2009 YAMAHA XT250 Service Repair Manual

3C5-28197-10 XT250X XT250XC SERVICE MANUAL LIT-11616-21-52

EAS20050 XT250X XT250XC SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, August 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-21-52

EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: ● This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. ● Designs and specifications are subject to change without notice. EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in se v ere injur y or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. ● The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. ● Sub-section titles appear in smaller print than the section title “2”. ● To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. ● Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. ● Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. ● A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”. ● Jobs requiring more information (such as special tools and technical data) are described sequentially “7”. 7 2 CLUTCH 5-31 Removing the clutch Order Job/Parts to remove Q’ty Remarks 1 Clutch spring 5 2 Pressure plate 1 3 Adjusting screw 1 4 Push plate 1 5 Friction plate 6 6 Clutch plate 5 7 Clutch damper spring 1 8 Clutch damper spring seat 1 9 Primary drive gear nut 1 10 Lock washer 1 11 Claw washer 1 12 Clutch boss nut 1 13 Lock washer 1 14 Clutch boss 1 15 Thrust washer 1 16 Clutch housing 1 17 Ball 1 18 Clutch push rod 1 19 Primary drive gear 1 For installation, reverse the removal procedure. New New E 8 Nm (0.8 m • kg, 5.8 ft • Ib) 75 Nm (7.5 m • kg, 54 ft • Ib) 80 Nm (8.0 m • kg, 58 ft • Ib) 1 2 5 6 7 8 12 13 15 16 17 9 10 11 19 18 14 3 4 (5) 3 4 5 6 1 CLUTCH 5-33 EAS25070 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: Primary drive gear nut “1” NOTE: Insert aluminum plate “a” between primary drive gear “2” and primary driven gear “3”, and loosen the primary drive gear nut. 3. Loosen: Clutch boss nut “1” NOTE: While holding the clutch boss “1” with the universal clutch holder “2”, loosen the clutch boss nut. EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear Replace the friction plates as a set. 2. Measure: Friction plate thickness Out of specification Replace the friction plates as a set. NOTE: Measure the friction plate at four places. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: Clutch plate Damage Replace the clutch plates as a set. 2. Measure: Clutch plate warpage (with a surface plate and thickness gauge “1”) Out of specification Replace the clutch plates as a set. EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: Clutch spring Damage Replace the clutch springs as a set. 2. Measure: Universal clutch holder 90890-04086 YM-91042 2 1 3 Friction plate thickness 2.70— 2.90 mm (0.106— 0.114 in) Wear limit 2.60 mm (0.1024 in) Warpage limit 0.20 mm (0.0079 in)

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. G M E B LS M 9 10 11 12 13 14 15 16 17 18 LT New BF S T R . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Brake fluid 13. Wheel-bearing grease 14. Lithium-soap-based grease 15. Molybdenum-disulfide grease 16. Silicone grease 17. Apply locking agent (LOCTITE®) 18. Replace the part

GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8 EAS20110 TABLE OF CONTENTS

1 2 3 4 5 6 7 8 9 GENERAL INFORMATION IDENTIFICATION ...........................................................................................1-1 VEHICLE IDENTIFICATION NUMBER ....................................................1-1 MODEL LABEL ........................................................................................1-1 IMPORTANT INFORMATION ........................................................................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-2 REPLACEMENT PARTS .........................................................................1-2 GASKETS, OIL SEALS AND O-RINGS ...................................................1-2 LOCK WASHERS/PLATES AND COTTER PINS ....................................1-2 BEARINGS AND OIL SEALS ...................................................................1-2 CIRCLIPS .................................................................................................1-3 CHECKING THE CONNECTIONS .................................................................1-4 SPECIAL TOOLS ...........................................................................................1-5

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts. 1 1

2009 YAMAHA XT250 Service Repair Manual

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