![Yamaha XV250 (1994) [118/291] Engine disassembly](/img/pdf.png)
Yamaha XV250 (1994) [118/291] Engine disassembly
![Yamaha XV250 (1994) [118/291] Engine disassembly](/views2/1121374/page118/bg76.png)
Содержание
- Xv250 service manual 1
- Xv250g c supplementary service manual 2
- Foreword 3
- Notice 4
- Particularly important information 4
- How to use this manual 5
- Adj eng 6
- Gen info 6
- Illustrated symbols 6
- Ilnsplflkq 6
- Refer to the illustration 6
- Contents 7
- Table of contents 7
- Gen info 8
- General information 8
- Motorcycle identification 8
- General specifications 9
- Specifications 9
- General specifications 10
- Maintenance specification 10
- Maintenance specifications 10
- Maintenance specifications 11
- Maintenance specifications 12
- Maintenance specifications 13
- Maintenance specifications 14
- Maintenance specifications 15
- Cable routing 16
- Cable routing 17
- Cable routing 18
- Cable routing 19
- Adjustment 20
- Brake pad inspection 20
- Chassis 20
- Periodic inspection and 20
- Periodic inspection and adjustment 20
- A tire size 3 0 18 47p 21
- B wear limit 1 mm 0 4 in 21
- C rim size 18 x 1 0 21
- Chassis 21
- Front wheel 21
- J wheel axle collar dust seal oil seal bearing spacer hub spoke bearing speedometer gear unit tire 21
- Rim runout limit radial 2 mm 0 8 in lateral 2 mm 0 8 in 21
- Front brake 22
- Caution _____________________ 23
- Front brake 23
- Front brake 24
- Front brake 25
- Front brake 26
- Front brake 27
- Front brake 28
- Front brake 29
- Front brake 30
- Front fork 31
- Steering head 32
- Xv250 s g xv250gc wiring diagram 33
- Xv250u c service manual 35
- How to use this manual 37
- Notice 37
- Particularly impotant information 37
- Illustrated symbols refer to the illustration 38
- Illustrated symbols to are designed as thumb tabs to indicate the chapter s number and content 38
- Illustrated symbols to are used to identify the specifications appearing in the text 38
- Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point 38
- Chapter 1 40
- Chapter 2 40
- Contents 40
- General information 40
- Specifications 40
- Table of contents 40
- Chapter 3 41
- Periodic inspections and adjustments 41
- Chapter 4 42
- Engine overhaul 42
- Carburetor 43
- Chapter 5 43
- Chapter 6 44
- Chassis 44
- Chapter 7 electrical 45
- Chapter 8 45
- Troubleshooting 45
- Chapter 1 general information 47
- Gen info 47
- General information 47
- Motorcycle identification 47
- Gen ta info 48
- Important information 48
- Gen info 49
- Special tools 49
- Gen info 50
- Special tools 50
- Gen info 51
- Special tools 51
- Gen ta info 52
- Special tools 52
- Special tools 53
- Chapter 2 specifications 54
- General specifications 54
- Specifications 54
- General specifications 55
- General specifications 56
- Maintenance specifications 57
- Maintenance specifications 58
- Maintenance specifications 59
- Maintenance specifications 60
- Maintenance specifications 63
- Spec pÿ 63
- Maintenance specifications 64
- Maintenance specifications 65
- Maintenance specifications 66
- Maintenance specifications 67
- Maintenance specifications 68
- Definition of units 69
- General torque specifications 69
- Lubrication points and lubricant type 70
- Lubrication points and lubricant type 71
- Lubrication diagrams 72
- Cable routing 75
- Chapter 3 periodic inspection and adjustment 77
- Insp a adj e 77
- Introduction 77
- Introduction maintenance intervals charts 77
- Maintenance interval charts 77
- Maintenance intervals charts 77
- Periodic inspection and adjustment 77
- General maintenance lubrication 78
- Insp a adj 78
- Maintenance intervals charts 78
- O o o o o 78
- O o o o o o 78
- 000 km 3 800 mi 2 every 12 000 km 7 600 mi and 3 every 24 000 km 15 200 mi intervals 79
- 1 sae 10w30 type se motor oil 79
- 40 50 60 f 79
- 5 10 15 c 79
- Brake system 79
- Check the brake fluid level and add the fluid as required 79
- Engine oil 79
- Maintenance intervals charts 79
- Note ______________________________________________________________________________ for farther odometer reading repeat the above maintenance at the period established 1 every 79
- O o o o o 79
- O o o o o o 79
- Oil seals every two years 79
- We recommended that on the inner parts of the master cylinder and caliper cylinder replace the 79
- We recommended that replace the brake hoses every four years or it cracked or damaged 79
- When disassembling the master cylinder or caliper cylinder replace the brake fluid normally 79
- Yamalube 4 or sae 20w40 type se motor oil 79
- A adj em 80
- Fuel tank removal and installation 80
- Engine 81
- Insp adj 81
- Valve clearance adjustment 81
- Insp adj 82
- Valve clearance adjustment 82
- Cam chain adjustment 83
- Insp adj 83
- Idle speed adjustment 84
- Throttle cable free play adjustment 84
- Insp adj 85
- Spark plug inspection 85
- Ignition timing check 86
- Compression pressure measurement 87
- Insp adj 87
- Engine oil level inspection 88
- Insp adj 88
- Engine oil replacement 89
- Insp adj 89
- Engine oil filter replacement 90
- Insp adj 90
- Clutch adjustment air filter cleaning 91
- Insp adj 91
- Air filter cleaning 92
- Insp adj 92
- Carburetor joint inspection fuel line inspection 93
- Crankcase ventilation hose inspection 93
- Exhaust system inspection 93
- Insp adj 93
- Canister inspection xv250uc only 94
- Insp adj 94
- Chassis 95
- Front brake adjustment rear brake adjustment 95
- Insp adj 95
- Brake fluid level inspection 96
- Insp a adj 96
- Insp adj 97
- Insp adj 98
- Shift pedal adjustment 98
- Drive chain slack adjustment 99
- Drive chain slack check 99
- Insp adj 99
- Insp adj 100
- Steering head adjustment 100
- Insp adj 101
- Steering head adjustment 101
- Insp adj 102
- Steering head adjustment 102
- Adjust 103
- Bolt steering stem 103
- Bolts handlebar crown 103
- Bracket speedometer 103
- Handlebar holder lower 103
- Headlight body bracket 103
- Headlight flasher light bracket 103
- Insp adj 103
- Master cylinder bracket 103
- Measure 103
- Nm 0 m kg 5 ft lb 103
- Nm 0 m kg 6 ft lb 103
- Nm 2 m kg 14 ft lb 103
- Nm 2 m kg 14ft lb 103
- Nm 5 m kg 39 ft lb 103
- Tire inspection 103
- Tire pressure 103
- Insp adj 104
- Tire inspection 104
- Insp adj 105
- Spoke inspection and tightening cable inspection and lubrication 105
- Wheel inspection 105
- Brake and shift pedals brake and clutch levers lubrication sidestand lubrication 106
- Swingarm lubrication 106
- Battery inspection 107
- Electrical 107
- Insp adj 107
- Battery inspection 108
- Insp adj 108
- Fuse inspection headlight beam adjustment 109
- Headlight bulb replacement 109
- Insp adj 109
- Headlight bulb replacement 110
- Insp adj 110
- Chapter 4 engine overhaul 111
- Engine overhaul 111
- Engine removal 111
- Engine removal 112
- Engine removal 113
- Engine removal 114
- Engine disassembly 115
- Engine disassembly 116
- Engine disassembly 117
- Engine disassembly 118
- Engine disassembly 119
- Engine disassembly 120
- Engine disassembly 121
- Engine disassembly 122
- Engine disassembly 123
- Engine disassembly 124
- Engine disassembly 125
- Engine disassembly 126
- Inspection and repair 127
- Inspection and repair 128
- Inspection and repair 129
- Inspection and repair 130
- Inspection and repair 131
- Inspection and repair 132
- Inspection and repair 133
- Inspection and repair 134
- Inspection and repair 135
- Inspection and repair 136
- Inspection and repair 137
- Inspection and repair 138
- Inspection and repair 139
- Inspection and repair 140
- Inspection and repair 141
- Inspection and repair 142
- Inspection and repair 143
- Inspection and repair 144
- Inspection and repair 145
- Inspection and repair 146
- Inspection and repair 147
- Engine assembly and adjustment 148
- Engine assembly and adjustment 149
- Transmission 149
- Crankshaft 150
- Engine assembly and adjustment 150
- Engine assembly and adjustment 151
- Engine assembly and adjustment 152
- Engine assembly and adjustment 153
- Engine assembly and adjustment 154
- Shift shaft oil pump 154
- Engine assembly and adjustment 155
- Clutch 156
- Engine assembly and adjustment 156
- Engine assembly and adjustment 157
- Engine assembly and adjustment 158
- Engine assembly and adjustment 159
- Cylinder and cylinder head 160
- Engine assembly and adjustment 160
- Engine assembly and adjustment 161
- Valve camshaft and timing chain 161
- Engine assembly and adjustment 162
- Engine assembly and adjustment 163
- Engine assembly and adjustment 164
- Engine assembly and adjustment 165
- Engine assembly and adjustment 166
- Engine assembly and adjustment 167
- Engine assembly and adjustment 168
- Engine assembly and adjustment 169
- Engine assembly and adjustment 170
- Engine assembly and adjustment 171
- Engine assembly and adjustment 172
- Carburetion 173
- Carburetor 173
- Chapter 5 carburetion 173
- Carburetor 174
- Section view 174
- Carburetor 175
- Carburetor 176
- Carburetor 177
- Carburetor 178
- Carburetor 179
- Fuel pum 180
- Fuel pump 180
- Fuel pump carb 181
- Chapter 6 chassis 183
- Chassis 183
- Front wheel 183
- Front wheel 184
- Front whee 185
- Front whee 186
- Front wheel 187
- Front wheel 188
- Rear wheel 189
- Rear wheel 190
- Rear whee 191
- Rear whee 192
- Front brake 193
- Front brak 194
- Front brak 195
- Front brake 196
- Master cylinder 196
- Front brake 197
- Front brake 198
- Front brake 199
- Front brak 200
- Front fork 201
- Chas q 202
- Front fork 202
- Front fork 203
- Front for 204
- Front fork 205
- Front fork 206
- Front fork 207
- Steering hea 208
- Steering head 208
- Steering head 209
- Steering hea 210
- Steering head 211
- Steering head 212
- Chas 3 213
- Steering hea 213
- Rear shock absorber and swingar 214
- Rear shock absorber and swingarm 214
- Rear shock absorber and swingarm 215
- Rear shock absorber and swingarm 216
- Rear shock absorber and swingarm 217
- Drive chain and sprockets 218
- Drive chain and sprockets 219
- Drive chain and sprockets 220
- Drive chain and sprockets 221
- Chapter 7 electrical 222
- Elec h 222
- Electrical 222
- Xv250u uc circuit diagram 222
- Circuit diagram 223
- Color code 223
- Elec в 224
- Electrical components 224
- Electrical components 1 224
- Electrical components 225
- Electrical components 2 225
- Ignition system 226
- Aforementioned circuit diagram shows ignition circuit in circuit diagram 227
- Ignition system 227
- Note for the color codes see page 7 2 227
- Ignition system 228
- Ignition system 229
- Elec s 230
- Ignition system 230
- Ignition system 231
- Ignition system 232
- Ignition system 233
- Ignition system 234
- Ignition system 235
- Elec к 238
- Electric starting system 238
- Aforementioned circuit diagram shows electrical starting circuit in wiring diagram 239
- Electric starting system 239
- Note _____________________________________________________________________________ for the color codes see page 7 2 239
- Electric starting system 240
- Electric starting system 241
- Electric starting system 242
- Electric starting system 243
- Electric starting system 244
- Electric starting system 245
- Electric starting system 247
- Starter motor test 247
- Electric starting system 248
- Elec s 249
- Electric starting system 249
- 4 1 i i j 1 250
- Charging system 250
- Circuit diagram 250
- Elec is 250
- Ooo 0 0 250
- Aforementioned circuit diagram shows charging circuit in circuit diagram 251
- Charging system 251
- Elec s 251
- Note ______________________________________________________________________________ for the color codes see page 7 2 251
- Charging system 252
- Charging system 253
- Elec a 254
- Lighting system 254
- Aforementioned circuit diagram shows lighting circuit in circuit diagram 255
- Elec h 255
- Lighting system 255
- Note ________________________________________________________________ ____ ________ for the color codes see page 7 2 255
- Lighting system 256
- Elec h 257
- Lighting system 257
- Elec h 258
- Elec h 259
- Lighting system 259
- Elec h 260
- Lighting system 260
- Lighting system 261
- Lighting system 262
- Signal system 264
- Aforementioned circuit diagram shows signal circuit in circuit diagram 265
- Note _____________________________________________________________________________ for the color codes see page 7 2 265
- Signal system 265
- Elec s 267
- O x x o 267
- Signal system 267
- X o x o 267
- Signal system 268
- Signal system 269
- Signal system 270
- Signal system 271
- Signal system 272
- Signal system 273
- Elec is 274
- Signal system 276
- Elec h 277
- Signal system 278
- Chapter 8 troubleshooting 280
- Starting failure hard starting 280
- Trbl shtg 280
- Troubleshooting 280
- Starting failure hard starting 281
- Trbl o 281
- Poor idle speed performance 282
- Poor medium and high speed performance 282
- Trbl o shtg 282
- Faulty gear shifting 283
- Trbl o shtg 283
- Clutch slipping dragging 284
- Overheating 284
- Trbl shtg 284
- And front fork malfunction 285
- Faulty brake 285
- Faulty brake front fork oil leakage 285
- Front fork oil leakage and front fork malfunction 285
- Trbl o 285
- Instable handling 286
- Trbl shtg 286
- Unstable handling 286
- Faulty signal and lighting system 287
- Trbl o shtg 287
- Overheating 288
- Trbl shtg 288
- Color code 289
- Xv250u xv250uc wiring diagram 289
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ENGINE DISASSEMBLY ENG TDC alignment steps Rear cylinder Turn the crankshaft counter clockwise with wrench Align the cam sprocket punch mark with the stationary pointer on the rear cylinder head When the slit is aligned with the stationary pointer the piston is at Top Dead Center TDC NOTE ________________________________ TDC on compression stroke check Both rocker arms must have a valve celarance when the slit on the rotor is aligned with the center line of the rear cylinder If not give the crankshaft one clockwise turn too meet above condition CRANKCASE COVER RIGHT 1 Remove Oil filter cover Oil filter 2 O ring Filter cover 2 Remove Crankcase cover Right Gasket Dowel pins NOTE ______________________________ _ Working in a crisscross pattern loosen screw 1 4 turn each Remove them after all are loosened Be sure not to give damages to the mating surface 4 8
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