Yamaha SR250G User manual

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YAMAHA
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SR250G
Service Manual

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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.