Yamaha XG250 - Service Manual - Taller - Reparation - Reparaturanleitung - Officina

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YAMAHA XG250 - SERVICE MANUAL


- English, French, German, Italian and Spanish Service Manual, in PDF format, to motorcycles Yamaha XG250


CONTENTS:



GENERAL INFORMATION
- IDENTIFICATION
Vehicle identification number
Model label
Engine serial number
- IMPORTANT INFORMATION
Preparation for disassembly and disassembly
Spare parts
Gaskets, oil seals and O-rings
Lock washers/lock plates and
split pins
Bearings and oil seals
elastic rings
- CHECKING THE CONNECTIONS
SPECIAL TOOLS

SPECIFICATIONS
- GENERAL SPECIFICATIONS
- ENGINE SPECIFICATIONS
- CHASSIS SPECIFICATIONS
- ELECTRICAL SYSTEM SPECIFICATIONS
- TIGHTENING TORQUES
General tightening torque specifications
Engine tightening torques
Chassis tightening torques
- GREASE POINTS AND TYPES OF LUBRICANT
Engine
Chassis
- TABLE AND DIAGRAMS OF THE GREASE SYSTEM
Engine lubrication chart
Greasing diagrams
- CABLE ARRANGEMENT

PERIODIC CHECKS AND ADJUSTMENTS
- PERIODIC MAINTENANCE
Introduction
Chart for periodic lubrication and maintenance
- ENGINE
Valve clearance adjustment
Checking the exhaust gas
Checking the exhaust gas
Engine idle adjustment
Throttle cable slack adjustment


Checking the spark plug
Compression pressure measurement
Checking the engine oil level
Engine oil change
Clutch cable slack adjustment
Replacing the air filter element
Checking the carburetor gasket and
Intake manifold
Checking the fuel line
Checking the cylinder head breather tube
Checking the exhaust system
- CHASSIS
Front disc brake adjustment
Rear disc brake adjustment
Checking the brake fluid level
Checking the front brake pads
Checking the rear brake pads
Checking the front brake pipe
Checking the rear brake pipe
Rear brake light switch adjustment
Bleeding the hydraulic brake system
Drive chain slack adjustment
Drive chain lubrication
Checking and adjusting the column
Address
Checking the front fork
Checking the tires
Checking the wheels
Checking and adjusting the spokes
Checking and lubricating the cables
Lubricating the levers
Pedal lubrication
Side stand lubrication
Rear suspension lubrication
- ELECTRIC SYSTEM
Checking and charging the battery
Checking the fuses
Changing the headlight bulb
Headlight beam adjustment

CHASSIS
- CHASSIS, GENERAL
- FRONT WHEEL
Front wheel removal
Checking the front wheel

Front wheel removal
Checking the gear unit
Speedometer
Front wheel assembly
Static front wheel balancing
Installing the front wheel (disc)
- REAR WHEEL
Disassembling the rear wheel (disc)
Checking the rear wheel
Rear wheel removal
Checking and replacing the wheel sprocket
Rear
Rear wheel assembly
Static rear wheel balancing
Installing the rear wheel (disc)
- FRONT BRAKE
Introduction
Checking the front brake disc
Changing the front brake pads
Disassembly of the front brake caliper
Disassembling the front brake caliper
Checking the front brake calipers
Front brake caliper assembly
Installing the front brake caliper
Disassembly of the front brake master cylinder
Checking the front brake master cylinder
Assembling the front brake master cylinder
Installing the front brake master cylinder
- BACK BRAKE
Introduction
Checking the rear brake disc
Changing the rear brake pads
Disassembling the rear brake caliper
Rear brake caliper disassembly
Checking the rear brake caliper
Rear brake caliper assembly
Installing the rear brake caliper
Disassembly of the rear brake master cylinder
Checking the rear brake master cylinder
Rear brake pump assembly
Installing the rear brake master cylinder
- HANDLEBAR
Handlebar removal
Checking the handlebar
Handlebar installation
- FRONT FORK
Disassembly of the front fork bars
Disassembly of the front fork bars
Checking the fork legs
Lead
Assembling the front fork bars
Installing the front fork legs
- STEERING COLUMN
Bottom Bracket Disassembly
Checking the steering column
Steering column installation
- REAR SHOCK ABSORBER ASSEMBLY
Rear shock absorber manipulation
Dispose of a rear shock absorber
Disassembly of the rear shock absorber assembly
Checking the shock absorber assembly
Rear
Installing the rear shock absorber assembly
- SWING
Swingarm disassembly
Checking the swingarm
Swingarm assembly
- CHAIN ​​TRANSMISSION
Drive chain removal
Checking the drive chain
Checking the motor sprocket
Checking rear wheel sprocket
Drive chain assembly

ENGINE
- ENGINE DISASSEMBLY
Engine installation
- HEAD
Cylinder head disassembly
Checking the cylinder head
Checking the chain guides
Distribution
Checking the chain tensioners
Distribution
Cylinder head assembly
- ROCKER AND CAMSHAFT
Removal of rocker arms and camshaft
Checking the camshaft
Checking the rocker arms and shafts
Rockers
Installing the camshaft and rocker arms
- VALVES AND VALVE SPRINGS
Valve disassembly
Checking valves and valve guides
Checking valve seats
Checking the valve springs
Valve assembly
- CYLINDER AND PISTON
Piston disassembly
Checking the cylinder and piston
Checking the piston rings
Checking the piston pin
Piston and cylinder assembly
- CLUTCH
Clutch disassembly
Checking the friction plates
Checking the clutch discs
Checking the clutch springs
Checking the clutch box
Checking the clutch shoulder
Checking the pressure plate
Checking the push rods
Clutch
Checking the drive gear
Primary
Clutch assembly
- OIL PUMP AND COMPENSATOR GEAR
Removing the compensator gear and the
Oil pump
Checking the oil pump
Checking the compensator gear
Drive Gear Assembly
Compensator
Oil pump assembly
Balancer Gear Installation
- CHANGE AXIS
Checking the gear shaft
Checking the stop lever
Shift shaft assembly
- ELECTRICAL START
Checking the starter motor
Assembling the starter motor
- PICKUP COIL ROTOR AND ENGINE CLUTCH
- BOOT
Removing the pickup coil rotor
Checking the starter clutch
Pickup coil rotor installation
- CRANKCASE
Crankcase disassembly
Checking the crankcase
Crankcase assembly
- CRANKSHAFT ASSEMBLY
Disassembly of the crankshaft assembly
Removing the piston seal
Checking the crankshaft and connecting rod
Checking the timing chain,
Camshaft and chain guide sprocket
Distribution
Installing the plunger seal
Crankshaft assembly assembly
- GEARBOX
Disassembly of the gearbox
Checking the shift forks
Checking the shift drum assembly
Checking the gearbox
Assembling the forks and drum assembly
Exchange

FUEL SYSTEM
- FUEL TANK
Checking the fuel cock
- CARBURETOR
Checking the carburetor
carburetor assembly
Carburetor assembly
- AIR INDUCTION SYSTEM
Checking the air induction system

ELECTRIC SYSTEM
- IGNITION SYSTEM
Electric diagram
Troubleshooting
- ELECTRICAL STARTING SYSTEM
Electric diagram
Circuit cutting system operation
Boot
Troubleshooting
- CHARGING SYSTEM
Electric diagram
Troubleshooting
- LIGHTING SYSTEM
Electric diagram
Troubleshooting
- SIGNALING SYSTEM
Electric diagram
Troubleshooting
- CARBURETOR HEATER SYSTEM
Electric diagram
Troubleshooting
- ELECTRIC COMPONENTS
Checking the switches
Checking bulbs and sockets
Checking the fuse
Checking and charging the battery
Checking the relays
Checking the turn signal relay
Diode check
Checking the spark plug cover
Checking the ignition coil
Checking the pickup coil
Checking the stator coil
Checking the rectifier/regulator
Checking the horn
Checking the thermostat switch
Checking the carburetor heater

TROUBLESHOOTING
- TROUBLESHOOTING
General information
Startup failures
Incorrect engine idle
Low performance at medium and high regimes
Faulty gear shift
The shift pedal does not move
The marches jump
Broken clutch
Overheating
Poor brake performance
Damaged front fork bars
Unstable driving
Faulty lighting or signaling system


ELECTRICAL DIAGRAM OF THE XG250