![Yamaha XV250 (1994) [162/291] Engine assembly and adjustment](/img/pdf.png)
Yamaha XV250 (1994) [162/291] Engine assembly and adjustment
![Yamaha XV250 (1994) [162/291] Engine assembly and adjustment](/views2/1121374/page162/bga2.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 ASSEMBLY AND ADJUSTMENT ENG 2 Apply 4 stroke engine oil To the piston pin bearing piston ring grooves and piston skirt areas 3 Install Gasket New Dowel pins O rings 4 Offset the piston ring end gaps as shown NOTE ______________________________ Be sure to check the manufacturer s marks or numbers stamped on the rings are on the top side of the rings Before installing the cylinder apply a liberal coating of 4 stroke engine oil to the piston rings Top ring Oil ring Lower rail 2nd ring Oil ring Upper rail 5 Install Cylinder NOTE __________________________________ Install the cylinder with one hand while com pressing the piston rings with the other hand Tie the cam chain with a piece of mechanics wire and feed it through the chain opening 4 52
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