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Yamaha SRV250G 1992-1996 Workshop Service Repair Manual

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The Yamaha SRV250G, produced between 1992 and 1996, is a motorcycle designed for riders seeking classic styling and reliable performance within the 250cc segment. Characterized by its air-cooled, DOHC V-twin...
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Type: Motorcycle
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Sku: 69598
Yamaha SRV250G 1992-1996 Workshop Service Repair ManualYamaha SRV250G 1992-1996 Workshop Service Repair ManualYamaha SRV250G 1992-1996 Workshop Service Repair ManualYamaha SRV250G 1992-1996 Workshop Service Repair Manual
The Yamaha SRV250G, produced between 1992 and 1996, is a motorcycle designed for riders seeking classic styling and reliable performance within the 250cc segment. Characterized by its air-cooled, DOHC V-twin engine, this model offers a blend of retro aesthetics and manageable power, making it suitable for both beginner riders and those appreciating a stylish, functional machine for commuting or leisure. Its engineering emphasizes durability and a straightforward riding experience, positioning it as a competent competitor in the entry-level to mid-range sport/standard motorcycle market of its era. This comprehensive workshop service repair manual provides detailed factory-level guidance for the Yamaha SRV250G. It covers all essential aspects of maintenance, repair, and troubleshooting, including engine assembly and tuning, fuel and ignition systems, transmission and drivetrain, chassis, suspension, brakes, and electrical systems. The manual is structured to assist owners, mechanics, and technicians in performing routine maintenance, diagnosing issues, and executing complex repairs, ensuring the longevity and optimal performance of the motorcycle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
SRV250G
Year:
1992-1996
Codes
Vin Prefix:
3XF
👋 Introduction
Market Position
Segment:
Entry-level to mid-range sport/standard motorcycle segment, often favored for its classic styling and manageable performance.
Competitive Analysis
Competitors:
Competed against models like Honda CB400 Four, Kawasaki Zephyr 400, Suzuki GS500, and other similarly positioned naked or semi-faired Japanese motorcycles of the era.
Key Features
Styling:
Classic Japanese motorcycle styling, often with a single headlight, round gauges, and a relatively upright riding position.
Target Audience:
Beginner riders, commuters, those seeking a stylish and reliable motorcycle with manageable power, and enthusiasts appreciating retro aesthetics.
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair for Yamaha SRV250G (1992-1996)
Page Count
Page Count:
Hundreds of pages (exact count not specified, typical for full workshop manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English (presumed, based on product description context of sales business)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine assembly, disassembly, tuning, troubleshooting, cooling system, lubrication system, fuel system (carburetion), ignition system, exhaust system
Transmission Drivetrain:
Clutch, gearbox (transmission), final drive (chain and sprockets), lubrication
Chassis Suspension:
Front fork, rear shock absorber, swingarm, frame inspection and repair, steering system
Braking System:
Front and rear brake systems (likely hydraulic disc front, drum or disc rear), master cylinders, calipers, brake lines, bleeding procedures
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starting system, wiring diagrams, instrument cluster, sensors
Body Frame:
Fuel tank, seat, fenders, side covers, handlebars, footpegs, fairings/bodywork (if applicable), fasteners
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid replacement, coolant replacement (if liquid-cooled), valve clearance adjustment
Repair Procedures:
Engine rebuilds, carburetor overhaul, transmission gear replacement, suspension component repair, electrical component diagnosis and replacement, brake system overhaul
Troubleshooting Guides:
Diagnostic charts, common problem identification, symptom-based troubleshooting for engine, electrical, and mechanical issues
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance tasks
Technical Depth
Depth:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to complete engine and component overhauls.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans, designed for clear printing of text, diagrams, and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF, printable by user)
Paper Type
Paper Type:
N/A (Digital PDF, user printable on desired paper)
Searchability
Searchability:
Likely text-searchable PDF for quick information retrieval, assuming proper OCR was performed on original scans.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, DOHC, V-twin
Displacement:
249cc (249 cm³)
Bore X Stroke:
52.0 mm x 57.9 mm (approximate, typical for this displacement V-twin)
Compression Ratio:
9.5:1 (typical for this era and engine type)
Performance
Horsepower:
Approx. 30-34 HP @ 8500 RPM (estimated, actual figures may vary slightly by market and specific tuning)
Torque:
Approx. 2.6 kgf·m @ 7000 RPM (estimated, actual figures may vary slightly by market and specific tuning)
Fuel System
Carburetion:
Dual Mikuni carburetors (e.g., VM26 or similar 26mm constant velocity type), often with vacuum operated petcock.
Fuel Type:
Unleaded gasoline, 90-96 octane rating (RON+MON)/2 recommended.
Lubrication
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 API SF or SG classified motorcycle oil)
Oil Capacity:
Approx. 2.0 liters (with filter change)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
O-ring sealed chain drive
Features
Gear Ratios:
Specific gear ratios would be detailed in the manual, crucial for performance tuning and troubleshooting.
Transmission Oil Type:
Yamaha Gear Oil Hypoid 80W-90 (or equivalent API GL-4)
Transmission Oil Capacity:
Approx. 0.8 liters (specific figure from manual)
📐 Dimensions
Exterior
Length:
Approx. 2075 mm (varies slightly by year/spec)
Width:
Approx. 745 mm (varies slightly by year/spec)
Height:
Approx. 1055 mm (varies slightly by year/spec)
Weights
Dry Weight:
Approx. 151 kg (varies slightly by year/spec)
Wet Weight:
Approx. 166 kg (with fluids, estimate)
Fuel Capacity:
Approx. 14 liters (including 3-liter reserve)
Dimensions
Wheelbase:
Approx. 1435 mm
Ground Clearance:
Approx. 135 mm
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with relevant Japanese domestic market (JDM) and international safety regulations of the early to mid-1990s. Specific crash test ratings are not typically published for motorcycles in the same way as cars.
Active Features
Braking System Features:
Hydraulic disc front brake for strong stopping power, rear brake typically drum or disc depending on exact model variant. Often featured braided steel lines for improved feel.
Lighting:
Halogen headlight, tail light, brake light, and turn signals for visibility.
Passive Features
Frame Construction:
Steel frame (likely diamond or cradle type) designed for stability and rider feedback.
Tires:
Tubeless tires (front: 110/80-17, rear: 140/70-17, typical sizes but refer to manual for exact specifications).
Suspension Tuning:
Adjustable front fork preload (some models) and rear suspension damping can be fine-tuned for rider preference and load.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, fuel gauge (if equipped), odometer, trip meter, warning lights (oil pressure, neutral, high beam, turn signals). Simple and functional design.
Driver Assistance
Rider Aids:
Limited electronic rider aids, typical for its era. Focus is on mechanical feedback and rider control. ABS was not a common feature on this model.
Connectivity
Connectivity Features:
N/A - No modern connectivity features like Bluetooth or smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or 6 months, whichever comes first. (Refer to manual for precise intervals.)
Air Filter Cleaning:
Every 6,000 km or annually. Replacement as needed.
Spark Plug Replacement:
Every 10,000 km or annually. Specific plug type required (e.g., NGK CR9E or equivalent).
Valve Clearance Check:
Every 12,000 km or every two years.
Brake Fluid Replacement:
Every 2 years or as needed due to moisture absorption. Use DOT 3 or DOT 4 fluid.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40
Engine Oil Standard:
API SF or SG classification
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
N/A (Air-cooled engine)
Known Issues
Carburetor Issues:
Potential for gumming or clogging of carburetors if fuel sits for extended periods, especially with ethanol-blended fuels. Synchronization may be required over time.
Charging System:
Regulator/rectifier failure can occur on older units, leading to battery charging issues. Stator output can degrade.
Valve Guides:
Wear in valve guides could lead to oil consumption over high mileage. Regular valve clearance checks are crucial.
Electrical Connections:
Corrosion on electrical connectors, particularly in exposed areas, can lead to intermittent faults. Periodic inspection and cleaning recommended.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycle History:
Yamaha Motor Company has a rich heritage in motorcycle manufacturing dating back to the 1950s, known for innovation, performance, and reliability across various motorcycle segments.
Model Evolution
Srv250 Development:
The SRV250 series was developed to offer a stylish, V-twin powered alternative in the popular 250cc class, blending retro aesthetics with modern (for its time) engineering. It was particularly popular in the Japanese domestic market (JDM).
Production
Production Period:
Produced from approximately 1992 through 1996. Variants may exist, and this manual covers the core G-series models within this timeframe.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-received in its primary market (Japan) for its styling, comfortable ride, and reliability as a 250cc V-twin. Often cited as a good beginner bike or stylish commuter.
Ratings
Customer Satisfaction:
While specific awards are unlikely for this model, its longevity and continued presence in the used market indicate a degree of owner satisfaction and durability.
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