Yamaha XT250X User manual

3C5-28197-10
XT250X
XT250XC
SERVICE MANUAL
LIT-11616-21-52
2008

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 severe injury 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
T
R
.
.
8 Nm (0.8 m •kg, 5.8 ft •Ib)
T
R
.
.
75 Nm (7.5 m •kg, 54 ft •Ib)
T
R
.
.
80 Nm (8.0 m •kg, 58 ft •Ib)
1
2
5
6
7812
13
15
16 17
910
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
13
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
BLS
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

IMPORTANT INFORMATION
1-2
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-5.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.

IMPORTANT INFORMATION
1-3
CAUTION:
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

CHECKING THE CONNECTIONS
1-4
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
●Lead
●Coupler
●Connector
2. Check:
●Lead
●Coupler
●Connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect sev-
eral times.
3. Check:
●All connections
Loose connection →Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
●Lead
●Coupler
●Connector
NOTE:
Make sure all connections are tight.
5. Check:
●Continuity
(with the pocket tester)
NOTE:
●If there is no continuity, clean the terminals.
●When checking the wire harness, perform
steps (1) to (3).
●As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
90890-03132

SPECIAL TOOLS
1-5
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration Reference
pages
Pocket tester
90890-03132
1-4
, 3-7 , 3-8 ,
5-52 , 7-35 ,
7-36 , 7-37 ,
7-40 , 7-41 ,
7-42 , 7-43 ,
7-44 , 7-45, 7-47
Special thickness gauge
90890-01399
3-5
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
3-6
Digital tachometer
90890-06760
YU-39951-B
3-7, 3-8, 3-11
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-11
Compression gauge
90890-03081
Engine compression tester
YU-33223
3-12

SPECIAL TOOLS
1-6
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
3-23
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3-24, 4-49
Spoke wrench
90890-01522
3-27
Cylinder cup installer
90890-01996
4-22, 4-33
Damper rod holder
90890-01460
4-42, 4-44
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-44
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
4-44, 4-45
Tool name/Tool No. Illustration Reference
pages
YM-A9409-7/YM-A5142-4

SPECIAL TOOLS
1-7
Fork seal driver attachment (ø35)
90890-01369
Replacement 35 mm
YM-A9409-5
4-44
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
5-14
Weight
90890-01084
YU-01083-3
5-14
Valve spring compressor
90890-04019
YM-04019
5-18, 5-23
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
5-20
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
5-20
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-20
Tool name/Tool No. Illustration Reference
pages
YU-01083-3

SPECIAL TOOLS
1-8
Universal clutch holder
90890-04086
YM-91042
5-33, 5-35
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-47, 5-48
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-47
Yamaha bond No. 1215 (Three Bond
No.1215®)
90890-85505
5-56
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-59
Tool name/Tool No. Illustration Reference
pages

SPECIAL TOOLS
1-9
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
5-60
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
5-60
Adapter (M10)
90890-01383
Adapter #2
YU-90062
5-60
Spacer
90890-01288
5-60
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
7-43
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
7-46
Tool name/Tool No. Illustration Reference
pages
YU-90058/YU-90059

1
2
3
4
5
6
7
8
9
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................2-1
ENGINE SPECIFICATIONS...........................................................................2-2
CHASSIS SPECIFICATIONS.........................................................................2-9
ELECTRICAL SPECIFICATIONS..................................................................2-11
TIGHTENING TORQUES...............................................................................2-13
GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-13
ENGINE TIGHTENING TORQUES..........................................................2-13
CHASSIS TIGHTENING TORQUES........................................................2-15
LUBRICATION POINTS AND LUBRICANT TYPES .....................................2-18
ENGINE....................................................................................................2-18
CHASSIS..................................................................................................2-19
LUBRICATION SYSTEM CHART AND DIAGRAMS ....................................2-21
ENGINE OIL LUBRICATION CHART ......................................................2-21
LUBRICATION DIAGRAMS .....................................................................2-23
CABLE ROUTING..........................................................................................2-25

GENERAL SPECIFICATIONS
2-1
EAS20280
GENERAL SPECIFICATIONS
Model
Model 3C58 (U49)
3C59 (CAL)
Dimensions
Overall length 2150 mm (84.6 in)
Overall width 805 mm (31.7 in)
Overall height 1160 mm (45.7 in)
Seat height 810 mm (31.9 in)
Wheelbase 1360 mm (53.5 in)
Ground clearance 285 mm (11.22 in)
Minimum turning radius 1900 mm (74.8 in)
Weight
With oil and fuel 132.0 kg (291 lb)
Maximum load 160.0 kg (353 lb)