Yamaha XT250 2008 Manuals

Yamaha XT250 2008 Manuals

Manuals and User Guides for Yamaha XT250 2008. We have 2 Yamaha XT250 2008 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XT250 2008 Service Manual

Yamaha XT250 2008 Service Manual (282 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10.58 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Important Information
  11
- Preparation for Removal and Disassembly
  11
- Replacement Parts
  11
- Gaskets, Oil Seals and O-Rings
  11
- Lock Washers/Plates and Cotter Pins
  11
- Bearings and Oil Seals
  11
- Circlips
  12
- Checking the Connections
  13
- Special Tools
  14
Specifications

19
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  28
- Electrical Specifications
  30
- Engine Tightening Torques
  32
- General Tightening Torque Specifications
  32
- Tightening Torques
  32
- Chassis Tightening Torques
  34
- Engine
  37
- Lubrication Points and Lubricant Types
  37
- Chassis
  38
- Engine Oil Lubrication Chart
  40
- Lubrication System Chart and Diagrams
  40
- Lubrication Diagrams
  42
- Cable Routing
  44
Periodic Checks and Adjustments

55
Chassis

83
- General Chassis
  85
- Front Wheel
  86
- Checking the Front Wheel
  88
- Disassembling the Front Wheel
  88
- Removing the Front Wheel
  88
- Adjusting the Front Wheel Static Balance
  89
- Assembling the Front Wheel
  89
- Installing the Front Wheel (Disc)
  90
- Rear Wheel
  92
- Checking and Replacing the Rear Wheel Sprocket
  94
- Checking the Rear Wheel
  94
- Disassembling the Rear Wheel
  94
- Removing the Rear Wheel (Disc)
  94
- Adjusting the Rear Wheel Static Balance
  95
- Assembling the Rear Wheel
  95
- Installing the Rear Wheel
  95
- Front Brake
  96
- Checking the Front Brake Disc
  101
- Introduction
  101
- Replacing the Front Brake Pads
  102
- Checking the Front Brake Caliper
  103
- Disassembling the Front Brake Caliper
  103
- Removing the Front Brake Caliper
  103
- Assembling the Front Brake Caliper
  104
- Installing the Front Brake Caliper
  104
- Checking the Front Brake Master Cylinder
  105
- Removing the Front Brake Master Cylinder
  105
- Assembling the Front Brake Master Cylinder
  106
- Installing the Front Brake Master Cylinder
  106
- Rear Brake
  108
- Checking the Rear Brake Disc
  113
- Introduction
  113
- Replacing the Rear Brake Pads
  113
- Disassembling the Rear Brake Caliper
  114
- Removing the Rear Brake Caliper
  114
- Assembling the Rear Brake Caliper
  115
- Checking the Rear Brake Caliper
  115
- Installing the Rear Brake Caliper
  115
- Removing the Rear Brake Master Cylinder
  116
- Assembling the Rear Brake Master Cylinder
  117
- Checking the Rear Brake Master Cylinder
  117
- Installing the Rear Brake Master Cylinder
  117
- Handlebar
  119
- Checking the Handlebar
  120
- Installing the Handlebar
  120
- Removing the Handlebars
  120
- Front Fork
  123
- Disassembling the Front Fork Legs
  126
- Removing the Front Fork Legs
  126
- Assembling the Front Fork Legs
  127
- Checking the Front Fork Legs
  127
- Installing the Front Fork Legs
  130
- Steering Head
  131
- Checking the Steering Head
  133
- Installing the Steering Head
  133
- Removing the Lower Bracket
  133
- Rear Shock Absorber Assembly
  135
- Checking the Connecting Arm and Relay Arm
  136
- Checking the Rear Shock Absorber Assembly
  136
- Disposing of a Rear Shock Absorber
  136
- Handling the Rear Shock Absorber
  136
- Installing the Relay Arm
  136
- Removing the Rear Shock Absorber Assembly
  136
- Installing the Rear Shock Absorber Assembly
  137
- Swingarm
  138
- Checking the Swingarm
  139
- Installing the Swingarm
  139
- Removing the Swingarm
  139
- Chain Drive
  141
- Checking the Drive Chain
  142
- Removing the Drive Chain
  142
- Checking the Drive Sprocket
  143
- Installing the Drive Chain
  143
Engine

145
- Engine Removal
  147
- Installing the Engine
  150
- Installing the Shift Pedal
  150
- Cylinder Head
  152
- Removing the Cylinder Head
  154
- Checking the Camshaft Sprocket and Timing Chain Guide (Exhaust System Side)
  155
- Checking the Cylinder Head
  155
- Checking the Tappet Covers and Camshaft Sprocket Cover
  155
- Checking the Timing Chain Tensioner
  156
- Installing the Cylinder Head
  156
- Camshaft
  159
- Checking the Camshaft
  160
- Removing the Rocker Arms and Camshaft
  160
- Checking the Rocker Arms and Rocker Arm Shafts
  161
- Installing the Camshaft and Rocker Arms
  161
- Checking the Valves and Valve Guides
  164
- Removing the Valves
  164
- Valves and Valve Springs
  164
- Checking the Valve Seats
  166
- Checking the Valve Springs
  167
- Installing the Valves
  169
- Cylinder and Piston
  171
- Checking the Cylinder and Piston
  172
- Removing the Piston
  172
- Checking the Piston Rings
  173
- Checking the Piston Pin
  174
- Installing the Piston and Cylinder
  174
- Clutch
  176
- Checking the Clutch Plates
  179
- Checking the Clutch Springs
  179
- Checking the Friction Plates
  179
- Removing the Clutch
  179
- Checking the Clutch Boss
  180
- Checking the Clutch Housing
  180
- Checking the Clutch Push Rods
  180
- Checking the Pressure Plate
  180
- Checking the Primary Drive Gear
  180
- Checking the Primary Driven Gear
  180
- Installing the Clutch
  180
- Oil Pump and Balancer Gear
  184
- Checking the Oil Pump
  186
- Checking the Oil Strainer
  186
- Removing the Balancer Gear
  186
- Assembling the Oil Pump
  187
- Install the Oil Pump and Balancer Gear
  187
- Shift Shaft
  189
- Checking the Shift Shaft
  190
- Checking the Stopper Lever
  190
- Installing the Shift Shaft
  190
- Generator and Starter Clutch
  191
- Checking the Starter Clutch
  193
- Removing the Generator
  193
- Removing the Starter Clutch
  193
- Installing the Generator
  194
- Installing the Starter Clutch
  194
- Electric Starter
  196
- Checking the Starter Motor
  198
- Assembling the Starter Motor
  199
- Crankcase
  200
- Assembling the Crankcase
  202
- Checking the Bearing and Oil Seal
  202
- Checking the Crankcase
  202
- Checking the Timing Chain, Crankshaft Sprocket, Timing Chain Guide (Intake Side)
  202
- Disassembling the Crankcase
  202
- Checking the Crankshaft and Connecting Rod
  205
- Crankshaft Assembly
  205
- Installing the Crankshaft Assembly
  205
- Removing the Crankshaft Assembly
  205
- Transmission
  207
- Checking the Shift Drum Assembly
  209
- Checking the Shift Forks
  209
- Checking the Transmission
  209
- Installing the Shift Forks and Shift Drum Assembly
  210
Fuel System

211
- Checking the Fuel Cock
  213
- Fuel Tank
  213
- Carburetor
  214
- Checking the Carburetor
  217
- Assembling the Carburetor
  218
- Installing the Carburetor
  219
- Air Induction System
  220
- Checking the Air Induction System
  223
Electrical System

225
- Circuit Diagram
  226
- Ignition System
  226
- Troubleshooting
  228
- Circuit Diagram
  230
- Electric Starting System
  230
- Starting Circuit Cut-Off System Operation
  232
- Troubleshooting
  234
- Charging System
  236
- Circuit Diagram
  236
- Troubleshooting
  238
- Circuit Diagram
  240
- Lighting System
  240
- Troubleshooting
  242
- Circuit Diagram
  244
- Signaling System
  244
- Troubleshooting
  246
- Carburetor Heating System
  250
- Circuit Diagram
  250
- Troubleshooting
  252
- Electrical Components
  254
- Checking the Switches
  258
- Checking the Bulbs and Bulb Sockets
  261
- Checking and Charging the Battery
  262
- Checking the Fuse
  262
- Checking the Relays
  265
- Checking the Turn Signal Relay
  266
- Checking the Diode
  267
- Checking the Spark Plug Cap
  267
- Checking the Ignition Coil
  268
- Checking the Pickup Coil
  269
- Checking the Stator Coil
  269
- Checking the Horn
  270
- Checking the Rectifier/Regulator
  270
- Checking the Speed Sensor
  271
- Checking the Thermo Switch
  271
- Checking the Carburetor Warmer
  272
Troubleshooting

273
- General Information
  274
- Incorrect Engine Idling Speed
  274
- Starting Failures
  274
- Faulty Clutch
  275
- Faulty Gear Shifting
  275
- Jumps out of Gear
  275
- Poor Medium-And-High-Speed Performance
  275
- Shift Pedal Does Not Move
  275
- Faulty Front Fork Legs
  276
- Faulty Lighting or Signaling System
  276
- Overheating
  276
- Poor Braking Performance
  276
- Unstable Handling
  276

Advertisement

Yamaha XT250 2008 Owner's Manual

Yamaha XT250 2008 Owner's Manual (100 pages)

Brand: Yamaha | Category: Motorcycle | Size: 2.17 MB

Table of Contents

Table of Contents
6
Location of Important Labels
8
Safety Information
12
Description
16
Left View
16
Right View
17
Controls and Instruments
18
Instrument and Control Functions
19
Main Switch/Steering Lock
19
Indicator Lights
20
Multi-Function Display
21
Handlebar Switches
22
Clutch Lever
23
Shift Pedal
23
Brake Lever
24
Brake Pedal
24
Fuel Tank Cap
24
Fuel
25
Fuel Cock
26
Starter (Choke) Knob "1
27
Seat
28
Helmet Holder
28
Adjusting the Shock Absorber Assembly
29
Sidestand
30
Ignition Circuit Cut-Off System
30
For Your Safety - Pre-Operation Checks
32
Pre-Operation Check List
33
Operation and Important Riding Points
35
Starting and Warming up a Cold Engine
35
Starting a Warm Engine
36
Shifting
36
Engine Break-In
38
Parking
38
Periodic Maintenance and Adjustment
39
Owner's Tool Kit
40
Periodic Maintenance Chart for the Emission Control System
41
General Maintenance and Lubrication Chart
43
Removing and Installing the Cowling and Panels
47
Checking the Spark Plug
49
Canister (for California Only)
51
Engine Oil and Oil Filter Element
51
Replacing the Air Filter Element and Cleaning the Check Hose
54
Cleaning the Spark Arrester
55
Carburetor
56
Checking the Engine Idling Speed
57
Checking the Throttle Cable Free Play
57
Valve Clearance
57
Tires
58
Spoke Wheels
59
Adjusting the Clutch Lever Free Play
60
Adjusting the Brake Lever Free Play
60
Adjusting the Rear Brake Light Switch
61
Checking the Front and Rear Brake
61
Pads
61
Checking the Brake Fluid Level
62
Changing the Brake Fluid
63
Drive Chain Slack
63
Cleaning and Lubricating the Drive
64
Checking and Lubricating the Cables
65
Checking and Lubricating the Throttle Grip and Cable
65
Checking and Lubricating the Brake and Shift Pedals
66
Checking and Lubricating the Brake and Clutch Levers
66
Checking and Lubricating the Sidestand
67
Lubricating the Rear Suspension
67
Checking the Front Fork
68
Checking the Steering
68
Checking the Wheel Bearings
69
Replacing the Fuse
71
Replacing the Headlight Bulb
71
Replacing the Tail/Brake Light Bulb
73
Replacing a Turn Signal Light Bulb
73
Supporting the Motorcycle
74
Front Wheel
75
Rear Wheel
75
Troubleshooting
77
Troubleshooting Chart
78
Motorcycle Care and Storage
79
Matte Color Caution
79
Care
79
Storage
81
Specifications
83
Consumer Information
86
Identification Numbers
86
Reporting Safety Defects
88
Motorcycle Noise Regulation
89
Maintenance Record
90
Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
92

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals