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Table Of Contents - Yamaha TZR250 1987 Service Manual

Table Of Contents

Table of Contents

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Table of Contents

How To Use This Manual3

Particularly Important Information3

Illustrated Symbols4

Motorcycle-Identification13

General Information13

Frame Serial Number13

Engine Serial Number13

Preparation For Removal And Disassembly14

All Replacement Parts15

Lock Washers/Plates And Cotter Pins15

Bearings And Oil Seals15

Special Tools16

For Engine Service17

For Chassis Service18

For Electrical Components18

Specifications20

Maintenance Specifications22

General Torque Specifications/Definition Of Units34

Lubrication Points And Lubricant Type35

Lubrication Diagram37

Coolant Flow Chart38

Cable Routing39

Periodic Maintenance/Lubrication Intervals43

Periodic Inspection And Adjustment43

Cowlings Removal45

Cowlings Installation46

Side Covers Removal47

Engine Y.p.v.s. Cable Adjustment48

Adjustment Steps49

Carburetor Synchronization50

Checking Steps51

Idle Speed Adjustment53

Throttle Cable Free Play Adjustment54

Autolube Pump Cable Adjustment55

Coolant Level Inspection58

Coolant Replacement59

Cooling System Inspection63

Front Brake Adjustment65

Rear Brake Adjustment65

Brake Fluid Inspection66

Brake Pad Inspection/Brake Light Switch Adjustment67

Drive Chain Slack Adjustment68

Drive Chain Lubrication/Steering Head Adjustment70

Steering Head Adjustment71

Front Fork Oil Replacement73

Front Fork Oil Replacement/Front Fork Adjustment75

Rear Shock Absorber Adjustment76

Recommended Combinations Of Front Fork And Rear Shock Absorber Settings77

Tire Inspection78

Wheel Inspection79

Cable Inspection And Lubrication/Lever And Pedal Lubrication/Sidestand Lubrication/Swingarm And Relay Arm Lubrication80

Battery Inspection81

Battery Inspection/Fuse Inspection83

Headlight Beam Adjustment/Headlight Bulb Replacement85

Engine Overhaul87

Engine Removal87

Transmission Oil87

Muffler Assembly88

Autolube Pump Cable And Hose89

Y.p.v.s. Cables91

Engine Disassembly94

Cylinder Head, Cylinders And Pistons94

Cluth And Primary Drive Gear96

C.d.i. Magneto100

Crankcase (Upper)101

Transmission, Shifter And Crankshaft102

Power Valves103

Oil Pump And Strainer104

Inspection And Repair105

Cylinder Head105

Cylinder And Piston106

Piston Rings108

Piston Pin And Bearing109

Primary Drive112

Transmission And Shifter112

Kick Starter114

Autolube Pump115

Oil Pipe And Strainer117

Engine Assembly And Adjustment118

Oil Pump Clearance119

Crankshaft, Piston And Piston Ring125

Transmission127

Bolt Tightening Steps128

Change Lever Position Adjustment Steps132

Shift Shaft And Change Pedal133

Kick Axle And Kick Idle Gear135

Clutch And Primary Drive Gear136

Cylinder Head, Cylinder And Pistons140

Cylinder And Cylinder Head143

Remounting Engine144

Cooling System149

Installation153

Thermostatic Valve And Radiator155

Section View163

Measurement And Adjustment Steps170

Fuel Level Adjustment172

Wheel Bearing Replacement Steps179

Front And Rear Brake186

Front And Read Brake188

Brake Pad Replacement188

Caliper Disassembly192

Caliper Piston Removal Steps193

Master Cylinder Disassembly194

Air Bleeding204

Removal Steps209

Steering Head And Handlebars215

Bearing Race Replacement Steps219

Left-Hand Handlebar Replacement Steps220

Ring Nut Tightening Steps221

Rear Shock Absorber And Swingarm225

Handling Notes226

Notes On Disposal226

Rear Shock Absorber227

Drive Chain And Sprockets234

Driven Sprocket Replacement Steps236

Meter Assembly239

Tzr Circuit Diagram243

Electrical Components245

Ignition And Starting System247

Circuit Diagram247

Ignition Control Circuit Operation249

Troubleshooting250

If Ignition System Should Become Inoperative (No Spark Or Intermittent Spark)250

Charging System260

The Battery Is Not Charged262

Lighting System265

Headlight, Taillight Or Auxiliary Light Do Not Come On267

Lighting System Tests And Checks271

Signal System274

Flasher Light, Brake Light Or Horn Do Not Operate276

Signal System Tests And Checks280

Reed Switch Test283

Display System284

Indicator Lights And Meter Lights Do Not Come On286

Display System Tests And Checks289

Oil Level Gauge Operation Check292

When Engine Is Hot, Temperature Gauge Does Not Move295

Thermo Unit Resistance Measurement Steps298

Yamaha Power Valve System299

When Main Switch Is Turned To "On", Servomotor Does Not Operate One Cycle301

Tzr250 Wiring Diagram305

Starting Failure/Hard Starting306

Starting Failure/Hard Starting/Poor Idle Speed Performance308

Poor Medium And High Speed Performance309

Faulty Gear Shifting311

Clutch Slipping/Dragging312

Improper Kicking313

Faulty Brake/Front Fork Oil Leakage And Front Fork Malfunction314

Instable Handling315

Faulty Signal And Lighting System316

Faulty Signal And Lighting System/Faulty Y.p.v.s.317

Overheating Or Over-Cooling318

Handling Of Asbestos Parts319

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