1980-1982 Yamaha SR250G Exciter Motorcycle Service Manual

Description

This 138 page, 1980 1981 1982 Yamaha SR250 Exciter Service Manual is a reproduction of the original out of print manual. If you are looking for a collectible original this is NOT it, however this book does provide detailed service information, step-by-step repair instruction and maintenance specifications for 1980-1982 Yamaha SR250 Exciter motorcycles.

Table of Contents

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EXTERNAL VIEW
SPECIAL TOOLS

PERIODIC INSPECTIONS AND ADJUSTMENTS
MAINTENANCE AND LUBRICATION CHART
Introduction
Maintenance Interval Charts
Periodic Maintenance Emission Control System
General Maintenance/Lubrication
ENGINE
Carburetor
Air Filter
Engine Oil
Engine Oil and Oil Filter Replacement
Clutch Adjustment
Free Play Adjustment
Cam Chain Adjustment
Valve Clearance Adjustment
CHASSIS
Fuel Petcock
Front Brake and Wheel
Front Brake Adjustment
Spoke Adjustment and Torque
Front Axle
Tire Pressure
Rear Brake and Wheel
Rear Brake Adjustment
Brake Lining Inspection
Spoke Adjustment and Tension
Rear Axle
Tire Pressure
Drive Chain Tension Check
Drive Chain Tension Adjustment
Drive Chain Lubrication
Front Fork Oil Change
Suspension Steering and Swing Arm
Rear Shock Absorber
Cable Inspection and Lubrication
Throttle Cables and Grip Lubrication
Lubrication of Levers Pedals, etc
ELECTRICAL
Ignition Timing
Spark Plug

ENGINE OVERHAUL
REMOVAL
Preparation for Removal
Fuel Tank
Muffler Footrest and Brake Pedal
Wiring and Cables
Carburetor
Drive Chain
Engine Mounting Bolts
DISASSEMBLY
Cylinder Head and Cylinder
Piston Pin and Piston
Crankcase Cover (Right) and Starter Motor
Clutch Assembly and Drive Gear
Clutch Push Lever Axle
Balancer Gear
Oil Pump Assembly
Change Shaft Assembly
Crankcase
Transmission
Crankshaft
INSPECTION AND REPAIRING
Cylinder Head
Valves Valve Springs Valve Guides and Valve Seats
Camshaft and Camshaft Bearing
Cylinder
Piston and Piston Rings
Piston Pin
Crankshaft
Oil Pump
Primary Drive
Clutch
Transmission
Bearings and Oil Seals
Crankcase
ENGINE ASSEMBLING AND ADJUSTMENT
Crankshaft Installation
Shifter
Oil Pump
Balancer Drive Gear and Driven Gear
Push Lever Assembly
Clutch
Clutch Adjustment
Crankcase Cover Right
Piston
Cylinder
Cylinder Head
Cam Shaft, Cam Shaft Driven Sprocket and Cam Chain
Drain Plug
MOUNTING

CARBURETION
AIR FILTER
CARBURETOR
Component
Disassembly
Fuel Level
Function

CHASSIS
FRONT WHEEL
From Axle
Checking Brake Shoe Wear
Brake Drum
Brake Shoe Plate
Replacing Wheel Bearings
Front Wheel Installation
REAR WHEEL
Removing the Rear Wheel
Checking Brake Shoe Wear
Brake Drum
Replacing Wheel Bearings
Installing Rear Wheel
RIMS AND SPOKES (FRONT AND REAR WHEEL)
Checking for Loose Spokes
Checking Rim “Run-Out”
TIRES AND TUBES
Removal
Installation
DRIVE CHAIN AND SPROCKETS
Drive Sprocket
Driven Sprocket
Chain Inspection
Chain Maintenance
FRONT FORKS
Disassembly
Inspection
STEERING HEAD
Installation
SWING ARM
Inspection
Lubrication
Removal
REAR SHOCK ABSORBERS
Removal
Inspection
CABLES AND FITTINGS
Cable Maintenance
Throttle Maintenance
Lubrication of Levers Pedals, etc

ELECTRICAL
IGNITION SYSTEM
Block Diagram
Description
Operation
Ignition Timing
Pick-up Coil Resistance Test
Replacing Procedure of Pickup Coil
Spark Gap Test
Ignition Coil Test
Troubleshooting
SPARK PLUG
CHARGING SYSTEM
Block Diagram
AC Magneto Generator Output Test
AC Voltage Regulator with Rectifier
LIGHTING SYSTEM
Lighting Circuit
Battery
Lighting Tests and Checks
Flasher Relay and Horn
Switches
TARTING SYSTEM
Description
Function of the Diode in the Relay
Operation
Starter Motor Removal
Starter Motor Inspection
Starter Motor Installation
Starter Relay Switch Inspection

APPENDICES
SPECIFICATIONS
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Torque Specifications
General Torque Specifications
Conversion Tables
LUBRICATION CHART
WIRING DIAGRAM
CABLE ROUTING

his manual includes the base manual for 1980 Yamaha SR250 Exciter motorcycles as well as the supplement manuals for 1981 and 1982