1987 Yamaha SRX250T/TC Service Manual (P/N LIT-11616-06-04)

• Exact coverage: 1987 Yamaha SRX250T, model code 2NV (starting VIN JYA2NV00HA000101; starting engine number 2NV-000101), and SRX250TC, model code 2NW (starting VIN JYA2NW00HA000101; starting engine number 2NW-000101). This is Yamaha P/N LIT-11616-06-04, first edition, February 1987, supplied as a 250-page PDF.
• Periodic service procedures cover pad-type valve-clearance inspection and pad selection, engine oil/filter/strainer service, oil-flow and compression checks, clutch and throttle adjustment, ignition timing, brakes, steering, forks, drive chain, battery, and lubrication points. A separate canister and hose inspection applies to the SRX250TC only.
• Engine repair coverage runs from removal and complete teardown through inspection and reassembly of the DOHC top end, piston and cylinder, crankshaft and balancer shaft, oil pump, primary drive, clutch, starter drive, crankcases, and constant-mesh six-speed transmission.
• Carburetor work includes the Teikei Y22PV primary/secondary carburetor section view, removal and separation, cleaning and inspection, diaphragm and coasting-enricher service, float and fuel-level adjustment, primary full-open adjustment, and secondary-carburetor synchronization.
• Chassis procedures address front and rear wheel service, front brake caliper and master-cylinder repair and bleeding, fork overhaul, steering-head bearings, rear-shock removal, swingarm and linkage inspection, and drive-chain/sprocket replacement. The gas-oil rear shock is treated as a replace-as-an-assembly unit, not as an internal rebuild.
• Electrical diagnosis uses system circuit diagrams and fault-tracing charts for starting, charging, ignition, lighting, and signals, with starter-motor inspection, switch tests, flasher-cancel diagnosis, cable routing, and the full SRX250T/TC wiring diagram.

Yamaha wrote this service manual primarily for its dealers and qualified mechanics. It assumes a basic understanding of motorcycle repair concepts and procedures, so it is best suited to trained technicians and mechanically experienced owners equipped for precision measurement, engine work, hydraulic brake service, and electrical testing.

Engine and Maintenance Overview

The maintenance chapter gives the factory inspection schedules and the procedures behind them. Its valve section shows how to identify the installed adjusting pads, use the intake and exhaust selection charts, fit replacement pads, and verify the result. Oil-pressure confirmation, compression diagnosis, clutch mechanism adjustment, steering-head setup, front-fork oil service, and ignition-timing checks are also covered.

For deeper repair work, the engine chapter separates top-end, bottom-end, and transmission operations. Top-end coverage includes camshaft and cap inspection, valve-guide replacement, valve-seat cutting and lapping, cylinder and piston measurement, and cam-chain timing. The lower-end sections cover crankshaft inspection and installation, balancer-gear indexing, trochoid oil-pump clearances, clutch wear checks, transmission shafts and gears, shift forks and shift cam, starter drive, crankcase bearings, and oil seals. The manual also identifies the piston, clutch, carburetor, and AC magneto as components that can be serviced without removing the engine.

During cam timing, excessive camshaft rotation can cause piston and valve damage, and transmission operation must be checked before the crankcase screws are torqued. The crankcase-separation guidance warns against forcing a case half that hangs up because the gasket mating surface can be damaged.

Carburetion, Chassis, and Electrical Repair

The carburetor chapter explains the linked primary and secondary circuits, including the vacuum piston, starter system, fuel system, and coasting enricher. Chassis coverage extends from wheel bearings and rear drum-brake inspection to front disc-brake overhaul and bleeding, fork seal and damper-rod work, steering-bearing replacement, swingarm free-play checks, suspension-linkage service, and chain-and-sprocket inspection.

Electrical troubleshooting is organized around specific symptoms such as no cranking, no charging, no spark or intermittent spark, inoperative lighting, turn signals that do not cancel, brake- or neutral-light faults, and fuel-meter problems. Representative illustrations include the Y22PV carburetor section view, crankshaft/balancer-shaft exploded assembly, transmission/shifter exploded assembly, lubrication-flow chart, starting-circuit operation diagram, and SRX250T/TC wiring diagram.

Safety notes cover secure motorcycle support during wheel, fork, and steering work, full bleeding of the front-brake circuit after it is opened, and the handling restrictions for the pressurized rear shock.

Technical Specifications and Shop Data

Factory tables consolidate engine and chassis tightening torques, general fastener torque guidance, oil grades and capacities, carburetor settings, valve and camshaft clearances, piston and crankshaft inspection limits, clutch and transmission wear data, fork and suspension specifications, brake and wheel limits, and electrical test values. The appendices add unit definitions, conversion tables, lubrication diagrams, and detailed cable and harness routing.

The special-tool list identifies the YM-4106 tappet adjusting tool for pad changes, YM-91042 universal clutch holder, YU-01135 crankcase separator, YU-90050/YM-1383 crankshaft installing set, YM-33256 front-fork cylinder holder, and YU-03112 pocket tester. These references let a repair shop confirm tooling needs before beginning an overhaul or diagnostic job.