minute,

cut

the

engine

immediately

for

foar

of

seizure.

Rustart

the

eugine

after

solving

the

|

problem(s)

and

recheck

the

ail

pre

sure.

|

1.

Oil

filtor

replacement

NOTE:

When

replacing

the

engine

cil

after

the

brook

in

peroc.

clear

the

oi!

strainer

a:

the

bottom

of

the

engine

a.

Star:

the

enginy.

Alle:

a

few

minutes

of

warm-up

stop

the

engine

b.

Place

an

cll

pan

under

the

engine.

apg

©.

Romove

the

ail

fillyr

cap,

drain

pluy

and

air

bleed

screw

attached

to

the

oil

ilk

ter

cover,

and

crain

the

engine

oll.

NOTE:

———

12

oil

filter

cover

is

secured

by

three

ews.

The

lower

one

should

be

\oosened

until

the

Uhreaded

portion

comes

out

com-

oletely.

1

Bible!

sm

CAUTION:

When

remaving

the

drnin

plug,

the

|

compression

spring,

oi

strainer

and

O-

|

ring

will

fall

off.

Take

care

not

to

lose

these

parts.