2008-2012 Yamaha XT250 XT 250 XT250X Service & Repair Manual
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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 man-
ual. 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 vehi-
cle 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 vehi-
cle 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 disassem-
bly 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 proce-
dure.
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 univer-
sal clutch holder “2”, loosen the clutch boss nut.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion 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
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This is a comprehensive service repair manual for the Yamaha XT250 XT 250 XT250X for the years 2008, 2009, 2010, 2011, and 2012. It is a valuable resource for both professional mechanics and DIY enthusiasts. The manual covers a wide range of topics including the engine, general information, transmission, chassis, lighting, steering, seats system, clutch, suspension, locks, brakes, lubrication, electrical, frame fuel system, and battery.
These manuals are available in Adobe Acrobat format, compatible with both PC and Mac, and can be printed as needed for reference. They are ideal for avoiding grease stains on expensive paper manuals. Instant delivery ensures no waiting for a CD to arrive via mail, making it convenient for users. Please note that high-speed internet connection is recommended due to the large file sizes.
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