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Yamaha SRV250G 1992-1996 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: SRV250G Sub Model: Virago (variant for specific markets, though SRV250 is its own model) Codes Chassis Code: 4DN Engine Code: 4DN 👋 Introduction...
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Type: Motorcycle
Vendor:
Sku: 75905
Yamaha SRV250G 1992-1996 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
SRV250G
Sub Model:
Virago (variant for specific markets, though SRV250 is its own model)
Codes
Chassis Code:
4DN
Engine Code:
4DN
👋 Introduction
Market Position
Segment:
Lightweight/Mid-size Cruiser/Standard Motorcycle.
Target Demographic:
Riders seeking a stylish, comfortable, and manageable motorcycle for urban commuting and casual cruising. Often appealing to those new to motorcycling or preferring a less aggressive riding posture.
Competitive Analysis
Key Competitors:
Honda Shadow series, Kawasaki Vulcan series, Suzuki Intruder series, other Japanese and some European lightweight cruisers of the era.
Key Features
Engine Layout:
V-twin engine configuration, offering characteristic torque and styling.
Design Philosophy:
Combines classic cruiser styling with Yamaha's engineering prowess, often featuring comfortable ergonomics and a focus on reliability.
Handling Characteristics:
Typically a balanced and accessible handling profile, suitable for diverse riding conditions.
📋 Manual Details
Coverage Areas
Applicable Years:
1992, 1993, 1994, 1995, 1996
Page Count
Total Pages:
295
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English (presumed, based on typical market availability of such manuals)
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, top-end (cylinder head, valves, camshafts), bottom-end (crankshaft, connecting rods, pistons), timing system, lubrication system.
Fuel System:
Carburetor (Mikuni VM series likely) disassembly, cleaning, adjustment, fuel pump, fuel tank, fuel lines.
Ignition System:
CDI unit, ignition coils, spark plugs, wiring diagrams.
Transmission:
Gearbox disassembly, inspection, repair, clutch operation, shift mechanism.
Drivetrain:
Rear drive system (likely chain drive), sprocket replacement, chain adjustment and maintenance.
Cooling System:
Air cooling system inspection and maintenance, cooling fins.
Exhaust System:
Exhaust pipes, mufflers, mounting hardware, potential for emissions-related components.
Brakes:
Front and rear brake systems (likely drum or disc depending on market), caliper/drum inspection, pad/shoe replacement, fluid flush, master cylinder overhaul.
Suspension:
Front fork (telescopic) overhaul, oil change, seal replacement; rear shock absorber inspection and replacement.
Steering:
Handlebar assembly, steering stem bearings, lubrication, adjustment.
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), lighting (headlight, taillight, turn signals), starter motor, horn, instrument cluster.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank mounting, fenders.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake adjustments, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension servicing, brake system repairs.
Component Disassembly Reassembly:
Detailed step-by-step instructions for removing, overhauling, and reinstalling various motorcycle components.
Specifications And Tolerances:
Torque values, clearances, fluid capacities, wear limits for critical engine and chassis parts.
Technical Depth
Depth:
Comprehensive. Covers everything from routine maintenance to complete engine and gearbox rebuilds.
Target Audience:
Professional motorcycle technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Searchability:
Likely text-searchable PDF, enabling quick access to specific information.
Printability:
Printable PDF pages for on-bench use.
Print Quality
Image Resolution:
Assumed to be sufficient for clear diagrams and illustrations. Quality may vary based on original source.
Binding Type
Binding Type:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Type:
Air-cooled, 4-stroke, SOHC, V-twin
Displacement:
249 cc (249cc)
Bore X Stroke:
49.0 mm x 66.0 mm (typical for this engine)
Compression Ratio:
9.5:1 (typical for this engine)
Valve Train:
SOHC, 2 valves per cylinder
Performance
Horsepower:
Approx. 20-22 HP at 7500-8000 RPM (market dependent, estimated)
Torque:
Approx. 20-21 Nm at 5500-6000 RPM (market dependent, estimated)
Fuel System
Carburetion:
Likely twin Mikuni VM Series carburetors (e.g., VM26 or similar)
Fuel Capacity:
Approx. 12 Liters (3.2 Gallons)
Lubrication
Oil Capacity:
Approx. 2.5 Liters (with filter change)
Oil Type:
Yamalube 4 (or equivalent JASO MA certified 10W-40)
🔧 Transmission
Standard
Type:
Constant mesh, 5-speed
Features
Clutch:
Wet, multi-plate
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2175 mm (85.6 in)
Width:
Approx. 785 mm (30.9 in)
Height:
Approx. 1125 mm (44.3 in)
Wheelbase:
Approx. 1480 mm (58.3 in)
Weights
Dry Weight:
Approx. 155 kg (342 lbs)
Wet Weight:
Approx. 171 kg (377 lbs) (with fluids)
Gvwr:
Not typically specified for motorcycles, but rider and payload capacity is relevant.
🛡️ Safety Features
Ratings
Safety Features:
Standard motorcycle safety equipment: reliable braking systems, adequate lighting, stable chassis. No electronic rider aids like ABS or traction control typical for this era and class.
Passive Features
Lighting:
Halogen headlamp, LED or incandescent taillight and brake light, incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle of this era typically features analog gauges only).
Driver Assistance
Rider Aids:
None. Basic mechanical and electrical systems.
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Spark Plug Replacement:
Every 10,000 km (6,000 miles).
Air Filter Cleaning:
Every 5,000 km (3,000 miles) or as needed based on operating conditions.
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after riding in rain.
Brake Fluid Flush:
Every 2 years or 20,000 km (12,000 miles).
Fluid Specifications
Engine Oil:
Yamalube 4 (or equivalent JASO MA certified SAE 10W-40 API SE or SF)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil:
Yamaha Suspension Oil (or equivalent SAE 10W fork oil, approximately 340-350cc per leg)
Known Issues
Carburetor Issues:
Can suffer from fuel gumming if left unused; requires periodic cleaning and synchronization.
Electrical Connectors:
Corrosion on connectors can lead to intermittent electrical faults, especially in humid climates.
Clutch Slippage:
Can occur with high mileage or aggressive use, requiring clutch plate replacement.
Fork Seals:
Can degrade over time, leading to oil leaks and requiring seal replacement.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Company boasts a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.
Model Evolution
Srv250 Lineage:
The SRV250G is part of Yamaha's cruiser lineage, often drawing inspiration from its larger Virago siblings while offering a more accessible displacement.
Production
Manufacturing Location:
Primarily Japan.
Production Period:
Mid-1980s to mid-late 1990s for the SRV250 series.
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the SRV250G are not widely documented; however, Yamaha's overall reputation in the motorcycle industry signifies quality and reliability.
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