Yamaha XT250 Dual Sport Motorcycle Manuals

Yamaha XT250 Dual Sport Motorcycle Manuals

Manuals and User Guides for Yamaha XT250 Dual Sport Motorcycle. We have 3 Yamaha XT250 Dual Sport Motorcycle manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XT250 Service Manual

Yamaha XT250 Service Manual (282 pages)

Brand: Yamaha | Category: Motorcycle | Size: 8 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Symbols
  6
- 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
- Tightening Torques
  32
- Lubrication Points and Lubricant Types
  37
  - Engine
    37
  - Chassis
    38
- Lubrication System Chart and Diagrams
  40
  - Engine Oil Lubrication Chart
    40
  - Lubrication Diagrams
    42
- Cable Routing
  44
Periodic Checks and Adjustments

55
Chassis

83
- General Chassis
  85
- Front Wheel
  86
- Rear Wheel
  92
- Front Brake
  96
- Rear Brake
  108
  - Introduction
    113
  - Checking the Rear Brake Disc
    113
  - Replacing the Rear Brake Pads
    113
  - Removing the Rear Brake Caliper
    114
  - Disassembling the Rear Brake Caliper
    114
  - Checking the Rear Brake Caliper
    115
  - Assembling the Rear Brake Caliper
    115
  - Installing the Rear Brake Caliper
    115
  - Removing the Rear Brake Master Cylinder
    116
  - Checking the Rear Brake Master Cylinder
    117
  - Assembling the Rear Brake Master Cylinder
    117
  - Installing the Rear Brake Master Cylinder
    117
  - Handlebar
    119
  - Removing the Handlebars
    120
  - Checking the Handlebar
    120
  - Installing the Handlebar
    120
- Front Fork
  123
  - Removing the Front Fork Legs
    126
  - Disassembling the Front Fork Legs
    126
  - Checking the Front Fork Legs
    127
  - Assembling the Front Fork Legs
    127
  - Installing the Front Fork Legs
    130
- Steering Head
  131
  - Removing the Lower Bracket
    133
  - Checking the Steering Head
    133
  - Installing the Steering Head
    133
- Rear Shock Absorber Assembly
  135
- Swingarm
  138
  - Removing the Swingarm
    139
  - Checking the Swingarm
    139
  - Installing the Swingarm
    139
- Chain Drive
  141
  - Removing the Drive Chain
    142
  - Checking 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
- Camshaft
  159
- Valves and Valve Springs
  164
  - Removing the Valves
    164
  - Checking the Valves and Valve Guides
    164
  - Checking the Valve Seats
    166
  - Checking the Valve Springs
    167
  - Installing the Valves
    169
- Cylinder and Piston
  171
  - Removing the Piston
    172
  - Checking the Cylinder and Piston
    172
  - Checking the Piston Rings
    173
  - Checking the Piston Pin
    174
  - Installing the Piston and Cylinder
    174
- Clutch
  176
  - Removing the Clutch
    179
  - Checking the Friction Plates
    179
  - Checking the Clutch Plates
    179
  - Checking the Clutch Springs
    179
  - Checking the Clutch Housing
    180
  - Checking the Clutch Boss
    180
  - Checking the Pressure Plate
    180
  - Checking the Clutch Push Rods
    180
  - Checking the Primary Drive Gear
    180
  - Checking the Primary Driven Gear
    180
  - Installing the Clutch
    180
- Oil Pump and Balancer Gear
  184
  - Removing the Balancer Gear
    186
  - Checking the Oil Pump
    186
  - Checking the Oil Strainer
    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
  - Removing the Generator
    193
  - Removing the Starter Clutch
    193
  - Checking the Starter Clutch
    193
  - Installing the Starter Clutch
    194
  - Installing the Generator
    194
- Electric Starter
  196
  - Checking the Starter Motor
    198
  - Assembling the Starter Motor
    199
- Crankcase
  200
- Crankshaft Assembly
  205
- Transmission
  207
Fuel System

211
- Fuel Tank
  213
  - Checking the Fuel Cock
    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
- Ignition System
  226
  - Circuit Diagram
    226
  - Troubleshooting
    228
- Electric Starting System
  230
  - Circuit Diagram
    230
  - Starting Circuit Cut-Off System Operation
    232
  - Troubleshooting
    234
- Charging System
  236
  - Circuit Diagram
    236
  - Troubleshooting
    238
- Lighting System
  240
  - Circuit Diagram
    240
  - Troubleshooting
    242
- Signaling System
  244
  - Circuit Diagram
    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 the Fuse
    262
  - Checking and Charging the Battery
    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 Rectifier/Regulator
    270
  - Checking the Horn
    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

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Yamaha XT250 Owner's Manual

Yamaha XT250 Owner's Manual (100 pages)

Brand: Yamaha | Category: Motorcycle | Size: 2 MB

Table of Contents

Important Manual Information
4
Table of Contents
6
Safety Information
8
Location of Important Labels
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
Clock Mode
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
27
Helmet Holder
28
Adjusting the Shock Absorber
28
Assembly
28
Sidestand
30
Ignition Circuit Cut-Off System
30
Pre-Operation Checks
32
Pre-Operation Check List
33
Checking the Spark Plug
49
- To Check/Install Spark Plug
  50
- To Change Engine Oil
  51
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
Checking the Engine Idling
56
Carburetor
56
Speed
56
Checking the Throttle Cable Free Play
57
Valve Clearance
57
- Tires
  57
- Spoke Wheels
  59
- Accessories and Replacement Parts
  60
- Adjusting the Clutch Lever Free Play
  60
- Adjusting the Brake Lever Free Play
  61
- Adjusting the Rear Brake Light Switch
  62
- Checking the Front and Rear Brake Pads
  62
- Checking the Brake Fluid Level
  63
- Changing the Brake Fluid
  64
- Drive Chain Slack
  64
- Cleaning and Lubricating the Drive Chain
  65
- Checking and Lubricating the Cables
  66
- Checking and Lubricating the Throttle Grip and Cable
  66
- Checking and Lubricating the Brake and Shift Pedals
  66
- Checking and Lubricating the Brake and Clutch Levers
  67
- Checking and Lubricating the Sidestand
  68
- Lubricating the Rear Suspension
  68
- Checking the Front Fork
  68
- Checking the Steering
  69
- Checking the Wheel Bearings
  70
- Battery
  70
- Replacing the Fuse
  71
- Replacing the Headlight Bulb
  72
- Replacing the Tail/Brake Light Bulb
  73
- Replacing a Turn Signal Light Bulb
  74
- Supporting the Motorcycle
  75
- Front Wheel
  75
- Rear Wheel
  76
- To Install Front Wheel
  76
- Troubleshooting
  78
- Troubleshooting Chart
  79
- Motorcycle Care and Storage
  80
- Matte Color Caution
  80
- Care
  80
- Storage
  82
- Specifications
  84
- Consumer Information
  87
- Identification Numbers
  87
- Reporting Safety Defects
  89
- Motorcycle Noise Regulation
  90
- Maintenance Record
  91
- Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
  93

Yamaha XT250 Owner's Manual

Yamaha XT250 Owner's Manual (100 pages)

Brand: Yamaha | Category: Motorcycle | Size: 2 MB

Table of Contents

Table of Contents
6
Location of Important Labels
8
Safety Information
12
Description
17
Left View
17
Right View
18
Controls and Instruments
19
Instrument and Control Functions
20
Main Switch/Steering Lock
20
Indicator Lights and Warning Lights
21
Multi-Function Display
22
Handlebar Switches
24
Clutch Lever
25
Shift Pedal
26
Brake Lever
26
Brake Pedal
26
Fuel Tank Cap
27
Fuel
27
Seat
29
Helmet Holder
29
Adjusting the Shock Absorber Assembly
30
Sidestand
31
Ignition Circuit Cut-Off System
32
For Your Safety - Pre-Operation Checks
34
Operation and Important Riding Points
36
Engine Break-In
36
Starting the Engine
37
Shifting
38
Parking
39
Tool Kit
41
Periodic Maintenance Chart for the Emission Control System
42
General Maintenance and Lubrication Chart
44
Removing and Installing the Cowling and Panels
48
Checking the Spark Plug
50
Canister (for California)
52
Engine Oil and Oil Filter Element
52
Why Yamalube
54
Replacing the Air Filter Element and Cleaning the Check Hose
55
Cleaning the Spark Arrester
56
Checking the Engine Idling Speed
57
Checking the Throttle Grip Free Play
57
Valve Clearance
57
Tires
58
Spoke Wheels
59
Adjusting the Clutch Lever Free Play
60
Adjusting the Brake Lever Free Play
61
Brake Light Switches
62
Checking the Front and Rear Brake Pads
62
Checking the Brake Fluid Level
63
Changing the Brake Fluid
64
Drive Chain Slack
64
Cleaning and Lubricating the Drive Chain
66
Checking and Lubricating the Cables
66
Checking and Lubricating the Throttle Grip and Cable
67
Checking and Lubricating the Brake and Shift Pedals
67
Checking and Lubricating the Brake and Clutch Levers
68
Checking and Lubricating the Sidestand
68
Lubricating the Rear Suspension
69
Lubricating the Swingarm Pivots
69
Checking the Front Fork
69
Checking the Steering
70
Checking the Wheel Bearings
70
Battery
71
Replacing the Fuses
72
Replacing the Headlight Bulb
73
Replacing the Brake/Tail Light
74
Bulb
74
Replacing a Turn Signal Light Bulb
75
Supporting the Motorcycle
76
Front Wheel
76
Rear Wheel
77
Troubleshooting
79
Troubleshooting Chart
80
Motorcycle Care and Storage
81
Matte Color Caution
81
Care
81
Storage
83
Specifications
85
Consumer Information
87
Identification Numbers
87
Reporting Safety Defects
89
Motorcycle Noise Regulation
90
Maintenance Record
91
Yamaha Motor
94
Warranty
94
Yamaha Extended Service (Y.e.s.)
95

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