Yamaha XG250 Manual de usuario

SERVICE MANUAL

XG250

4D6-28197-E0

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to

performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-

cle will operate as designed. If there is any question about a service procedure, it is imperative that you

contact a Yamaha dealer for any service information changes that apply to this model. This policy is

intended to provide the customer with the most satisfaction from his vehicle and to conform to federal

environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersand

will appear in future editions of this manual where applicable.

NOTE:

●

This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

●

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT!YOUR SAFETY

IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage to

the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

●

The manual is divided into chapters and each chapter is divided into sections. The current section

title is shown at the top of each page “1”.

●

Sub-section titles appear in smaller print than the section title “2”.

●

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section “3”.

●

Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-

bly step “4”.

●

Symbols indicate parts to be lubricated or replaced “5”.

Refer to “SYMBOLS”.

●

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc “6”.

●

Jobsrequiringmore information (such as special tools and technical data) are described sequentially

“7”.

CLUTCH

5-29

Removing the clutch

Order Job/Parts to remove Q ty Remarks

1 Clutch spring 5

2 Pressure plate 1

3Primary drive gear nut 1

4Friction plate 6

5 Clutch plate 5

6 Cushion spring 1

7 Seat plate 1

8 Clutch boss nut 1

9 Clutch boss 1

10 Thrust washer 1

11 Clutch housing 1

12 Claw washer 1

13 Primary driven gear 1

14 Locknut/Washer 1/1

15 Push rod1 1

16 Push plate 1

17 Push rod 2/Ball 1/1

678

12 13

16 15

CLUTCH

5-32

2. Straighten the lock washer tab.

3. Loosen:

Primary drive gear nut

Clutch boss nut

NOTE:

Place the aluminum plate a between clutch

housing 1 and primary drive gear 2 , and

then loosen the primary drive gear nut 3 .

While holding the clutch boss 4 with the uni-

versal clutch holder, loosen the clutch boss

nut 5 .

4. Remove:

Clutch boss nut 1

Lock washer 2

Clutch boss 3

Thrust washer 4

Clutch housing 5

5. Remove:

Primary drive gear nut 1

Lock washer 2

Claw washer 3

Primary drive gear 4

EAS25100

CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-

tion plates.

1. Check:

Friction plate

Damage/wear Replace the friction plates

as a set.

2. Measure:

Friction plate thickness

Out of specification Replace the friction

plates as a set.

NOTE:

Measure the friction plate at four places.

Universal clutch holder

90890-04086

YM-91042

Friction plate thickness

2.90—3.10 mm (0.11—0.12 in)

Wear limit

2.80 mm (0.1102 in)

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

BLS M

91011

12 13 14

15 16

LT New

123

456

1. Serviceable with engine mounted

2. Filling ﬂuid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum-disulﬁde oil

12. Wheel-bearing grease

13. Lithium-soap-based grease

14. Molybdenum-disulﬁde grease

15. Apply locking agent (LOCTITE®)

16. Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

IDENTIFICATION ........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER...................................................1-1

MODEL LABEL .......................................................................................1-1

ENGINE SERIAL NUMBER....................................................................1-1

IMPORTANT INFORMATION .....................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................1-2

REPLACEMENT PARTS ........................................................................1-2

GASKETS, OIL SEALS AND O-RINGS..................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS...................................1-2

BEARINGS AND OIL SEALS..................................................................1-2

CIRCLIPS................................................................................................1-3

CHECKING THE CONNECTIONS..............................................................1-4

SPECIAL TOOLS........................................................................................1-5

IDENTIFICATION

1-1

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

MODEL LABEL

The model label “1” is affixed to the frame. This

information will be needed to order spare parts.

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the

elevated part of the right rear section of the en-

gine.

IMPORTANT INFORMATION

1-2

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS” on page 1-5.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have been

“mated” through normal wear. Mated parts

must always be reused or replaced as an as-

sembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and al-

low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands

may be similar in function and appearance, but

inferior in quality.

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

“1” and cotter pins. After the bolt or nut has been

tightened to specification, bend the lock tabs

along a flat of the bolt or nut.

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. When

installing oil seals “1”, lubricate the oil seal lips

with a light coat of lithium-soap-based grease.

Oil bearings liberally when installing, if appropri-

ate.

IMPORTANT INFORMATION

1-3

CAUTION:

Do not spin the bearing with compressed air

because this will damage the bearing surfac-

es.

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use.

When installing a circlip “1”, make sure the

sharp-edged corner “2” is positioned opposite

the thrust “3” that the circlip receives.

CHECKING THE CONNECTIONS

1-4

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for

stains, rust, moisture, etc.

1. Disconnect:

●

Lead

●

Coupler

●

Connector

2. Check:

●

Lead

●

Coupler

●

Connector

Moisture

→

Dry with an air blower.

Rust/stains

→

Connect and disconnect sev-

eral times.

3. Check:

●

All connections

Loose connection

→

Connect properly.

NOTE:

If the pin “1” on the terminal is flattened, bend it

up.

4. Connect:

●

Lead

●

Coupler

●

Connector

NOTE:

Make sure all connections are tight.

5. Check:

●

Continuity

(with the pocket tester)

NOTE:

●

If there is no continuity, clean the terminals.

●

When checking the wire harness, perform

steps (1) to (3).

●

As a quick remedy, use a contact revitalizer

available at most part stores.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

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