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Yamaha XG250 Service Manual

Yamaha XG250
278 pages
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SERVICE MANUAL
XG250
4D6-28197-E0

Table of Contents

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Yamaha XG250 Specifications

General IconGeneral
BrandYamaha
ModelXG250
CategoryMotorcycle
LanguageEnglish

Summary

Introduction and Important Information

Manual Usage and Safety Notices

Provides notices and guidance on using the manual safely and effectively.

How to Use This Manual

Service Manual Symbols

General Information

Identification

Details vehicle, engine serial numbers, and model labels.

Important Information

Covers essential guidelines for removal, disassembly, parts, and seals.

Checking Connections

Procedure for inspecting leads, couplers, and connectors for proper function.

Special Tools

Lists necessary special tools for accurate tune-up and assembly.

Specifications

General, Engine, Chassis, Electrical Specs

Key specs for vehicle, engine, chassis, and electrical systems.

Tightening Torques and Lubrication

Specifies fastener torques and identifies lubrication points and types.

Lubrication Diagrams and Cable Routing

Illustrates lubrication flow and details cable routing procedures.

Periodic Checks and Adjustments

Periodic Maintenance Procedures

Recommended checks and adjustments for reliable vehicle operation.

Engine System Maintenance

Periodic maintenance for engine components.

Chassis System Maintenance

Periodic maintenance for chassis components.

Electrical System Maintenance

Periodic checks for battery, fuses, and lighting system.

Chassis Components and Systems

Front and Rear Wheel Service

Procedures for removing, checking, and installing front and rear wheels.

Brake System Service

Details front and rear brake inspection, pad replacement, and system service.

Handlebar, Front Fork, and Steering Head

Instructions for handlebar installation, front fork disassembly, and steering head maintenance.

Rear Suspension and Drive Chain

Covers rear shock absorber, swingarm, and chain drive maintenance.

Engine Mechanical Systems

Engine Removal, Cylinder Head, and Valve Train

Service for engine removal, cylinder head, rocker arms, camshaft, valves, and springs.

Piston, Cylinder, Clutch, and Oil Systems

Procedures for piston, cylinder, clutch, oil pump, and balancer gear service.

Shaft, Starter, Crankcase, and Transmission

Service for shift shaft, starter motor, pickup coil, crankcase, crankshaft, and transmission.

Fuel System

Fuel Tank and Fuel Cock Service

Covers removing and checking the fuel tank and fuel cock.

Carburetor System Service

Procedures for carburetor removal, disassembly, checking, and installation.

Air Induction System Check

Instructions for checking the air induction system components.

Electrical System

Ignition and Starting Systems

Details circuit diagram and troubleshooting for ignition and electric starting.

Charging and Lighting Systems

Provides circuit diagrams and troubleshooting for charging and lighting systems.

Signaling, Carburetor Heater, and Components

Covers signaling, carburetor heater, and checks for electrical components.

Troubleshooting Guide

General Info and Starting Failures

Basic troubleshooting guide and diagnosis for starting failures.

Engine and Fuel System Problems

Troubleshooting for incorrect idling, poor performance, and fuel system issues.

Chassis, Handling, and Braking Issues

Diagnoses problems with chassis, handling, brakes, and front fork.

Lighting, Signaling, and Horn Faults

Troubleshooting for failures in lighting, signaling, and horn operation.

XG250 2005 Wiring Diagram

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