Yamaha SR250G User manual

YAMAHA

SR250G

Service

Manual

CHAPTER

MOTORCYCLE

IDENTIFICATION

EXTERNAL

VIEW...

SPTCIAL

TOOLS

GENERAL

INFORMATION

seed

1-2

CHAPTER

GENERAL

INFORMATION

MOTORCYCLE

IDENTIFICATION

The

freie

sera!

aunber

-s

located

the

right--and

side

head

pive

The

frst

these

digi:s

identity

the

model.

“his

lowina

dass.

fhe

remaining

digits

identify

the

production

number

unit.

The

engine

serial

number

locates

raised

hess

the

.pner

reas.

nght-hand

side

the

engire

Engine

idenzfication

follows

the

some

code

‘rsme

iden:

fication.

Starting

Sarlal

Number

Large

seat

sume

EXTERNAL

VIEW

VEHICLE

EMISSION

CONTRO

BATTERY

CAUTION

LABEL

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,

wou

Crankcase

separating

“oct

|P/Na.

9080-01

136-20)

Tappa

wsting

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

wrench

(P/N

90890-07266-00)

‘Spoke wienen

(P/Mo,

90899-0808

7.00),

NFORMATION

LAREL

PLATE

“4

preg

compressor

(#/No.

80890-01263.00)

wwe

(P/No.

80090-21227-00)

Pir.

WuEED-

21.

Aches

suet

oiler

Pmt.

90820.

MAINTENANCE

AND

LUBRICATION

CHART

ENGINE

CHASSIS

CHAPTER

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

Introduction

Maintenance

Interval

Charts

Periadic

Maintenance

Emission

Control

System

General

Maintenance/Lubrication.

Carburetor.

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

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

Rear

Shock

Ahsarher

Cable

Inspection

and

Lubricat

Throttle

Cables

and

Grip

Lutri

Lubrication

Levers.

Pedals,

etc.

ation

ELECTRICAL...

erent

Ignition

Timing

Spar<

Plug

CHAPTER

PERIODIC

INSPECTIONS

AND

ADJUSTMENTS

MAINTENANCE

AND

LUBRICATION

CHART

Introduction

This

cheptor

includes

all

information

neces-

sary

perform

recommended

inspection

end

adjustments.

These

preventative

main-

tenerce

procedures,

followed.

will

insure

reliable

vehicle

operation

and

longer

service

life

The

need

for

costly

overhaul

work

will

greatly

“aduced.

This

informa-

tion

applies

not

only

vehicles

already

service,

but

also

new

vehicles

thst

are

being

propered

for

salo.

Any

sorvico

tech

ncian

performing

preparation

work

should

familiar

with

th's

entire

chantor

Periodic

Maintenance

Intervals

Charts

Proper

periodic

maintenance

important

Especially

important

are

the

maintenance

services

emissions

control,

The:

controls

not

only

function

ensure

cleaner

ait

bul

ary

also

vita!

proper

engine

opera

tion

and

maximum

performance.

the

fol-

lowing

tables

periodic

maintenance.

the

services

emissions

control

are

grouped

seperately.

Emission

Control

System

forere

Treveater

voy

200

000

Cars

chain

‘Drax

caustcha

Valve

clearence

woreneas

RGUEVEve

Cena

wha

Spubeky

Crankease

ventiaticr

Root

mereary

Check

sine

yim

{ebace

aint

nese

‘aoe

hoe

ercke

image

eee

‘heck

eds

magia

sowed

aks’

cab

pay

Wneaeary

‘Teievecommenced

hat

hase

arma

sunvccd

bya

Yarwha

Seas

2the

Cuan

General

Maintenance/

Lubrication

‘

Thisvecammenced

sat

shave

have

mawcud

bya

Vorane

dese

hw"

‘Thereaher

evary

ion

Zo0cke

£000km

15002

ies

evome

HoCEm)

500m)

aréments

[ort2

mons

tami

[Werwmore

aman

Rat

o ©

foe

faorsze

rows

[petormaanee

Sre"SE

motan

Tes

wer

|Olemoner

iemantandcaen

2 ¢

Wet

format

”

tewaiedes

Yemebe

acre

Syeaon

vase

femal

esi

Varaha

chan

ane

Drvecnon

APY

CRANE

Seno

bab

hock

nai

ncn

oer

800

(300

JONV/30

moter

Yarrana

cra

mane

depycdankbe

Meubeciiar

Fiesta

{TUN/30

motor

nemn

Lar

8996

Acumen

Yarana

cana

[Saiecedal

—Acpychsnkbe

|Site

tees

Bae

Tow

mat

Yoreha

none

Araalewen

—Acpychainhin|

]

{ete

SAE

c ¢

feoreivatshahs

eee

Nicci

ama

Depjauanise

Yorabecren

sx!

[Emre

sony

smaniube

tla

ube

EAE

[bw

somnor

Dan

swan

12+

roncion

Retin

[rennet

seciaten

}

Tek

traree

]

Simenng

gem

1ae

[Seated

Seseme”

Mat

pores

‘every

16.0008m

"8"

NOTE:

The

air

filter

should

cleaned

moro

often

than

spes

fied

inzervals

the

motorcycle

operated

extremely

dusty

area.

ENGINE

Carburetor

Idle

speed

setting

procedure

Start

the

engine

2nd

warm

for

few

minutes.

Set

the

2ngire

idle

speed

specified

r/min,

turning

the

thro:

tle

stop

screwy

increase

the

engine

speed

and

tack

off

the

screw

de-

thie

engine

specd

tachometer

for

checking

justing

the

engine

speed

Idle

speed

1.200

ole

mixture

The

idle

mixture

set

the

factory

the

use

special

equipmem

Nat

attampt

should

9¢

made

the

dealer

change

this

adjustment

Throvtle

cable

adjustment

NOTE:

cle

speed

should

set

before

making

this

adjustment

The

thrattle

grip

should

have

play

(0.08

in)

the

wrning

direction

the

grip

flange,

the

play

net

this

range,

take

the

fellowing

step

for

adjustment

Loosen

the

adjuster

fuck

nut

the

throttle

cable.

and

tum

the

adjuste

out

the

play

corrcet.

A’

avjustmant,

bg)

les

tie

ock

nut

Air

Filter

The

air

filter

protects

the

engine

from

dirt

which

can

enter

with

the

intake

sir

and

cause

rend

engine

wear

This

dirt

filterad

from

the

air

the

air

filter

element.

This

mode!

uses

cartridge

type

air

filter

element

which

consists

foam

ruboer

moistened

with

oil

When

his

filter

element

becomes

dirty

should

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

squacz

ing

the

element

Then

apply

equivalent

squeez®

out

the

excess

cil

should

wet

but

not

dripping

When

installing

the

air

filter

elem

case,

sure

its

sealing

surface

hatches

purfecty

the

sealing

surface

the

case

"167

not

air

leaksge

ube

2-cycle

cil

and

Element

the

entire

sur

The

air

filter

element

should

cleaned

the

specifec

intervals

should

cleaned

often

the

motercycle

cperated

custy

wet

areas

CAUTION

The

engine

should

never

run

without

the

air

cleaner

element

installed:

ex-

cessive

piston

and/or

cylinder

wear

may

result.

Oillevel

measuremem

uanght

position.

Warm

several

T)nutes

NOTE:

___________

sure

the

motorcycle

positioned

straight

when

checking

the

oil

level:

slignt

tit

(ower

the

sive

can

produce

false

readings.

With

the

engine

stopped,

check

the

nil

evel

through

level

wincow

located

the

lower

ert

the

right

side

orankeas®

caver

Nore:

————_____

Wait

“ew

minutes

until

the

oil

ievel

settles

before

checking

Level

wedow

Misimam

srk

Oil

capacity

Afzer

angine

evertaul

1.6

(1.7

qd)

Aftor

ol!

filter

replace:

1.311

(1.4

Engine

Oil

and

Oil

Fitter

Replacement

;-CAUTION

After

replacement

engine

oil,

sure

check

the

oil

pressure

the

follow-

ing

procedure.

Remove

the

air

bleed

screw

from

oil

filter

cover,

and

loosen

the

check

bolt

the

cylindar

head.

Start

the

engine

and

keep

idle

running

til!

oi!

flows

out

the

bleed

hole.

and

the

check

bolt

(see

the

following

photo).

The

check

bolt

has

slit

for

checking

oil

Ifo

oil

comes

out

even

after

lapse

‘of

over

one

minute,

cut

the

engine

immediately

for

foar

seizure.

Rustart

the

eugine

after

solving

the

problem(s)

and

recheck

the

ail

pre

sure.

Oil

filtor

replacement

NOTE:

When

replacing

the

engine

cil

after

the

brook

peroc.

clear

the

oi!

strainer

the

bottom

the

engine

Star:

the

enginy.

Alle:

few

minutes

warm-up

stop

the

engine

Place

cll

pan

under

the

engine.

apg

©.

Romove

the

ail

fillyr

cap,

drain

pluy

and

air

bleed

screw

attached

the

oil

ilk

ter

cover,

and

crain

the

engine

oll.

NOTE:

———

oil

filter

cover

secured

three

ews.

The

lower

one

should

\oosened

until

the

Uhreaded

portion

comes

out

com-

oletely.

Bible!

CAUTION:

When

remaving

the

drnin

plug,

the

compression

spring,

strainer

and

O-

ring

will

fall

off.

Take

care

not

lose

these

parts.

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